description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM OF PRIORITY
[0001] The application claims the benefit of Taiwan Patent Application No. 099117089, filed on May 27, 2010, in the Taiwan Patent and Trademark Office, the disclosures of which are incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for cells cultivation, in particular to a method for cells cultivation for hair follicle microtissues.
BACKGROUND OF THE INVENTION
[0003] Tissue engineering is a technology used for cultivating and transplanting cells which can be applied in repair of tissue and organ. Tissue engineering is already widely applied to deal with each kind of medical issue with the prosperity of biotechnology. For example, doctors can treat patients with tissue transplantation by using derma and cartilage which are artificially cultivated.
[0004] Take an example for treating alopecia with embedding hair. If the hair quantity on the occipital of hindbrain is sufficient, the hair follicles of the occipital scalp can be transplanted to the baldheaded area. However this method is only an autologous transplantation of hair follicles to redistribute the position of hair follicles, it still can not produce new ones. For nearly all baldheaded patients, this method is apparently not applicable.
[0005] Furthermore, a large amount of cells must be provided in the above method, and the generating efficiency of new hair follicles is unclear, and in additional, the direction of new born hair can not be effectively controlled for the time being. Further, since the dermal papilla cells of hair follicles are typically aggregated as a tight regiment in a living creature, the amount of the transplanted cells should be large and tightly disposed to ensure having enough induced signal produced from the dermal papilla cells. A loosen distributed density of cells can not produce new hair follicles. Furthermore, the thickness of hair is in association to the size of dermal papilla cells, the amount of implanted cells must be controlled to produce the same thickness of hair for same size of new born hair follicles. There are numerous factors which can effect the solving of transplantation issues, and this result increases its difficulty.
[0006] From above mentioned, a new cultivation method and apparatus for microtissues are needed urgently. Thus, based on the drawbacks of prior art, the inventor gave the utmost attention and finally invented the cultivation method for microtissues with experiment and research. Based on the spirit to work with perseverance, the problem of prior art was solved. The particular design in the present invention not only solves the problems described above, but also is easy to be implemented. Thus, the invention has the utility for the industry.
SUMMARY OF THE INVENTION
[0007] The original concept is to FIG. out a method for tissue cultivation which can cultivate hair follicle derma and epidermis cells to develop toward normal hair follicle style so as to ensure the transplantation efficiency, and can rapidly produce a large amount of microtissue array which can induce the growth of hair. In addition, the hair has appropriate arrangement direction after being transplanted to desired area.
[0008] According to above thought, a method for tissue cultivation, which includes steps of: (a) forming a patterned microarray on a hydrophobic membrane; (b) attaching the hydrophobic membrane to a carrier; (c) disposing plural cells on the hydrophobic membrane for the cultivation of microtissue; and (d) causing the plural cells to form plural hair follicle microtissues on the carrier according to the patterned microarray.
[0009] Preferably, the present invention which addresses a method for tissue cultivation further includes a step of forming a transplantation area on a dermal surface and disposing the hair follicle microtissue on the transplantation area.
[0010] Preferably, the present invention which addresses a method for tissue cultivation further includes a step of attaching the hair follicle microtissue to a substrate and cohering the substrate on the transplantation area to transplant the hair follicle microtissue on the transplantation area.
[0011] Preferably, the present invention which addresses a method for tissue cultivation, wherein the patterned microarray includes plural holes, and each of the plural holes has a diameter ranged from 200 μm to 800 μm.
[0012] Preferably, the present invention which addresses a method for tissue cultivation, wherein the plural cells include at least one being selected from a group consisting of an embryonic stem cell, a mesenchymal stem cell, a dermal papilla cell, a hair follicle stem cell, a hematopoietic stem cell, a dermal cell and an epidermis cell.
[0013] According to above thought, a method for tissue cultivation includes the steps of: (a) providing a membrane; (b) forming a hole on the membrane; (c) attaching said membrane to a carrier; (d) causing the hole to form a microwell with the carrier; (e) disposing plural cells on the membrane; and (f) cultivating the plural cells to form a microtissue in the microwell.
[0014] According to above thought, an apparatus for microtissue cultivation which includes a carrier; and a membrane disposed on the carrier and having a hole where plural cells are cultivated to form a microtissue.
[0015] Preferably, the present invention which addresses an apparatus for tissue cultivation which includes a substrate to cultivate the microtissue and to be cohered on a transplantation area to transplant the microtissue.
[0016] Preferably, the present invention which addresses an apparatus for tissue cultivation, wherein the membrane is a hydrophobic membrane and the material of the membrane includes at least one being selected from a group consisting of a siloxane, an alkene and a polycarbonate, and the carrier includes at least one being selected from a group consisting of a glass, a ceramics, a polystyrene, a silicon wafer, a gelatin and a metal.
[0017] According to above thought, an apparatus for microtissue cultivation which includes a membrane having a microwell for cultivating plural cells into a microtissue therein.
[0018] The present invention may best be understood through the following descriptions with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a diagram showing a membrane which is segmented by cutting machine according to an embodiment of the present invention;
[0020] FIG. 2 is a diagram showing a membrane after cutting according to an embodiment of the present invention;
[0021] FIG. 3 is a diagram showing membranes which are attached to a carrier according to an embodiment of the present invention; and
[0022] FIG. 4 is a diagram showing cultivated cells which are centralized in microwells structure according to an embodiment of the present invention.
[0023] FIG. 5 is an optical image showing cultivated microtissues in different sizes of holes according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purposes of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed.
[0025] In the embodiment of this invention, a method for microtissues cultivation, which includes: (a) forming a patterned microarray on a hydrophobic membrane; (b) attaching the hydrophobic membrane to a carrier; (c) disposing plural cells on the hydrophobic membrane for the cultivation of microtissue; and (d) causing the plural cells to form plural hair follicle microtissues on the carrier according to the patterned microarray.
[0026] The membranes utilized in this embodiment of this invention are hydrophobic and may be, but not limited to, made of a siloxane, an alkene or a polycarbonate. For example, polydimethylsiloxane (PDMS) of siloxane polymer may be used for the membrane due to its good oxygen infiltration, low surface energy and hydrophobic surface.
[0027] For manufacturing the hydrophobic membrane, first of all, PDMS and crosslinker can be mixed with a ratio of 10 to 1 in weight to form solution and then eliminate bubbles within the solution by using a vacuum ball. A suitable amount of solution is obtained and is smeared rotationally on a surface of base material (such as glass) equally. The PDMS will be formed as a membrane of PDMS by a crosslinking reaction after a few days.
[0028] Next, the base material 2 covered with PDMS membrane 1 is disposed under the cutting machine 3 as shown in FIG. 1 . FIG. 1 shows that the membrane 1 is segmented by the cutting machine 3 according to an embodiment of the present invention. In FIG. 1 , the cutting machine 3 is segmenting the membrane 1 to form particular pattern arrays which has plural holes 12 on that membrane 1 as shown in FIG. 2 . FIG. 2 shows a diagram of a membrane 11 after cutting according to the embodiment of the present invention. In this embodiment the diameter of the membrane 11 is around 15 mm, and the diameters of those holes 12 on the membrane 11 are around 200 μm to 800 μm. For example, the total amount of holes 12 may be hundreds to thousands. Laser sintering machine may be used for the cutting machine 3 , but not limited thereto, and a microarray spotter can be selected to form plural holes on the membrane. The shape of patterned arrays is not limited to a particular shape. As for forming particular patterned arrays on the membrane 1 , the patterned arrays can be depicted through AutoCAD on computer and then patterned array material can be inputted to the cutting machine 3 such as the laser sintering machine. The particular patterned arrays to fit in with necessity can be burned on the membrane 1 after setting appropriate parameters. The plural membranes 11 with particular patterned arrays should be cleaned by alcohol many times after the cutting is finished, and then, the membrane can be stored in alcohol for preparation after confirming there being not extra burned object and dust existing.
[0029] A few of alcohol can be applied to make those membranes to be attached to a carrier 4 after the preparation of the PDMS membrane as shown in FIG. 3 . FIG. 3 shows a diagram of membranes attached to the carrier 4 according to an embodiment of the present invention. The carrier 4 adopted in FIG. 3 may be a fillister 41 with 24 corning, but not limited thereto, and other materials such as glass, ceramics, polystyrene, poly N-isopropylacrylamide, silicon wafer, gelatin and metal can be chosen to form the carrier 4 . The shape of those membranes 11 can be matched up with and attached to the cell cultivation fillister 41 if the carrier 4 is the commercially available 24 corning. Those membranes 11 are disposed on the carrier 4 , and the holes 12 of the membranes 11 form a microwell structure with carrier 4 . Those are cleaned by phosphate-buffered isotonic saline (PBS) and join 0.5 ml DMEM (Dulbecco's Modified Eagle Medium, GIBCO) culture medium which contains 10% of fetal bovine serum (FBS), then put into the cell cultivation box for half an hour. After the extra air of DMEM cultivation solution attached to membranes 11 , bubbles are removed by a pipet to continue to process cell cultivation.
[0030] The cultivated cells in this embodiment of the present invention may be an embryonic stem cell, a mesenchymal stem cell, a dermal papilla cell, a hair follicle stem cell, a hematopoietic stem cell, a dermal cell, an epidermis cell or a combination thereof. The mesenchymal stem cells which are located within bone marrow are belonged to one kind of adult stem cells, and they are easily separated and cultivated with fast proliferation in vitro. Those stem cells can be differentiated to particular function of cells under stimulation of appropriate growth factors and are suitable due to possessing differentiation ability of similar a dermal papilla cell and a connective tissue sheath cell.
[0031] The dermal papilla cell are tight cell mass within a human body, and the implanted microtissues should be large in quantity and disposed close together to ensure enough induced signal produced from dermal papilla cells, in the other side, the cells will not produce new hair follicles if the microtissues are excessively loosen. Furthermore, since the thickness of hair is in relation to the size of dermal papilla cells, the amount of implanted cells must be controlled to produce same thickness of hair for same size of new born hair follicles. Thus, in the embodiment of this invention, the holes on the membrane used for cultivating cells may have diameters ranged from 200 μm to 800 μm and preferably from 200 μm to 400 μm.
[0032] Afterwards, a suitable amount of cultivated cells are extracted, and the dermal papilla cells with cell quantity counted by hemocytometer counter are put into a centrifugal machine with a rotation speed of 1,000 rpm for ten minutes. Those cells are attached into the above mentioned carrier 4 with particular patterned arrays of the membrane segments, then a culture medium is joined, and the cells may be cultivated, for example, in cells cultivation box (REVCO) with 5% CO 2 in 37 centigrade. The carrier 4 is drawn out every half an hour from the cells cultivation box and is shaken 3 to 4 times to bring the cells equally distributed on the membranes.
[0033] FIG. 4 is a diagram of the cultivated cells centralized in the plural microwell structure which is formed with the plural holes 12 and the carrier 4 of membrane 11 . Since PDMS is a high hydrophobic material, most cells do not attach to PDMS membranes, and the cells attach to culture medium of the carrier 4 by utilizing the nature of cells not being attached to PDMS, thus, the dermal papilla cells will be quite restrained and heaped in microwells. A large amount of cells can grow in the microwell 12 with narrow space, therefore, an objective of a local high density of cells quantity and area is achieved, and the microtissue can be formed for transplantation.
[0034] Although the above mentioned embodiment of this invention is to dispose membrane on a carrier to cultivate microtissue, the membrane can directly form microwells as well, and the bottom of microwell come into being suitable environment for cells to be attached and grow such as disposing the attachable culture medium in the bottom of microwell and then a microtissue can be formed by disposing and cultivating cells in the structure of microwell. This is to say, the membrane itself can contain the effect of carrier and this characteristic is also in the scope of this invention.
[0035] The formation of dermal papilla microtissue is observed.
[0036] In order to confirm the efficacy of the embodiment of this invention, the formation result of microtissue in the embodiment is observed below.
[0037] Referring to FIG. 5 , it shows an optical image of cultivated microtissues in different sizes of holes according to the embodiment of the present invention. A 4×10 5 cells are put in the microwell structure which is formed of individual holes and the carrier of membrane, and the cultivated dermal papilla will have the status of piling up in holes the next day in a size of 200 μm, 300 μm of microarray, but a similar cell mass of microtissue is not produced. A microtissue with a uniform ball shape which can be viewed with borders has the phenomenon of centralization apparently, and this microtissue will get together more tightly to cause a shrinkage in size after the third or fourth day, then the cells on borders will spread out toward the bottom of culture medium and this will lead to disappearance of borders of the original microtissue, and the status is maintained afterwards. And then the cultivation situations of dermal papilla cells in a hole with a bigger diameter and a hole with a small diameter are not quite the same. Initially there is not phenomenon of full out with overcrowded cells, but the upper layer of cells are gradually stacked after the bottom layer being posted level, after that these stacked cells will congregate toward one point. The formed microtissue is not like those in microholes with a small diameter to have apparent ball shape, but a stacked situation of a similar pillow shape is observed in certain range.
[0038] Besides, according to the experimental result of the embodiment in this invention revealed, wherein the 5×10 4 cells given to a 24 corning with measured area in 1.9 cm 2 will not form cell mass no matter what are the size of microholes. The cell mass can be formed in smaller size of microholes such as 200 μm, 300 μm and 400 μm when the cells being increased to above 1×10 5 in quantity, however the most portion of cultivated cells is with the situation of posted level to the culture medium, only small amount of cells will be stacked to form microtissue, hence the cultivated cell quantity will effect the formation of microtissue.
[0039] The microtissues which are similar to the dermal papilla taken from the beard of an ordinary mouse can be obtained efficiently within three days to five days by adoption of high cell density and a small size of microholes which are included in the patterned array with plural microwells structure. Since the size of dermal papilla from the beard of the ordinary mouse is ranged from 100 μm to 200 μm, the microtissues obtained in the patterned array with a hole size ranged from 200 μm to 400 μm are located within this range. Although there is formation of the dermal papilla microtissue under the cell density of 5.26×10 4 /cm 2 , the inventor discovered that the most large quantity and integrated model of microtissue was formed in cell density of 2.1×10 5 /cm 2 . For mass production, although the quantity of membrane holes is 100/1.9 cm 2 in the experiment, a 300 to 500 holes according to the hole sizes can be obtained on size of 1.9 cm 2 , and the smaller size of membrane holes can have the more large number of holes and obtain more usable microtissue efficiently.
[0040] In order to prove the effect of microtissue cultivation, a activity staining is applied to dermal papilla microtissue for different cultivation periods by utilizing Live/Dead Viability Kit, the experiment of activity staining for cell microtissues having cultivated for five days discovered that the microtissue show a large amount of green fluorescence and not show nearly any red fluorescence, and the appearance represents the cell is reactivated in these microtissues and only a few of cells are causing death. However, the experiment with microtissue cultivated with twelve days discovered red fluorescence in the middle portion, and the appearance represents internal portion of the microtissue cells being caused death, and after the cultivation which is experienced with many days, the cell in the internal of microtissue could not be obtained enough nutrition and the situation of causing death of internal cells is foreseeable.
[0041] For observation of whether these dermal papilla microtissues possess the induced ability to hair follicle revival, a anti-aSMA and a anti-NCAM antibodies with cell marks of a-smooth muscle actin which is shortened to a-SMA and NCAM to proceed the experiment of immune fluorescence dyeing for dermal papilla microtissue. In part of the experiment, the microtissue mass can smoothly dyed with these cell marks by adopting cultivation of three days, cultivation of five days and cultivation of seven days, however, wherein the dyeing experiment is performed after extended twelve days, the fluorescence strength in these cell mass is very weak. Many cells in microtissue after multiple days of cultivation are causing death, hence the stored a-SMA and NCAM is a few and the fluorescence strength is very weak. According the above result, the PDMS membrane with plural holes of patterned array can limit the ambit of cell growth and the forming dermal papilla microtissue actually contain the growth activity and possess the particular cell marks, however a cultivation in long period of time is not possible, because portion of cells will be causing death and loosing the capability to induce revival of hail follicle.
[0042] The transplantation of microtissues.
[0043] Owing to the short working range of induced signal generated from dermal papilla, the position of transplantation in vitro should be very close to epidermis of the dermal cell to ensure effective propagation of induced signal, or the dermal papilla cell and epidermis cells should be implanted to a deeper position under skin and direct the induced signal to propagate to epidermis cells. The microtissue which is cultivated with the method provided by the embodiment of this invention can be transplanted in vitro with transplantation methods of forming a transplantation area such as a wound on a dermal surface and disposing the hair follicle microtissue on the transplantation area, or attaching the cultivated microtissue to a substrate which can be a thing such as artificial skin and cohering the substrate on the transplantation area to transplant the hair follicle microtissue on the transplantation area. There are of course other transplanting methods, and any transplanting method to adopt cultivated microtissue of this invention is belonged the application area of this invention.
[0044] In summary the embodiment of above mentioned invention, the patterned array microtissue which is cultivated from the method of an embodiment of this invention can be developed toward normal hair follicles style and be guaranteed the transplantation efficiency, and can rapidly manufacture a large amount of microtissue array which can induce the growth of hair. In addition, the hair has appropriate arrangement direction after transplanting to desired area.
[0045] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. Therefore, the above description and illustration should not be taken as limiting the scope of the present invention which is defined by the appended claims. | A method for culturing microtissue is provided. The method includes steps of: (a) forming a pattern microarray on a hydrophobic film; (b) adhering the hydrophobic film to a carrier; (c) disposing a plurality of cells on the hydrophobic film for culturing depending on the pattern microarray, and forming a plurality of hair follicle microtissues. | 2 |
This application is a continuation of U.S. patent application Ser. No. 10/983,163 filed Nov. 5, 2004 now abandoned which claimed the benefit of provision application Ser. No. 60/517,998, filed Nov. 5, 2003.
BACKGROUND OF THE INVENTION
The present invention relates to a laser device used in aligning a hitch of a towing vehicle with a hitch coupler of a trailer to permit trailer coupling in a fast and easy manner.
When a trailer having a hitch coupler is to be hitched to a towing vehicle having a hitch, it is difficult to align the hitch with the hitch coupler because the driver of the towing vehicle is driving in a reverse direction and care must be exercised in aligning the hitch and hitch coupler together before the hitch coupler can be secured to the hitch.
There are many known systems, mainly mechanical systems, for helping in aligning the hitch with the hitch coupler. An example of this type of device is shown in United States Patent Application Publication No. US 2003/0051654 A1. An improvement on these mechanical systems was made when using light sources for use in the alignment process. Examples of these types of systems are shown in U.S. Pat. Nos. 6,120,052 and 6,386,572 B1.
The present invention provides a significant improvement to known systems by providing an easy and convenient system to permit a user to accurately and quickly align a trailer coupler with a trailer hitch.
SUMMARY OF THE INVENTION
The present invention relates to a trailer hitch alignment device which uses a pair of laser beams to properly align a hitch mounted to a towing vehicle with a hitch coupler mounted to a trailer. The invention includes a first laser light source mounted to the towing vehicle and oriented to direct a first laser light beam towards the trailer along a longitudinal axis of the trailer to impinge on a first marker spot located on the hitch coupler mounted to the trailer. A second laser light source is also mounted to the towing vehicle in spaced apart relation with the first laser light source and oriented to direct a second laser light beam towards the trailer at an angle to the first light beam to impinge on a second marker spot on the trailer when the hitch and hitch coupler are aligned. When the towing vehicle is moved towards the trailer with the first laser beam impinging on the first marker spot and further moved towards the trailer until the second laser beam impinges on the second marker spot, the hitch coupler is aligned with the hitch.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be clearly understood and readily carried into effect, a preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings wherein:
FIG. 1A is a schematic drawing depicting a towing vehicle and a fifth wheel trailer with a laser device according to the present invention mounted to the towing vehicle;
FIG. 1B is a top view of the schematic drawing shown in FIG. 1A ;
FIG. 2 is a front elevational view of a cover used with the present invention;
FIG. 3 is a top view of the cover shown in FIG. 2 ;
FIG. 4 is a cross sectional view taken along the line 4 - 4 in FIG. 2 ;
FIG. 5 is a front elevational view of the present invention with the cover removed;
FIG. 6 is a top view of the present invention shown in FIG. 5 ;
FIG. 7 is a bottom view of the present invention shown in FIG. 5 ;
FIG. 8 is a left hand view of the present invention shown in FIG. 5 ;
FIG. 9 is an elevational view of a laser light source used with the present invention;
FIG. 10 is a top schematic view of a towing vehicle having the present invention mounted thereto together with a trailer having a ball hitch coupler; and
FIG. 11 is a top schematic view as shown in FIG. 10 with the trailer separated from the towing vehicle.
DESCRIPTION OF PREFERRED EMBODIMENTS
A laser device 10 , according to the present invention, is shown in FIG. 1 where, in a preferred embodiment, it is attached to the rearward side of a cab provided on a conventional pulling vehicle 11 such as a pick up truck. Device 10 is centered laterally across the cab of the truck immediately behind the cab of the truck.
The laser device 10 includes a cover 12 as shown in FIGS. 2 and 3 . The cover 12 has a “L” shaped configuration as shown in FIG. 4 with a top wall 16 and a front wall 18 . Wall 18 of cover 12 has three openings 20 a , 20 b and 20 c , each opening receiving a laser light source 22 a , 22 b and 22 c , respectively.
The cover 12 partially encloses a channel base member 24 shown in FIGS. 5 through 8 . The channel base member 24 includes a top wall 26 , a bottom wall 30 and a back wall 28 . The cover 12 is placed on the channel base member 24 with the top wall 16 resting on top wall 26 of the channel base member 24 and the front wall 18 covering the space between channel base member walls 26 and 30 .
Screws (not shown) are used to secure the cover 12 to the channel base member 24 . The screws extend through openings 32 provided in cover top wall 16 and into threaded holes 34 provided in top wall 26 of the base channel member 24 .
The channel base member 24 is secured to the towing vehicle with screws or bolts and nuts 36 (shown in FIG. 8 ) which extend through openings 38 provided in top wall 26 and further through openings 40 provided in bottom wall 30 .
The laser light sources 22 a , 22 b and 22 c include a housing for allowing the laser light to be directed outwardly through openings 40 a , 40 b , and 40 c , respectively. At the end of the housing opposite the openings 40 a , 40 b , and 40 c a stem is provided which is fixedly secured to a ball 42 as shown in FIGS. 8 and 9 . A mounting plate 44 is provided for each of the laser light sources 22 a , 22 b and 22 c . The mounting plate 44 has an opening therethrough sized to receive the stem of the laser light sources but also sized sufficiently small to prevent the ball 42 from passing through the opening. Three screws 46 are used for securing the mounting plate 44 to the back wall 28 of the channel base member 24 . When the screws 46 are loosened the light source 22 a and correspondingly the light sources 22 b and 22 c may be swivelled on the ball 42 to a desired position. At the desired position, the screws 46 are then tightened to secure the light source 22 a , and correspondingly light sources 22 b and 22 c , in the desired position.
The laser light sources 22 a , 22 b , 22 c are powered from a power source not shown. In a preferred embodiment the power source is a 12 volt battery used with the towing vehicle. A switch (not shown) is used to selectively activate all three laser light sources 22 a , 22 b , and 22 c . The laser light sources are connected in parallel with wires 23 and 25 which are electrically connected to power cable 27 , as shown in FIG. 5 .
In operation, the laser device 10 is mounted, in a preferred embodiment, to the cab provided on a conventional pulling vehicle 11 with the laser light source 22 b being centered laterally across the truck at the longitudinal axis of the truck, immediately behind the cab of the truck.
The following description will relate to the use of the laser light sources in aligning a fifth wheel trailer with the hitch of a towing vehicle. As shown in FIG. 1B , a trailer coupler 48 is mounted to a fifth wheel trailer 50 . The towing vehicle 11 has a trailer hitch 52 mounted on the bed of the towing vehicle 11 . The laser light source 22 b provides a laser beam 54 and the laser light source 22 a provides a laser beam 56 . In order to properly orient the laser beams 54 and 56 , the towing vehicle 11 must first be hitched to the fifth wheel trailer 50 with the trailer coupler 48 engaging the trailer hitch 52 . When the fifth wheel trailer has been hitched to the towing vehicle 11 , the laser beam 54 is oriented by loosening the plate 46 and swivelling the laser light source 22 b so that the beam 54 is directed directly over the hitch 52 and centered on the upright trailer coupler 48 . In a preferred embodiment, an alignment marker strip 64 is attached to the trailer coupler 48 at a central location and the laser beam 54 adjusted to impinge on the marker strip. The plate 46 is then tightened so that the laser light source 22 b remains in this position.
As can be seen in FIG. 1B , with this orientation of laser light source 22 b , the light beam 54 passes directly over the trailer hitch 52 . Next, the laser beam 56 is oriented, again by loosening plate 46 and swivelling the light source 22 a to the desired position, so that the light beam 56 is vertically aligned with the light beam 54 on marker strip 64 . The plate 46 is then tightened to secure the laser light source 22 a at the selected position. With this orientation the light beam 56 passes over the trailer hitch 52 as shown in FIG. 1B .
The two laser light sources 22 a and 22 b can now be used to align the towing vehicle 11 having the trailer hitch 52 with a hitch coupler 48 of the fifth wheel trailer 52 .
When aligning the fifth wheel trailer with the towing vehicle, the vehicle 11 is driven in reverse until the laser beam 54 is centered on the marker strip 64 mounted to trailer coupler 48 . Reverse movement is then continued until the laser beam 56 impinges on the marker strip 64 at a position vertically above the light beam 54 . At this point, the trailer coupler 48 is directly above the trailer hitch 52 and can be lowered to hitch the fifth wheel trailer 52 to the towing vehicle 11 .
The present system can also be used to align a ball trailer hitch 58 mounted to the towing vehicle 11 to a ball hitch coupler 60 mounted to a trailer 62 as shown in FIGS. 10 and 11 . In using this device, it is convenient to use the alignment marker strip 64 mounted to the forward facing face of the trailer 62 . In a preferred embodiment, the laser light sources 22 b and 22 c are used to align the ball trailer hitch 58 with the ball hitch coupler 60 . As before, the trailer 62 is first hitched to the trailer ball hitch 58 of the towing vehicle 11 before aligning the light sources 22 b and 22 c . The laser beam 54 again is directed across the top of the ball trailer hitch 58 to impinge on the marker strip 64 . Laser source 22 c is then oriented, as above described, so that a laser light beam 66 impinges on the marker strip 64 at a position directly above the laser light beam 54 .
With this arrangement, and when aligning the trailer 62 with the towing vehicle 11 , the towing vehicle 11 is moved in a reverse direction until the light beam 54 is centered on the marker strip 64 , as was done before with the fifth wheel trailer. The vehicle 11 is then continued in reverse with the light beam 54 centered on the marker strip 64 until the laser beam 66 impinges on the marker strip 64 at a position directly above the light beam 54 as shown in FIG. 11 . At this position, the ball trailer hitch 58 is aligned with the ball hitch coupler 60 . The coupler 60 may then be lowered onto the ball hitch 58 .
The present invention can be used in a similar manner in hitching a towed vehicle having a tow bar to a towing vehicle. In this arrangement, the laser device 10 is mounted to the front of the towed vehicle with the laser beam 54 extending forwardly over the hitch coupler of the tow bar. The marker strip 64 is mounted on the towing vehicle vertically above the hitch provided with the towing vehicle. As before, the towed vehicle must be hitched to the towing vehicle to properly orient a second laser light source, either laser source 22 a or 22 c . Once the towed vehicle is hitched to the towing vehicle either light beam 56 or light beam 66 is oriented to impinge the marker strip 64 immediately above the light beam 54 .
After aligning the light beam 56 or 66 with the marker strip 64 , the laser light sources 22 b and 22 a or 22 c can be used to align the towed vehicle with the towing vehicle for properly hitching the vehicles together. When using the laser device 10 , in this manner, the towed vehicle is driven forwardly to orient the beam 54 on the marker 64 . The towed vehicle is then continued to be driven forwardly until the selected laser beam 56 or 66 impinges on the marker strip immediately above the light beam 54 . At this point the hitch and hitch coupler are properly aligned and may be joined to hitch the towed vehicle with the towing vehicle.
While the fundamental novel features of the invention have been shown and described, it should be understood that various substitutions, modifications, and variations may be made by those skilled in the art, without departing from the spirit or scope of the invention. Accordingly, all such modifications or variations are included in the scope of the invention as defined by the following claims: | The present invention includes a first laser light source mounted to a towing vehicle and oriented to direct a first laser light beam towards a trailer to impinge on a first marker spot located on a hitch coupler mounted to the trailer. A second laser light source is also mounted to the towing vehicle in spaced apart relation with the first laser light source and oriented to direct a second laser light beam towards the trailer at an angle to the first light beam to impinge on a second marker spot on the trailer when the hitch and hitch coupler are aligned. When the towing vehicle is moved towards the trailer with the first laser beam impinging on the first marker spot and further moved towards the trailer until the second laser beam impinges on the second marker spot, the hitch coupler is aligned with the hitch. | 1 |
RELATED APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 09/939,164, filed on Aug. 24, 2001, now U.S. Pat. No. 6,477,452, which is a continuation of U.S. patent application Ser. No. 09/607,189, filed on Jun. 29, 2000, which has been issued as U.S. Pat. No. 6,308,120 on Oct. 23, 2001.
A portion of this disclosure contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention relates to a vehicle service status tracking system and method.
SUMMARY OF THE INVENTION
The present invention provides a system and methods to allow multiple stations in geographically dispersed locations to monitor and track vehicle repair record and service status information. In a service area comprised of a number of geographically-bounded service regions, at least one regional communications terminal is provided in communication with a plurality of local communications terminals. Each local communications terminal is typically located at a separate repair or service location having responsibility for servicing the vehicles temporally located within the region.
The present invention provides a system and methods for maintaining and disseminating vehicle service information within and among regions. Vehicle service events are entered into a vehicle tracking system and maintained using a vehicle status database. Database files are exchanged among regional communications terminals and with a central equipment manager in order to provide timely and accurate dissemination of service status.
A further aspect of the present invention is the sharing of vehicle service status with marketing offices and retail locations. This enables personnel at such locations to understand the repair history of a particular vehicle.
A still further aspect of the present invention is the ability to predict vehicle availability or time of return from service. The system and methods according to the present invention provide an availability prediction for operations personnel to allocate fleet vehicles while taking account of anticipated vehicle demand.
Other advantages and objectives of the present invention are apparent upon inspection of this specification and the drawings appended thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram depicting the overall arrangement of a preferred embodiment of a vehicle tracking system according to the present invention;
FIG. 2 is a functional block diagram of a preferred embodiment of a vehicle tracking system according to the present invention;
FIG. 3 depicts the components of a preferred implementation of a local communications terminal and a regional communications terminal according to the present invention;
FIG. 4 depicts the contents of a vehicle status database according to a preferred embodiment of the present invention;
FIG. 5 depicts a preferred format for a control number for use with a vehicle tracking system according to the present invention;
FIG. 6 is an information flow diagram depicting the flow of vehicle repair and service status information throughout a preferred vehicle tracking system;
FIGS. 7A and 7B depict processing accomplished by a local communications terminal in a preferred embodiment of the present invention;
FIG. 8 depicts the processing accomplished by a regional communications terminal in a preferred embodiment of the present invention;
FIG. 9 depicts vehicle repair history processing performed by a local communications terminal and a regional communications terminal according to the present invention;
FIG. 10 is a preferred user interface by which a user enters equipment/location validation information at a local communications terminal according to the present invention;
FIG. 11 is a preferred user interface for a local communications terminal according to the present invention by which a user may enter portions of vehicle repair/service event information;
FIG. 12 is a preferred user interface for a local communications terminal according to the present invention by which a user may modify portions of vehicle repair/service event information;
FIG. 13 is a preferred user interface by which a local communications terminal according to the present invention displays a control number to a user;
FIG. 14A is a preferred user interface for a local communications terminal according to the present invention providing the capability for a user to edit location information and view location-related reports;
FIG. 14B is a preferred user interface for a local communications terminal according to the present invention providing the capability for a user to view a variety of repair shop oriented reports;
FIG. 14C is a preferred user interface for a local communications terminal according to the present invention providing the capability for a user to view a variety of traffic reports;
FIG. 14D is a preferred user interface for a local communications terminal according to the present invention providing the capability for a user to view a variety of special programs reports;
FIG. 15 is a preferred embodiment of an on-screen pop-up multiple breakdown advisory warning provided by a preferred embodiment of the present invention;
FIG. 16 is an example of a preferred campaign information warning report provided by a central equipment manager according to the present invention;
FIG. 17 is a preferred advisory warning generated by a local communications terminal and a regional communications terminal according to the present invention;
FIG. 18 is a preferred report generated by a local communications terminal according to the present invention showing a portion of the out-of-service vehicles whose service has not been completed within a projected repair time;
FIG. 19 is a preferred display of a calculated repair/service time provided by a local communications terminal according to the present invention; and
FIG. 20 is a preferred down equipment report generated by a local communications terminal and a regional communications terminal according to the present invention displaying information contained in a vehicle history file.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a system and methods to allow multiple stations in geographically dispersed locations to monitor and track vehicle repair record and service status information regardless of vehicle location.
FIG. 1 illustrates the overall arrangement of a preferred embodiment of a vehicle tracking system 100 according to the present invention. Referring now to FIG. 1, vehicle tracking system 100 includes a central equipment manager 101 , regional communications terminals 102 , and local communications terminals 103 . Preferably, a single regional communications terminal 102 is allocated to support a given particularly-bounded geographical region. For example, FIG. 1 shows three regions (Regions A, B, and C) each having a regional communications terminal 102 . However, one or more additional regional communications terminals 102 may provide backup communications and processing for one or more regions.
Each regional communications terminal 102 is preferably located in a regional company office or other such location having responsibility for maintaining and servicing the vehicles within a particular geographical region or regions. Each local communications terminal 103 is preferably located in a repair and service station having responsibility for repairing broken-down or out-of-service vehicles, as well as for providing routine service and preventive maintenance, for vehicles temporally within that region. A local communications terminal 103 communicates with a regional communications terminal 102 within its local region; however, a given local communications terminal 103 may communicate with one or more regional communications terminals 102 within or outside of its local region. Regional communications terminal 102 is thus provided in shared communication with multiple local communications terminals 103 .
FIG. 2 further illustrates the logical relationships among these elements of vehicle tracking system 100 . Referring now to FIG. 2, each regional communications terminal 102 communicates with central equipment manager 101 . Central equipment manager 101 maintains at a single office location vehicle service status information for all regions, and periodically disseminates this information to all regional communications terminals 102 and local communications terminals 103 .
In a preferred embodiment, each regional communications terminal 102 communicates with central equipment manager 101 and multiple local communications terminals 103 using a frame relay network 104 . Frame relay is a packet-switched protocol used for connecting terminals to a Wide Area Network (WAN) supporting T-1 or T-3 data rates. Alternatively, frame relay network 104 comprises public switched or private telecommunications circuits such as telephone landlines, the Internet, or wireless transmission systems including, but not limited to, personal communications services, cellular data, satellite, or point-to-point microwave communications. Regional communications terminals 102 are interconnected via frame relay network 104 .
Referring again to FIG. 2, vehicle tracking system 100 includes a vehicle status database 200 operably coupled to each local communications terminal 103 and regional communications terminal 102 . A vehicle status database 200 is also operably coupled to central equipment manager 101 . In a preferred embodiment, central equipment manager 101 is a mainframe computer system, such as a DEC® VAX™ or IBM® Model 3070 system, having a frame relay gateway and an Internet interface. Alternatively, central equipment manager 101 is implemented according to a client-server architecture. Central equipment manager 101 preferably communicates with regional communications terminals 102 via frame relay network 104 and with local communications terminal 103 via Internet interface 108 .
Central equipment manager 101 transmits a multiple breakdown advisory 215 (see FIG. 6) to all local communications terminals 103 and all regional communications terminals 102 , preferably once per 24-hour period. Central equipment manager 101 transmits a multiple breakdown advisory 215 to local communications terminals 103 as a database file via File Transfer Protocol (FTP) using Internet interface 108 . Preferably, central equipment manager 101 transmits multiple breakdown advisory 215 to regional communications terminals 102 as a database file via frame relay network 108 . Users at repair/service locations having local communications terminal 103 are able to withhold rental of vehicles listed on multiple breakdown advisory 215 if, in the user's judgment, the vehicle's repair history indicates a high likelihood of break-down during an extended trip such as, for example, an inter-regional or cross-country trip. This allows an operator of vehicle tracking system 100 to achieve higher overall customer satisfaction and to save money on operating costs such as vehicle towing.
Preferably, multiple breakdown advisory 215 is also used to indicate additional conditions affecting the status of a given vehicle such as, but not limited to, a stolen or missing vehicle. For example, FIG. 17 illustrates a preferred advisory warning generated by local communications terminal 103 and regional communications terminal 102 in response to receiving a multiple break-down advisory 215 from central equipment manager 101 providing and indication of a stolen or missing vehicle.
Referring again to FIG. 2, a local communications terminal 103 typically provides vehicle service status file 205 to a single regional communications terminal 102 . However, as shown in FIG. 2, local communications terminal 103 may alternatively provide vehicle service status file 205 to multiple regional communications terminals 102 located in different regions. The latter situation may occur, for example, when local communications terminal 103 is located sufficiently physically proximate to two or more regional communications terminals 102 such that it is advantageous for that repair/service location to support vehicles within the control span of either or both regional offices.
Referring again to FIG. 2, local communications terminal 103 includes an interface for receiving an entity master list 280 (see FIG. 6) transmitted from central equipment manager 101 . Preferably, central equipment manager 101 transmits entity master list 280 using FTP via Internet interface 108 . The entity master list 280 is useful for identifying the current set of regional company offices, retail locations, and marketing offices.
Local communications terminal 103 includes an interface to an Automated Repair Management System (ARMS) 105 for receiving vehicle history file 210 transmitted from central equipment manager 101 . In a preferred embodiment, ARMS 105 is a frame relay network. Central equipment manager 101 preferably transmits vehicle history file 210 to local communications terminals 103 as a database file via File Transfer Protocol (FTP) using ARMS 105 .
Referring again to FIG. 2, local communications terminal 103 preferably includes interfaces to retail outlet 106 and marketing office 107 using frame relay network 104 . Local communications terminal 103 transmits vehicle service status file 205 to retail outlet 106 and marketing office 107 via frame relay network 104 . In a preferred embodiment, retail outlet 106 and marketing office 107 include an availability database 300 containing, without limitation, information concerning the availability status of vehicles in the fleet. Users at retail outlet 106 and marketing office 107 are able to allocate vehicle resources to customers, and to predict equipment availability to customers, using the vehicle repair and service status provided in vehicle service status file 205 and availability database 300 .
FIG. 3 shows a preferred implementation of local communications terminal 103 and regional communications terminal 102 . Local communications terminal 103 and regional communications terminal 102 include a personal computer based server 150 having standard peripherals including monitor, printer (not shown), keyboard and mouse (not shown), and having an interface to a frame relay network 104 and an Internet interface 108 , and having a vehicle status database 200 . In a preferred embodiment, server 150 is an Intel® Pentium™-based personal computer (PC) running Microsoft® Windows™ operating system software, including Windows NT™ version 4.0. Server 150 executes programmed instructions in accordance with a software application program in order to achieve the functionality described herein. In a preferred embodiment, server 150 application software is written in FoxPro™ version 2.6 for Microsoft® Windows™. In a preferred embodiment, vehicle tracking system 100 includes two independent application programs: one application program for execution at local communication terminal 103 , and a second application program for execution at regional communications terminal 102 .
Local communications terminal 103 and regional communications terminal 102 include a web browser and electronic mail capability to enable electronic communication using the Internet, including Hypertext Transport Protocol (HTTP), File Transfer Protocol (FTP), and Simple Mail Transfer Protocol (SMTP). In a preferred embodiment, local communications terminal 103 and regional communications terminal 102 use Microsoft® Internet Explorer™ and Outlook™ application software.
In a preferred embodiment, vehicle status database 200 is implemented using FoxPro™ version 2.6™ version 7.0. Server 150 interfaces with vehicle status database 200 using FoxPro™ queries and instructions.
FIG. 4 describes the contents of vehicle status database 200 . Referring now to FIG. 4, vehicle status database 200 includes one or more vehicle service status files 205 , a vehicle history file 210 , and multiple break-down advisory 215 .
FIG. 6 illustrates the flow of vehicle repair and service status information comprising vehicle status database 200 throughout vehicle tracking system 100 , as described herein.
Vehicle service status file 205 is comprised of one or more service event notifications 220 . A service event notification 220 is created or modified by a user, usually a service professional, at a local repair or service location by logging vehicle repair and service information using local communications terminal 103 . Referring again to FIG. 4, service event notification 220 may include, for example, a control number 225 , a vehicle identifier 230 , an equipment type indicator 235 , current status 240 , location identifier 245 , date-in-building indicator 250 , type-of-service-required indicator 255 , an availability prediction 260 , and remarks 265 .
In a preferred embodiment, local communications terminal 103 provides for generation of availability prediction 260 by calculating an average repair/service time for the particular location and providing this information to the user. To calculate the average repair/service time, local communications terminal 103 retrieves from vehicle status database 200 service event notifications 220 for repair/service activities accomplished at this service location during the past thirty days. Local communications terminal 103 then computes an average repair/service time by averaging the number of days from date-in-building 250 to closing of the service event notification 220 for each service event notification within the thirty day period. FIG. 19 illustrates a preferred display of the calculated repair/service time provided by local communications terminal 103 . Alternatively, a period of time of shorter or longer duration than thirty days is used in calculating the average repair/service time. Preferably, the average repair/service time is calculated daily. Local communications terminal 103 displays the calculated average repair/service time to the user. Local communications terminal 103 further includes an operator interface that allows the user to enter availability prediction 260 using a keyboard, the user having considered a variety of factors including the average repair/service time.
In a first alternative, local communications terminal 103 calculates availability prediction 260 based on, without limitation, the mean-time-to-repair (typically measured in hours) to complete a particular service job for a particular item of equipment. In this alternative embodiment, vehicle status database 200 further includes a set of mean-time-to-repair values indexed by equipment type 235 and type-of-service-required 255 . Mean-time-to-repair values are periodically updated in response to changes in the calculated average repair/service time described above. Local communications terminal 103 sets availability prediction 260 equal to the mean-time-to-repair value associated with the particular equipment type 235 and type-of-service-required 255 . Local communications terminal 103 may modify availability prediction 260 based upon user-provided factors such as, but not limited to, the service backlog at this location, staffing levels at this location, and parts availability.
In a second alternative embodiment, local communications terminal 103 automatically calculates availability prediction 260 by setting availability prediction 260 equal to the date occurring three business days following the date service event notification 220 is entered into vehicle service database 200 . Local communications terminal 103 further includes an operator interface that allows a user to modify availability prediction 260 by manually entering a different projected availability date using a keyboard.
Local communications terminal 103 stores availability prediction 260 with its associated service event notification 220 record using vehicle status database 200 . In a preferred embodiment, availability prediction 260 is included in the service event notification 220 record as shown in FIG. 4 . Alternatively, the service event notification 220 record includes a pointer to a memory location containing availability prediction 260 .
FIG. 5 shows a preferred control number 225 for use with vehicle tracking system 100 . Referring now to FIG. 5, control number 225 is formed by sequentially concatenating two numeric digits corresponding to the current month, two numeric digits corresponding to the current day of the month, and a three-digit sequential service number 275 . Service number 275 is preferably determined by local communications terminal 103 at the time the user enters a new service event notification 220 . A distinct control number 225 is provided for each service request for an individual vehicle. Control number 225 thus patently conveys to an observer an indication of: (1) the date that a particular service event notification 220 was created for the associated vehicle, and (2) the order in which that service event notification 220 was created with respect to other service event notifications 220 logged by that local communications terminal 103 on a particular date.
Referring again to FIG. 4, vehicle service status file 205 is comprised of the service event notifications 220 entered or modified at a local communications terminal 103 since the last time vehicle service status file 205 was uploaded to regional communications terminal 102 . In a preferred embodiment, vehicle service status file 205 is created by local communications terminal 103 immediately prior to uploading it to regional communications terminal 102 . Local communications terminal 103 creates vehicle service status file 205 by formulating a query requesting retrieval all of the service event notifications 220 entered or modified (e.g., service ticket closed at the completion of repair, service location changed) since the time of the most recent upload. The retrieved service event notification 220 records are then stored as vehicle service status file 205 using vehicle status database 200 .
Referring again to FIG. 6, vehicle service status file 205 is then uploaded to regional communications terminal 102 using frame relay network 104 . In a preferred embodiment, local communications terminal 103 automatically uploads vehicle status file 205 periodically at a frequency of once every 30 minutes. Alternatively, the frequency of upload can be decreased to minimize the number of transmissions or increased to approach real-time notification. Personnel at regional company offices use regional communications terminal 102 to determine equipment status and location in order to manage reservations. For example, if equipment is scheduled to be serviced in a particular region, personnel at other regions will not reserve that vehicle for an inter-regional trip.
Regional communications terminal 102 aggregates each of the vehicle status files 205 received from local communications terminals 103 into a vehicle service status report 285 . Regional communications terminal 102 then transmits vehicle service status report 285 to central equipment manager 101 . In a preferred embodiment, regional communications terminal 102 automatically uploads vehicle service status report 285 periodically at a frequency of once every 30 minutes. In a preferred embodiment, vehicle service status report 285 is uploaded from regional communications terminal 102 using frame relay network 104 .
Vehicle history file 210 comprises all of the service event notifications 220 associated with a particular vehicle identifier 230 , preferably including all service event notifications 220 occurring in the previous twelve-month period.
Vehicle history file 210 is received by local communications terminal 103 and regional communications terminal 102 from central equipment manager 101 and stored using vehicle status database 200 . FIG. 20 illustrates a preferred down equipment report generated by local communications terminal 103 and regional communications terminal 102 displaying information contained in vehicle history file 210 received from central equipment manager 101 . Vehicle history file 210 preferably includes multiple breakdown advisory 215 , a separate indication also provided by central equipment manager 101 . In a preferred embodiment, multiple breakdown advisory 215 is provided as a separate record of vehicle history file 210 . Users of vehicle tracking system 100 are able to detect root cause problems or other systemic problems based on the pattern of recurring repair/service actions for a particular vehicle provided by vehicle history file 210 . For example, a series of dead battery service events can be indicative of an underlying electrical problem. Local communications terminal 103 and regional communications terminal 102 provide a history search capability to allow a user to review service event notifications 220 for a particular vehicle occurring over a period of time which is preferably the previous twelve-month period.
FIGS. 7A and 7B describe the processing accomplished by local communications terminal 103 in a preferred method of managing a fleet of vehicles, and vehicle repair record and service status information, in vehicle tracking system 100 (see FIG. 1) having multiple geographically remote service locations, according to the present invention.
Referring now to FIG. 7A, a user of vehicle tracking system 100 uses local communications terminal 103 to enter and log vehicle repair and service information (block 301 ). FIG. 10 illustrates a preferred user interface for local communications terminal 103 by which a user enters equipment/location validation information. Specifically, upon a determination of a repair or service action being required for a particular vehicle, a user enters information specific to the repair/service event using local communications terminal 103 . Referring again to FIG. 4, such user-entered repair/service event information includes, but is not limited to, vehicle identifier 230 , equipment type 235 , current status 240 , type of service required 255 , location 245 , date_in_building 250 , and any specific explanatory remarks 265 . FIG. 11 depicts a preferred user interface for local communications terminal 103 by which a user may enter portions of vehicle repair/service event information. FIG. 12 depicts a preferred user interface for local communications terminal 103 by which a user may modify portions of vehicle repair/service event information.
In a typical application, local communications terminal 103 is located in a repair and service station having responsibility for repairing and servicing vehicles. Referring again to FIG. 7A, a user, such as a service professional, preferably enters the repair/service event information using an interactive data entry screen and keyboard/mouse provided by local communications terminal 103 . For example, repair/service event information may be manually entered from a written work order, or, alternatively, in conjunction with creation of a written work order.
Alternatively, local communications terminal 103 receives repair/service event information from an external source via Internet interface 108 (block 303 ). External sources include, but are not limited to, a mobile repair unit, a remote repair or service location, or other location not equipped with local communications terminal 103 . In this case, an external source transmits vehicle repair/service information to local communications terminal 103 using an electronic message such as, for example, an email message, over Internet interface 108 .
After entry or receipt of vehicle repair/service information, local communications terminal 103 generates control number 225 for a new service event notification 220 as described herein in reference to FIG. 5 (block 305 ). FIG. 13 illustrates a preferred user interface by which local communications terminal 103 displays the generated control number 225 to a user. Local communications terminal 103 also generates availability prediction 260 as described elsewhere herein (block 307 ). In a preferred embodiment, control number 225 is generated per block 305 prior to availability prediction 260 being generated per block 307 ; however, these two operations may be accomplished without regard to any particular sequence, or in parallel as well. After obtaining vehicle repair/service information in blocks 301 or 303 , generating control number 225 in block 305 , and generating availability prediction 260 in block 307 , local communications terminal 103 creates service event notification 220 using this information as shown in FIG. 4 (block 309 ).
After creating service event notification 220 , each such new service event notification 220 is stored in the local vehicle status database 200 operably coupled to the local communications terminal 103 that generated that service event notification 220 (block 311 ). FIGS. 14A through 14D illustrate a preferred user interface for local communications terminal 103 by which a user may request to receive a variety of service event reports generated by local communications terminal 103 using the vehicle repair/service information contained in vehicle repair database 200 .
Referring now to FIG. 14A, local communications terminal 103 provides the capability for a user to edit location information and view location-related reports.
Referring now to FIG. 14B, local communications terminal 103 provides the capability for a user to view a variety of repair shop oriented reports, including reports indicating various aspects of equipment disposition and availability at this location, including equipment for which the scheduled repair date has been exceeded. FIG. 18 illustrates a preferred report generated by local communications terminal 103 showing a portion of the out-of-service vehicles whose service has not been completed within a projected repair time.
Referring now to FIG. 14C, local communications terminal 103 provides the capability for a user to view a variety of traffic reports.
Referring now to FIG. 14D, local communications terminal 103 provides the capability for a user to view a variety of special programs reports, including campaign information (received from, for example, a particular vehicle manufacturer), equipment history search, control number search, and shop transfers.
Referring now to FIG. 7B, service event notification 220 processing as described with respect to FIG. 7A continues as required at local communications terminals 103 (reference blocks 313 , 315 , and 317 ). However, new service event notifications 220 are periodically uploaded to regional communications terminal 102 (block 331 ), marketing offices 107 (block 333 ), and retail outlets 106 (block 335 ). Local communications terminal 103 maintains a series of software-implemented upload timers used to determine when the current set of new service event notifications 220 are collected and uploaded to each of these destination nodes. In a preferred embodiment, a first timer, TIMER_1, is used to determine when local communications terminal 103 uploads the current set of new service event notifications 220 to regional communications terminal 102 (block 313 ). Another timer, TIMER_2, is used to determine when local communications terminal 103 uploads the current set of new service event notifications 220 to marketing office 107 (block 315 ). A third timer, TIMER_3, is used to determine when local communications terminal 103 uploads the current set of new service event notifications 220 to retail outlets 106 (block 317 ).
In a preferred embodiment, local communications terminal 103 employs three separate upload timers each having independent expiration times but each being set to a value of approximately 30 minutes. The timer values are each independently modifiable by the user. In a first alternative embodiment, a single timer may be used to effect periodic uploading of the current set of new service event notifications 220 to regional communications terminal 102 , marketing offices 107 , and retail outlets 106 . In a second alternative embodiment, service event notification 220 upload is accomplished aperiodically in response to the occurrence of one or a combination of external events, or upon receiving an upload request from the destination node.
Referring again to FIG. 7B, upon the expiration of upload TIMER — 1 (block 313 ), local communications terminal 103 retrieves from its local vehicle status database 200 the set of service event notifications 220 entered since the time of the last upload action associated with TIMER — 1 (block 319 ). In a preferred embodiment, this is accomplished by formulating a database query to retrieve service event notifications 220 having entry dates later in time than the most recently accomplished upload action associated with TIMER — 1. This database query is then transmitted to vehicle status database 200 . Vehicle status database 200 responds by providing to local communications terminal 103 the set of service event notifications 220 , if any, meeting the query criteria.
Local communications terminal 103 gathers the set of service event notifications 220 from block 319 into a vehicle service status file 205 (block 325 ) as described in FIG. 4 . In block 331 , local communications terminal 103 then uploads vehicle service status file 205 to regional communications terminal 102 via Frame relay network 104 . Similarly, upon the expiration of upload TIMER — 2 (block 315 ), local communications terminal 103 retrieves from its local vehicle status database 200 the set of service event notifications 220 entered since the time of the last upload action associated with TIMER — 2 (block 321 ). Local communications terminal 103 gathers the set of service event notifications 220 from block 321 into a vehicle service status file 205 (block 327 ). In block 333 , local communications terminal 103 then uploads vehicle service status file 205 to marketing office 107 via frame relay network 104 .
Further, upon the expiration of upload TIMER — 3 (block 317 ), local communications terminal 103 retrieves from its local vehicle status database 200 the set of service event notifications 220 entered since the time of the last upload action associated with TIMER — 3 (block 323 ). Local communications terminal 103 gathers the set of service event notifications 220 from block 323 into a vehicle service status file 205 (block 329 ). In block 335 , local communications terminal 103 then uploads vehicle service status file 205 to retail outlet 106 via frame relay network 104 .
Referring now to FIG. 8, regional communications terminal 102 receives vehicle service status file 205 from one or more local communications terminals 103 via frame relay network 104 (block 351 ). Upon receiving vehicle service status file 205 , regional communications terminal 102 stores vehicle service status file 205 using its local vehicle status database 200 (block 353 ).
Regional communications terminal 102 maintains a software-implemented upload timer to determine when the current set of new vehicle service status files 205 are to be collected and uploaded to central equipment manager 101 (block 355 ). In a preferred embodiment, regional communications terminal 102 upload timer is set to a value of approximately 30 minutes. The timer value may be modified as required by the user. Alternatively, vehicle service status file upload is accomplished aperiodically in response to the occurrence of one or a combination of external events, or upon receiving a request for upload from central equipment manager 101 .
Upon the expiration of the upload timer (block 355 ), regional communications terminal 102 retrieves from its local vehicle status database 200 the set of vehicle service status files 205 entered since the time of the last upload action (block 357 ). In a preferred embodiment, this is accomplished by formulating a database query to retrieve vehicle service status files 205 having receipt dates later in time than the most recently accomplished upload action. This database query is then transmitted to vehicle status database 200 . Vehicle status database 200 responds by providing to regional communications terminal 102 the set of vehicle service status files 205 , if any, meeting the query criteria.
Regional communications terminal 102 collects the set of vehicle service status files 205 from block 357 into a vehicle service status report 285 (block 359 ). In a preferred embodiment, vehicle service status report 285 is a single file formed by sequentially appending the contents (i.e., service event notification 220 records) of each vehicle service status file 205 in a sequence from oldest to newest (with respect to time of receipt). In block 361 , regional communications terminal 102 then uploads vehicle service status report 285 to central equipment manager 101 via frame relay network 104 .
In a preferred embodiment, local communications terminal 103 and regional communications terminal 102 receive vehicle history file 210 , entity master 280 , and multiple breakdown advisory 215 from central equipment manager 101 once per 24-hour period.
Referring now to FIG. 9, central equipment manager 101 periodically transmits vehicle history file 210 to local communications terminals 103 and regional communications terminals 102 using electronic network 105 . Electronic network 105 may be referred to as an Automated Repair Management System (ARMS). Local communications terminal 103 and regional communications terminal 102 receive vehicle history file 210 (block 371 ) and store the received vehicle history file 210 using vehicle status database 200 (block 377 ).
Local communications terminal 103 and regional communications terminal 102 receive additional information from central equipment manager 101 via electronic network 105 . For example, FIG. 16 provides an example campaign information warning report received from central equipment manager 101 .
Referring again to FIG. 9, central equipment manager 101 periodically transmits entity master 280 list to local communications terminals 103 using Internet interface 108 and to regional communications terminals 102 using frame relay network 104 . Upon receiving entity master 280 list (block 373 ), local communications terminal 103 and regional communications terminal 102 store the received entity master 280 list using vehicle status database 200 (block 379 ).
Central equipment manager 101 also transmits multiple break-down advisory 215 to all local communications terminals 102 and all regional communications terminals 103 . Upon receiving a multiple breakdown advisory (block 375 ), local communications terminal 103 and regional communications terminal 102 provide a multiple breakdown advisory warning (block 387 ) to alert the user to consider this information in assessing the suitability of the vehicle for a particular rental itinerary. In a preferred embodiment, local communications terminal 103 and regional communications terminal 102 provide the advisory warning in the form of an on-screen pop-up warning box on the display device of processor 150 . FIG. 15 illustrates a preferred embodiment of an on-screen pop-up multiple breakdown advisory warning.
In addition, regional communications terminal 102 reviews service event notifications 220 received from local communications terminals 103 in vehicle service status files 205 for actual service completion times (block 381 ).
In a preferred embodiment, regional communications terminal 102 determines if the repair/service action has not occurred by the time specified by availability prediction 260 . Specifically, if the repair/service action is not accomplished within 24 hours of the projected completion date specified by availability prediction 260 (block 383 ), then regional communications terminal 102 provides a service time advisory warning (block 389 ). The time in excess of the availability prediction 260 that triggers the advisory warning is user-programmable from as little as two hours to as long as four weeks. In a preferred embodiment, regional communications terminal 102 provides the service time advisory warning in the form of an on-screen pop-up warning text box on the display device of processor 150 . The user may thereafter take corrective action such as, for example, telephoning the service location to determine the cause of the service delay.
In a preferred embodiment, local communications terminal 103 reviews service event notifications 220 for vehicles whose number of repair/service actions exceed a pre-defined threshold (block 385 ). If the repair threshold has been exceeded, then regional communications terminal provides multiple breakdown advisory 215 as described above for block 387 . In a preferred embodiment, the pre-defined threshold for multiple breakdown advisory is two service event notifications 220 within the last sixty-day period. If the threshold is exceeded, multiple breakdown advisory 215 provides the user the option of retrieving and displaying or printing the service event notifications 220 associated with the vehicle.
Thus, a system and methods for managing a fleet of vehicles has been shown that allows multiple geographically dispersed locations to monitor and track vehicle service status, including generating a prediction of vehicle availability.
While the above description contains many specific details of the preferred embodiments of the present invention, these should not be construed as limitations on the scope of the invention, but rather are presented in the way of exemplification. Other variations are possible. Accordingly, the scope of the present invention should be determined not by the embodiments illustrated above, but by the appended claims and their legal equivalents. | A system and methods to allow multiple stations in geographically dispersed locations to monitor and track vehicle repair record and service status information in a coordinated fashion. In a service area comprised of a number of geographically-bounded service regions, at least one regional communications terminal is provided in communication with a plurality of local communications terminals. Each local communications terminal and regional communications terminal communicates with a vehicle service status database. Vehicle service events are entered into a vehicle tracking system and maintained using the vehicle status database. Database files are exchanged between local communications terminals and regional communications terminals and with a central equipment manager in order to provide timely and accurate dissemination of service status. Vehicle service status, including an equipment availability prediction, is shared with marketing offices and retail locations to enable personnel at such locations to make informed decisions in allocating particular equipment to a customer based on the customer's needs. | 6 |
This is a national phase filing of International Application No. PCT/US2009/02260, which was filed on Apr. 10, 2009 and published in English on Oct. 15, 2009, which application claims the benefit of priority of U.S. Provisional Application No. 61/123,724 filed on Apr. 10, 2008, the entire contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a reward system to be used in connection with video game or computer software game players and/or members, and a method of using such a system.
2. Background of the Invention
The video game industry generated $21 billion in 2008, and there are over 11 million people in North America who participate as online gaming subscribers. In addition, 69% of American heads of households play computer and video games.
Moreover, 36% of American parents say they play computer and video games. Further, 80 percent of gamer parents say they play video games with their kids, and 66% feel that playing games has brought their families closer together. Thirty-eight percent of all game players are women. In fact, women over the age of 18 represent a significantly greater portion of the game-playing population (31%) than boys age 17 or younger (20%).
Forty-nine percent of game players say they play games online one or more hours per week. In addition, 34 percent of heads of households play games on a wireless device, such as a cell phone or personal digital assistant (PDA), up from 20% in 2002.
The Entertainment Software Association estimates that fifty-three percent of game players expect to be playing as much or more ten years from now than they do today. This massive audience of gamers is still within the infancy stage and will continue to grow as advancements in technology foster greater and easier accessibility into a wider demographic composition for engaging in online recreational activities.
In addition, online retail spending continues to grow at rates in excess of 20 percent year-over-year and comprises a significant portion of corporate revenue. This percentage shows no signs of slowing down or decreasing over time. The e-commerce implosion that occurred back in Y2K is no longer a consumer concern as online travel commerce, which is a more developed market, continues to experience double-digit gains.
Moreover, the Internet has emerged as a global medium for communication, information, commerce, and currently holds the largest repository of software titles for gamers.
The Internet's growing adoption rate has resulted in people who enjoy playing software games and wish to convert their hours of playtime into discounts when conducting commerce over the Internet. As consumers have recognized the advantages of e-commerce and have become more comfortable with the reliability and security of the Internet, companies have begun to offer more complex products and services online. Moreover, the adoption rate of the Internet as a vehicle for shopping has grown dramatically, and software gamers in general are typically familiar and comfortable conducting online transactions.
The growing acceptance of the Internet and e-commerce presents a significant opportunity for people to more efficiently and effectively research and purchase goods and services they desire. The vast information sharing and communications power of the Internet is expected to continue to influence significantly e-commerce for both consumers and product providers.
The present invention serves as a bridge between the gaming community and Internet commerce. For example, the invention described herein:
Can cost-effectively and efficiently reach and serve a large group of customers electronically from a central location. Can provide personalized, low-cost and real-time customer interaction. Will have low administrative costs because all information is captured and stored digitally. Will constantly be collecting and collating dynamic demographic and behavioral data about customers, increasing opportunities for direct marketing and personalized services.
In addition:
Users of the present invention (referred to herein as “members”) can quickly communicate or access account information without geographic or temporal limitations. Members can enjoy discounts and greater online shopping experience. Members can access a vast amount of information regarding the pricing, quality and specifications of products and services.
The present invention is advantageous as an Internet-based marketing and customer acquisition model for at least the following reasons:
The vast majority of computer based games are Internet accessible and require no warehousing and only physical or electronic delivery of a contract. Through a single medium, consumers can access information and compare products and prices from a vast number of e-commerce enabled companies. Members can compare the prices and specification of various products at their own pace, without sales pressure while exchanging their player points for an automatic discount. Consumer data related to members can be efficiently captured through a website, allowing real-time automated customer acquisition and streamlined overall processing. “White labeled” companies can reduce the inefficiencies and high costs associated with marketing and customer acquisition.
Possible sources of revenue from the present invention include the following:
Membership fees collected from enrolled gamers. Advertising revenue—the website may be used as a venue for tapping into a clearly defined niche market. Fees from marketing partners who sell context-appropriate products, such as peripherals and accessories manufacturers that are geared for the gaming community. White labeling—by allowing PC manufacturers and affinity groups the opportunity to employ the rewards system of this invention to directly service their own constituencies.
SUMMARY OF THE INVENTION
A reward system for a player of video games or computer games comprises:
(a) a gaming platform for participating in a video game or computer game; (b) a data collection module in communication with the platform, wherein the data collection module obtains and stores information received from the platform and assigns rewards points based upon the data and predetermined parameters; and (c) a purchasing module in communication with the data collection module, wherein the purchasing module receives information from the data collection module regarding the player's purchasing choices and arranges for the purchase of items corresponding to the choices.
In one embodiment the gaming platform is a personal computer or a videogame system such as PLAYSTATION 3®, XBOX® or Wii®.
In another preferred embodiment the data collection module is at least one computer server.
In another preferred embodiment, the purchasing module is at least one computer server.
The gaming platform, data collection module and purchasing module are all interconnected via the Internet to enable the player to use the reward system to acquire rewards points based upon various predetermined parameters, and to redeem the points acquired to purchase various items.
In one embodiment of this invention, the member is connected to the Internet via a personal computer. In another embodiment, the member is connected to the Internet via a mobile phone. In yet another embodiment, the member is connected to the Internet via a portable computing device such as a PDA.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic of web server operation.
FIG. 2 depicts an overview of a MySQL database.
FIG. 3 depicts an overview of the server arrangement in one embodiment of the invention.
FIG. 4 depicts an overview of a server farm arrangement.
FIG. 5 depicts an overview of a search engine bot.
FIG. 6 depicts a schematic of one embodiment of this invention.
FIG. 7 depicts a schematic of another embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The following definitions may be useful in connection with the detailed description of the invention set forth below.
Search Engine—Search engines work by compiling and storing information about a vast universe of web pages. These pages are retrieved by “bots” (also known as web crawlers or web robots)—which is basically a scripted computer program that scourers the web, cataloging every page and link (URL) that it encounters.
Information about these web pages are processed and stored in index database for people (in this case members) to query and retrieve. The information collected is stored in cache memory as simple text words, which can be very helpful when the web page itself has been updated or changed. When a member enters a query into a search engine, the search engine examines its database it gives a listing of web pages containing the information (or in this case product) according to its criteria.
Most search engines rank the results to provide the “best” results first. Search engines are also generally commercial ventures that are supported in part by ad revenue such as “sponsored links”.
FIG. 1 depicts a schematic of the interaction of a search engine database and a web server. As depicted in FIG. 1 , a query is entered into the search engine database. The query is routed to various search engine bots that search various databases to obtain the information desired, and transmit the information obtained to the search engine database, which then prepares and outputs the information obtained as a list of results.
Heuristic Algorithms—A heuristic algorithm is an algorithm that works to return optimal results for a searched-for item. The purpose of using algorithms is to provide good or better results quickly. Algorithms are essential to the way the search engine employed in conjunction with the present invention processes information. The algorithm tells the computer server what specific steps to perform and in what order.
An example of a heuristic algorithm in connection with this invention is when a member inputs the desired item that she wants, the heuristic algorithms takes the member's input and analyzes its database for a listing of that item, with the closest matching item and merchant first. Heuristic algorithms also are used to search the database of paid advertising merchants, displaying sponsored links on the right side of the member's web browser. Heuristic algorithms also help decide what old and even new merchant web pages should be crawled and also re-crawled.
MySQL Database—A database is a structured collection of information and data that is stored in web server. A database uses computer software such as MySQL and Oracle to arrange the storage of data. The servers will use MySQL, as it is cost-effective and has excellent reliability. MySQL is a multi-threaded, multi-member SQL database management system with currently more than 10 million installations worldwide. MySQL runs as a server providing multi-member access to a number of databases.
FIG. 2 depicts a simple overview of a typical MySQL database.
The servers employed in conjunction with the present invention will use the MySQL database system.
Web Server—The term “web server” is used to designate a computer and operating hardware system for the purpose of handling Internet traffic and requests. Like home computers, servers use operating system software (such as Linux) designated to run applications. Servers can also include additional applications that are used and bundled with the operating system such as spam blockers and anti-hacking software.
Server system applications can be divided among many server computers (such as server farms) over a wide range, thereby distributing the workload more evenly. Multiple servers can and are used for medium to heavy workloads, unattended, for a considerably length of time. Multiple servers are also usually in either a cabinet or rack mounted.
Dedicated high-load servers are used for specialized applications which are optimized for the needs of those servers. If a great deal of processing power is required in a server, there is a tendency to add more CPUs rather than increase the speed of a single CPU, again for reasons of reliability and redundancy. Many servers (such as those in server farms) use centralized air-conditioning used to keep servers temperatures.
Uninterruptible power supplies are also critical to maintain the servers in the event of a power failure. High-end servers also require powerful network connections to handle the large amounts of bandwidth that they typically receive and generate as they receive and reply to client requests. Servers run specific operating systems (such as Linux) that are designed specifically for them.
A basic overview of the server process with respect to the present invention is set forth in FIG. 3 . As depicted in FIG. 3 , the member initiates a query or seeks information, and that request is transmitted to the main server, which in turn interfaces with the application server and database server.
Server Farms—A server farm is a collection of computer servers maintained in clusters. The server farms have both a primary and backup servers, with the backup being utilized in case of primary server failure.
Server farms are generally co-located with the network switches and routers in order to enable communication between the different parts of the cluster and the members of the cluster. Server farms increasingly are being used instead of traditional mainframe computers used by large corporations.
Server farms need to consider such problems as redundancy, automatic failure, and can be reconfigured quickly if needed. Server farms streamline internal processing, by distributing the load between the individual servers expediting computing processes by harvesting the power of multiple servers.
Server farms rely on software that balances the load, and accomplishes the demand for processing power from individual servers, prioritizing the tasks and scheduling and rescheduling them depending on priority and demand that members put on the network.
The schematic of a typical server farm is set forth in FIG. 4 . In FIG. 4 , web servers 1 to N are all connected to a load-balancing device and various databases. Each database is also connected to a failover device which acts as a backup for each respective database, in case of database failure.
Search Engine Bot—A search engine bot (also known as a web robot, spider or web crawler) is a program that automatically browses the Internet in a persistent and methodical process, cataloging the information and links that it comes across.
Search engines use these automated bots as a means of collecting and cataloging information, providing up-to-date data. Search engine bots are used to create and catalog a copy of the pages that are identified. Search engine bots can also be programmed to collect only specific pages, such as items a member can obtain by using their earned points, in connection with the present invention.
Search engine bots also collect URLs that are visited. When a search engine bot visits these URLs, it catalogs and indexes them accordingly. A search engine bot such as the search engine bot used in conjunction with the present invention must have a good cataloging policy, as noted in the previous sections, but it must also have an optimized architecture.
It is also important that the search engine bot have high-performance programming that can download thousands of merchant web pages efficiently. Search engine bots also require efficient algorithms and structure that are proprietary.
FIG. 5 depicts a simple overview of a system using a search engine bot.
Cache Memory—Cache memory is basically memory set aside for the collection of data. Caching is also considered as a “temporary storage” where popular information can be stored for easy access. When the information is stored in the cache, future searches (such as a search engine) can be accessed quickly and more cost-effectively by the cached copy rather than having to re-search for that same information. A cache is simply a block of memory set aside for temporary storage of the data likely to be used again. Web servers frequently use CPUs and hard drives for caching.
With respect to the present invention, when a member wishes to access information, the server first checks the server cache. If an entry can be found matching the requested information, the entry of that information is used instead of having the server go back and retrieve that information again, and is called a “cache hit.”
The opposite situation is if the cache is queried and found not to contain information. This is known as a “cache miss.” When a “cache miss” happens, the data retrieved usually inserted into the server cache, and now is ready for future access.
However, the cache has a limited amount of memory, and as new information is retrieved, the old and less used information is cleared to make room for the new data using the server's “replacement policy,” which is usually predicated by the amount of random access memory (“RAM”) the server has. RAM is a type of computer data storage using integrated circuits that allow for the stored information to be accessed in any order.
Sponsored Links—Sponsored links are paid advertisements located somewhere on a search engine results page. The ads are typically for products and services that are generally or very specifically related to the keywords in the member's search query. Search engines sponsored links help to generate revenue to pay for the bandwidth and databases. Sponsored links may be used in conjunction with the present invention to deliver useful links.
In a preferred embodiment of this invention, members enrolled in the rewards system can earn two types of points based upon time and accomplishment. All members will earn points based upon passive play time. Passive play earns members one (1) point per hour while logged into a game. Active play time earns player a predetermined number of points based upon how successful the player is while competing within the game. Active play points are only available from within certain games (e.g., games developed by a specific developer) to augment their existing code to enable tracking of performance by members.
Within the passive and active modes of play there are multiple incentive models offered to members to create greater interest, competition, and enrollment. Such incentive models include, but are not limited to:
Passive Mode:
Members referring other gamers who enroll in the rewards system are awarded a one-time 500 point bonus for each new member enrolled.
Members referring other gamers who enroll in the rewards system also earn passive points at a faster rate. Each time a new player is referred to a site offering the rewards system membership and actually enrolls in the program, the referring member's ability to earn passive points is increased by adding 0.04 points per hour for each new membership referral. Thus, for example, if a member refers four (4) new members to the rewards system, that referring member receives a one-time bonus of 2,000 passive points, and accrues passive points at a factor of 2 per hour. Should a referred member elect to unsubscribe from the rewards system, the referring member will lose the benefit of the added 0.04 points per hour.
Active Mode:
In non-casino type games, members earn points based upon completing specific activities within a game.
In competitive type games, members are given a minimum amount of “active player points” each month to use during play. Skilled players who beat other players will accrue the defeated player's active points risked during play.
Within certain games, “accomplishment points” will be awarded to members who complete certain predefined objectives. Accomplishment points are a one-time, large point bonus awarded to the member(s) successfully completing the objective within the game.
The rewards system of the present invention provides multiple incentives to the software gamer that are not offered elsewhere currently in the market. The elements inherent in the invention help the consumer build the confidence and trust that is requisite for any goods and services purchase. The website offers members looking to redeem their accrued points the ability to type in whatever product or service they desire into a database, and then choose through a list of available items sorted by price, or manufacturer, or model.
Various menus will allow members to fully examine and easily isolate their choices on a product comparative basis while providing the tools to help them refine what they need, and deliver visibility to the full complement of goods and services available online.
The website used in conjunction with the rewards system of the present invention acts as a consumer reference desk by providing tips, and a non-biased expert resource from which to obtain player and consumer feedback. The website furnishes members with real-time online quotes for available products and services based on member-selected criteria, and the actual cost to the member is based upon redeemable player points that have been accrued.
For example, in one embodiment a member has up to $50 of redeemable points accrued and wishes to acquire a queried item (e.g., car stereo, watch, jewelry, apparel, etc.) from the website. By typing in “car stereo” into the website's search feature, a list of all available car stereos from online aggregators or goods providers (e.g., Best Buy®, Amazon®, eBay®, etc.) is returned to the member. The member then chooses from the list the car stereo desired, and based upon accrued player points, the member is either advised that the member has enough points to receive the item at no charge, or the member is charged the difference of the item less the value of redeemable points. In this instance the member would receive the car stereo for $50 less than price available online.
Thus, the website converts the member's accrued passive and active points into virtual dollars that can be applied towards any online purchase. In addition:
The website does not limit prize choices by members or require contractual obligations with aggregators. Because the website will use web robots (spiders) to gather all available online goods and services from existing e-commerce sites, there is no need for forging contractual agreements with the aggregators and suppliers of the e-commerce sites to provide members with an unlimited inventory of goods and services available at the current selling price less the member's accrued point total. The product for the member is purchased directly from the source. Thus, the fear that a member's point total will be artificially exhausted because the inventory of available prizes will be limited and the points necessary to acquire products at inflated prices disappears. Members can compare the prices listed in the website for prizes against the prices listed on any e-commerce site to conclude that the website is offering the best possible price and product anywhere on the Internet. This avoids the need to replicate that which is already available and working well, and avoids these duplicative costs which should not be included twice in the product's pricing.
FIG. 6 depicts a schematic of one embodiment of this invention. As shown in FIG. 6 , multiple members (i.e., Member #1, Member #2, Member #3 and Member #4) are using either a commercially available videogame platform (e.g., PLAYSTATION 3®, XBOX® or Wii®) or a personal computer (PC) or Macintosh® computer to engage in interactive gaming with one another via the Internet. In addition, each member is connected via the Internet to the gaming and rewards system of the present invention via servers and associated software and hardware, which in turn are connected via the Internet to various goods providers A, B and C (e.g., Best Buy®, Amazon®, eBay®). The rewards system of this invention resides in the servers. As described above, members may use the rewards system to accumulate points, and to redeem points for desired goods through the rewards system.
In a particularly preferred embodiment, the architecture of the rewards system relies on a number of key components to build the overall solution. The primary pieces of the infrastructure include the following features and/or components:
Member Rewards Agent—The Member Rewards Agent runs directly on various devices, including gaming consoles. The Agent monitors the member's activity, reports usage data, and provides access to the member's reward information. All communication is secured via SSL. Web Front End—The Web Front End provides for the member's registering or performing account lookup/management over the Internet. All communication is secured via SSL. Web Services Tier—The Web Services Tier is the primary application interface for interacting with the member. The Web Services Tier communicates securely via SSL with all external and internal systems, and also communicates directly to the Member Rewards Agent and the Game Integration Framework (discussed below). In addition, this tier communicates with external networks such as third-party gaming networks and redemption networks. Application Servers—The Application Servers have all of the application level business logic and act as a broker from the Web Front End tiers to the back end databases. The application servers are separated from both the web and database tiers by network security including firewalls. Database Services—The database used in connection with the rewards system of this invention is designed as a federated database to increase the level of security over sensitive member data. The sensitive data, including real name, payment information, and address are separated from the common account information such as member name and game usage. The sensitive database is further protected by a network firewall. Network Security—Firewalls are used to separate the tiers of the application to increase security and reduce any risk of accidental data loss. In addition to traditional network firewalls, web application firewalls will be leveraged to protect the web site and Web Services Tier from Internet-based attacks. Game Integration Framework—The Game Integration Framework provides a set of tools that games can use to integrate their game experience more fully with the rewards system of this invention. Gaming Networks—The rewards system of this invention will integrate with third-party networks (e.g., Xbox Live®, etc.) to obtain member usage data. Redemption Network—The Redemption Network will provide the actual product redemption opportunities and handle fulfillment of the member's orders.
Some of the above-designed components and/or features are described below in greater detail:
Member Rewards Agent
The Member Rewards Agent is software developed as appropriate for each target platform. The functionality and availability of the agent varies depending on the platform. The Agent monitors various activity, reports usage data, and provides access to the member's reward information. The primary purpose of the agent is to monitor the member's gaming activity to credit the member for her gaming activity. The agent has three levels of integration with running games. The levels of interaction are monitoring, hosted, and full integration.
The lowest and default level of interaction is to monitor the member's activity and track what games are being played on the system and for how long. This will rely on basic levels of system level calls to provide application data such as the WindowsEnum API function in Windows®. This level of monitoring is available and fairly robust on the desktop platforms. All of the current console platforms rely on an underlying operating system.
The second level of interaction is via a hosted solution. This level of interaction relies on the member accessing the rewards system website and executing code from the website that enables some level of member monitoring. Depending on the client platform and the level of access the member has, this could range from an ActiveX® control to simple Javascript® code. In cases where a fuller feature code is distributed (such as an ActiveX® control) the level of monitoring and detail will be similar to the monitoring level. For other platforms the monitoring would only apply to web-based games that could be launched from within the same browser as the monitoring code.
The highest level of interaction is a combination of the client agent receiving data directly from the member's running game(s) via the Game Integration Framework. This will allow for the client agent to receive more complete data directly to and from the individual games that offer the highest level of integration.
The member will have the ability to turn the monitoring client on and off as well as to block the client from reporting usage of some games or during certain hours if desired. The desktop client may work from behind corporate firewalls and through Internet proxies.
In addition, the monitoring capabilities of the Agent permits the member to view current information on their account including activity logs, marketing messaging, and other communications to/from the rewards system.
The Agent relies on the device's Internet connection to transmit data. The Agent has an offline caching mode to store usage data locally when the member is playing games while not connected to the Internet. For mobile devices without direct connectivity, such as the iPod®, the device's cached information is synced via the device's desktop connection.
All communications to/from the Agent are encrypted. The communication is made via SOAP or similar protocols depending on each individual platform. All of the communications are initiated by the Agent. The agent itself performs regular “check in” operations to pick up updates to the Agent code base or pick up any other communications directed towards the end member.
Web Front End
The Web Front End is a traditional member facing web site experience. The Web Front End is primarily for member registration and account management. In addition all of the client agents are available via the Web Front End, especially the hosted client option. The Web Front End integrates with advertising engines to allow for targeted advertising opportunities to the target gaming members. The Web Front End has many interfaces to be compatible with the range of browsing experiences including desktop browsers such Internet Explorer®, Safari®, Firefox®, and Chrome® as well as the embedded browsers available on the gaming consoles and mobile devices.
The Web Front End also provides the access point to other content such as the “Patriots of Freedom” and “Nuclear Jihad” games discussed herein. A variety of standard web-based member interactive games are also available for use and rewards points accumulation.
The Web Front End also offers integration with online gaming networks such as Xbox Live® and MSN Zone® to provide a more integrated online gaming experience for gamers leveraging these online services. In addition the website directly integrates with the redemption network(s), to permit the member to do redemption directly from the rewards system experience while still accessing all of the content from the redemption networks.
The Web Front End also contains social networking features to allow members to build their gaming profiles online. The rewards system is designed to become the gamer's “home” and permits them to consolidate their gaming achievements and presences from across multiple gaming platforms. The Web Front End may also be adapted for multi-language support.
Web Services Tier
The Web Services Tier provides a services level interface to the rewards system. The Web Services Tier has core services interfaced to the rewards system as well as services for integration with third-party networks.
The core services provide application level functionality for all of the member authentication, game usage reporting, account information, and member competition. The web services are used by the Member Rewards Agent and make up the back end of the Game Integration Framework (as discussed below).
The Web Services Tier also provides the access layer for all third party integrations including gaming networks and redemption networks.
Application Servers
The Application Servers contain all of the core business logic and act as the broker between the Web Front Ends and the back end databases. The Application Servers are the only tier of the application that has direct access to the database services.
The application servers are also responsible for back end billing and marketing services including outbound communications to the client agents. The Application Server performs all back end batch processing and reporting preparation.
Database Services
The Database Services provide all of the data for application in a centralized set of data stores. To maximize the security of member's private data, the database is federated across two databases with most of the application calls only having access to the primary database containing member account and usage information. All confidential client information is stored in a separate database that is only available to specific application calls and leverages separate authentication credentials from the primary database.
Network Security
Security is a key element of all components, as it is critical to maintain member security. In addition to the security embedded at each tier, network security provides additional protection. Each of the tiers is separated by a network firewall. In conjunction with the network firewalls, the web front end and web services tier are protected by a web application firewall. The web application firewall increases security by opening up the HTTP traffic that is passed through the firewall and inspecting the packets, including the ability to have visibility into the SSL traffic.
Game Integration Framework
The Game Integration Framework is a toolkit to allow third-party games to integrate directly with the system of this invention. The framework consists of a set of back end web services that can be accessed directly by game publishers as well as more customized versions of the framework for each platform. As an example, the framework may be developed using XNA® for the Xbox 360® and Windows® platforms.
The framework allows the game to fully integrate with the rewards system, including logging member activity, rewarding the member with “bonus” points, checking member balances, and allowing for interactive competition with points at risk.
The framework will include detection capabilities for a local agent to interact with the local agent in addition to interacting directly with the Web Services Tier.
Gaming Networks
The system of this invention also may integrate directly with online gaming networks such as Xbox®, Playstation Home®, MSN Arcade®, as well as online gaming providers such as World of Warcraft®. This integration will allow the member to gain credit for playing on these 3rd party networks without having to install the agent on the target devices.
Redemption Network
The system of this invention will integrate with third-party networks to allow members to leverage their earned points for rewards. The details of the integration will vary depending on each redemption network as the system will need to comply with the existing network's connectivity methods.
A schematic of another embodiment of the invention is set forth in FIG. 7 . As shown in FIG. 7 , multiple Member Rewards Agents (i.e., Agent #1, Agent #2, Agent #3 and Agent #4) are commercially available videogame platforms (e.g., PLAYSTATION 3®, XBOX® or Wii®), a personal computer (PC) or Macintosh® computer, mobile/cellular phone or PDA to engage in interactive gaming with one another via the Internet. The Agents communicate via SOAP over HTTPS. In addition, various gaming networks (e.g., XBOX Live®, PLAYSTATION Network®, MSN Zone®, WOW®) interface through the Internet via SSL with the Agents. A member/user is interconnected (via SSL) to the Internet and thereby connected to the gaming and rewards systems of this invention. More particularly, the member/user interconnects via the Internet to the Web Front End which contains the Member/user registration and account information and manages this information. The Web Front End is further interconnected to an applications server which performs various functions and transmits information to an Account/Usage database. Similarly, the various Agents are interconnected via the internet to the Web Service Tier and another applications server which performs various functions and provides additional information to the Account/Usage database. The Account/Usage database may provide additional customer data as required. The Web Service Tier also is in communication (via SOAP calls over HTTPS) with the various redemption networks/goods providers (e.g., Best Buy®, Amazon®, eBay®). As described above, members may use the rewards system of this invention to accumulate points, and to redeem points for desired goods through the rewards system via the system.
Unlike other types of programs, the rewards system of the present invention will not offer a limited inventory that requires members to give advance notice, adhere to blackout dates and restrictions, etc. Members can take advantage of their accrued points at any time, night or day, whenever they choose. Additionally, unlike other membership groups, members will not be required to log a predetermined number of hours per month (or year) to be eligible to use their accrued points.
The rewards system of the present invention offers members the ability to earn virtual dollars that can be used in conjunction with completing almost any online purchase.
The shopping service used in conjunction with the rewards system of this invention will offer members the ability to shop in multiple dimensions, which is unique in its comparative power. Members will have the functionality, ability to select the product desired, and the overall experience that is the norm in other Internet product executions. The member can identify her needs, research various products, read buyer reviews regarding a product or company, perform a complete comparative value analysis and choose the product or service that best satisfies her criteria. At that point, the member will be introduced to everything available on the Internet at a discount, while still enjoying the full benefits of the existing sales and fulfillment mechanisms of the aggregator/manufacturer/distributor/wholesale/retailer. Unlike existing Internet shopping services, the website used in conjunction with the rewards system of this invention will not be limited to a few companies that are representative of a category but instead will provide access to virtually the entire market, although this feature can be limited for specific “white labeling” applications.
The following features are exemplary of the invention:
Maintain a Broad and Deep Product Suite—One objective is to provide members with a comprehensive shopping solution for their needs. The depth of the product offering will be established by aggressively using web robots (spiders) to scour the Internet based upon keyword search to yield the widest array of potential matches possible (sortable by price, manufacturer, and model). Providing a full portfolio of meaningful choices will increase the attractiveness of the rewards system of the present invention, and, therefore, the value of membership enrollment to the gamer. Membership enrollment will increase in two ways: first, the additive power of each company's competitive price structure; and second, the gamer will stop shopping because they have the confidence that they shopped the whole marketplace to find the desired item. Technological Integration with Other Select Companies—The website used in conjunction with the rewards system of the present invention will integrate fully with any company's e-commerce page. By integrating with any product or service available online, superior selection and acquisition efficiencies can be achieved that present a unique and distinctive offering to members. Doing so will not only allow members to obtain premium goods and services online, but also reduce duplicate information entry, speed the purchase process, improve pricing information and enhance customer satisfaction. Pursue White Label License Agreements—The business-to-business aspects of the platform can be leveraged further by technology-licensing arrangements with third parties. Under such arrangements, a fee would be obtained for the use of the rewards system of the present invention to white label third-party sites and listing of their products (and/or services) on the website used in conjunction with the rewards system of the present invention. The technology can be implemented for a variety of third-party sources, from online retailers to large computer manufacturers. Such an initiative offers the potential for an additional source of revenue, as well as enhanced development of the e-brand. The platform has unusual appeal to large affinity groups and other entities that would like to offer their good and services directly to software gaming. A white label service allows third parties to deploy the platform on a selective basis. The third party can address specific target market to a clearly defined niche market with supporting demographics that clearly indicate sweet spots and allow for key product placement.
Another feature is that the rewards system of this invention will enable the transfer of highly filtered data from e-commerce pages to the website, allowing the charging of a premium for any white labeling agreement fee.
The present invention will benefit members by: (i) providing access to an unlimited choice of online goods and services; (ii) providing informative, independently evaluated, comparative information that helps members to make more informed purchasing decisions, and (iii) making the online shopping experience less burdensome, more convenient, and always at a discount.
The benefits to consumers include:
One-Stop Comparison Shopping—The platform allows members to evaluate multiple goods and services side-by-side. Like a search engine, the present invention sifts through the market and brings back the results for inspection and refinement. Members are able to enjoy comparative, competitive quoting from a breadth of online entities and purchase channels previously unavailable from any membership rewards service. For the first time, the pool of available online goods and services are reflective of the market in its entirety, as opposed to a select group of companies willing to enter into an agreement with a specific member base. Members can search and shop almost the entire Internet in one simple and easy experience. Reduced Search Cost and Barriers to Purchase—By providing all of the necessary information on one platform, the search costs and barriers-to-purchase consumers normally face is drastically reduced. The site contains plain language descriptions of products augmented with actual purchasers' comments, reviews, and rankings. Members obtain highly relevant insights about customer satisfaction, benefits, and manufacturers. This independent community validates the objectivity of the offering and creates the confidence for informed purchasing. Currently, the perceived search costs and aggravation associated with diligent research often outweigh the potential price and value savings consumers might realize. The platform significantly lowers these search costs, thereby allowing consumers to reap the appropriate value from their online purchases. Comprehensive, Easy-to-Use Information—Another feature of the present invention is the delivery of this content “in context” during the search discovery process. Access is offered to the most comprehensive database of information on products and services available. With the click of a mouse, members can access educational materials on products and services, including answers to frequently asked questions, a dictionary, informative articles, and product ratings. The website used in conjunction with the present invention is a nexus of non-biased insights and information on goods and services. Members are able to comment on, evaluate, and review the products, services, and companies across several criteria. The ultimate buying power is in the hands of the member: complete market access with tools, guidance and delivery choices designed to satisfy all needs at a discounted price. Convenience and Control—The rewards system of the present invention provides greater convenience to members by allowing them to access and review information and prices at any time. A member's request is fulfilled seamlessly and automatically through multiple heuristic algorithms and MySQL database, thereby minimizing the time and effort required to find a specific item and consummate a transaction. Search results are organized in an easy-to-use format and provide members with interactive website features to assist them in analyzing the product or service that is most suitable for their needs. For instance, products and services are tagged with a link to relevant information regarding that item, educating the member about that product or service, and giving expert recommendations. Viral Networking and Co-opting of Players' Rewards Points—The Patriots of Freedom scenario (discussed below) represents the first-ever truly collaborative massively multi-player online role-playing (“MMORPG”) in which an added incentive is tied to how proficient members excel within the confines of the game. Members who build the bigger and better network of players gain access to a greater prize pool potential, and can earn redeemable rewards in a shorter time frame. Aside from the usual excitement associated with playing an excellent MMORPG, converting the online gaming experiences into tangible assets causes members to have a more vested interest in the games they play.
The search engine used in conjunction with the present invention is an intelligent search engine designed to query the Internet for the items desired by people who belong to the rewards system of the present invention, and allow members to then shop for and purchase items by using their earned points. The search engine used in conjunction with the present invention works similar other search engines, in that both work using players input and heuristic algorithms to find items that a player wishes to purchase using their earned points.
The search engine used in conjunction with the present invention works by retaining information on popular searches both current and previous. The search engine used in conjunction with the present invention uses algorithms which work with an indexed database on its web server farms. The search engine used in conjunction with the present invention also works by using customized search “robots” (also known as “web bots”, “spiders”, or “web crawlers”) which traverse across the Internet cataloging merchant's web pages following the links along the way. The contents of the merchant's pages are scanned to determine how it should be indexed and then stored in a database. High traffic merchant pages are also cached. The purpose of caching this information is that it enables the search engine used in conjunction with the present invention to search its own database index faster and more easily, while using less bandwidth. When a member inputs her query into the search engine, the engine searches its own database and provides a listing of items searched for.
The search engine then provides an organized list of items to the member according to their rank. In one embodiment, in addition to the listing of searched-for items, the search engine on the left side of the member's browser, on the right side is a listing of sponsored links. Sponsored links (e.g., white labeling) are merchants that have paid to have their items appear on the search engine along side search results, which are based on keywords entered into the search engine, and generates money every time a member clicks on one of those sponsored links. Members can also rate merchants on things such as responsiveness in regard to their shipping and overall customer service. The search engine mission is to enable members to quickly and easily and buy anything sold by virtually anyone, anywhere by redeeming their points.
The primary source of revenue derived from the present invention will be the monthly and/or year membership enrollment fees that enable gamers (i.e., members) to accrue points in exchange for time spent playing video games. Members may range from the novice to the veteran gamer, all of whom would enjoy added incentives for engaging in playing video and computer games.
Any item or service that can be purchased online will be part of the inventory of products offered, with more expensive items (or services) requiring greater points to obtain.
Members enrolled with the reward system employed in this invention will be showcased on a website based upon most point accrued, most hours spent online, and most points earned for the day. Members will be able to enjoy comparative, competitive scoring from a breadth of software games and generate an online reputation hitherto unavailable within the software gaming industry. For the first time, the pool of software gamers and their rankings will be reflective of the market in its entirety as opposed to a select group of players within the confines of a specific game. In one embodiment of the invention, members will compete for the top spot and top prizes over their competitors.
In one embodiment of the invention, member dossiers will allow other members to pick and choose which members they would like to forge alliances with, and establish the best teams for obtaining the most points possible. Member dossiers give members metrics by which to gauge the true performance and ability of other members. All member dossiers are kept completely anonymous and access to any member personal information (IP Address, e-mail address, and any other pertinent data) is unavailable and restricted unless expressly released by the member.
Members are able to compare scores, ranked evaluations of specific members and their player attributes, as well as game reviews and commentary from other members and gaming experts. Members are also able to obtain highly relevant insights as to customer satisfaction, game quality, and tips and tricks from other members. This independent community objectively validates the gaming software offerings and creates the confidence for informed purchasing.
White labeling of the invention for affinity sponsors like PC manufacturers, peripheral and accessories companies, etc., means they can offer choice within a readily accessible pre-established target audience. Also, the platform provides a springboard for targeted efforts directed at specific percentage of the population; for example, the high ranking players are more apt to beta test and purchase (or redeem points using the rewards system of this invention for) higher-end products.
There currently is no existing structure in the software gaming industry to truly offer gamers compensation for their time playing any video game. The reward system of this invention offers compensation to members in exchange for the hours spent competing.
In one embodiment of this invention, the redemption of points can be conducted real-time during game play, or online by logging onto a website.
Creating an interface (or software utility) that members will receive via e-mail and then install locally on a personal computer or PDA or mobile phone enables members to use the invention and verify and track the hours spent playing software games. Additionally, in one embodiment of the invention, members can use this software to enable communication between various videogame systems (e.g., PLAYSTATION 3®, XBOX® or Wii®). This interface transmits all the pertinent gaming data to a central data recipient, and allows verification of every member's playing time and points accrued.
By tying tangible accolades that are accumulated based upon play within the software game, the desire of members to compete and play well within software games will be enhanced and thus lead to further enrollment in the rewards system of this invention. Thus a virtual marketplace within a community of millions of gamers will be created which will enable members to acquire goods and services based solely upon the act of playing a video game.
Merchant ratings allow members to easily provide input about their purchasing experience in an easy to read format that provides useful feedback to both the site and to the member.
Member reviews feature the following components:
Easy to view star ratings which provide a simple, visual way for members to rate and comment on the overall quality of their business purchase. Members can easily select from a scale of 1 to 5 stars (with 5 stars being the highest rating). These ratings and comments give members the opportunity to describe their purchasing experience, as well as shipping and delivery experience in their own words. Comments also provide the details behind the star ratings that they choose.
Overall rating scores are the average number of stars given by members who have posted ratings from the merchant. Merchant rating stars are displayed for merchants with 2 or more reviews within the past 12 months. Merchant ratings are also checked for accuracy in order to prevent any abuse resulting from a fraudulent review.
In another embodiment of this invention, downloadable software is provided that allows members to interface with servers used in conjunction with the present invention to monitor their game playing for the purpose of maintaining (passive and active) point totals. These points are then redeemed by members for discounts on e-commerce-based products or services.
The downloadable software is easily installed on the member's computer and allows verifiable tracking and accounting of member points that have been accrued or awarded.
This software can be installed on most computer operating systems, and is downloadable from the servers and the software package is then installed onto the member's computer.
The software is written in the C++ mid-level programming language, and the download utility software will be certified to contain no spyware, or any other types of malicious software or scripts. C++ comprises a combination of both high and low-level programming language features, and is the preferred programming for this level of utility.
The software itself will not only integrate with the member's computer, but will also integrate with wired and wireless routers so that outside computer controlled devices, such as MICROSOFT XBOX®, XBOX 360® consoles, NINTENDO Wii® console and SONY PS3®. The software will control the point distribution and reconciliation for the MAC and PC based games, and well as present an entrée into offering the present invention into the console-based gaming industry.
All of the above listed consoles (except for the original XBOX®) represent the seventh generation of home gaming consoles, and these consoles represent the ability to connect directly to the Internet via an Ethernet connection feature.
An Ethernet connection is a collection of computer network technologies for local area networks (LANs). Through the use of Ethernet connections in their gaming consoles, MICROSOFT®, SONY® and NINTENDO® have presented the owners of their home consoles with a myriad of online features.
These features include, but not limited to:
Online game playing capabilities, Online member profiles, Direct access to online game forums, Live online arcades, Friend lists, instant messaging, voice, video, picture, and data file, and; Online marketplaces (which allow players to purchase games, download demos, music, videos, etc.)
Besides being able to directly access the Internet using broadband services (cable, DSL and satellite), the Ethernet capabilities also allow for connection to members computers, through either a direct Ethernet connection straight into the computer, or a more popular configuration using either a wired or wireless router.
Through the use of a router, video game consoles are able to create a network that includes their gaming consoles, computers, entertainment centers (televisions, DVD players, surround sound systems, etc.), and other controlled devices.
The software will contain a graphical member interface (“GUI”), for installation, use and removal if so desired. A graphical member interface or GUI is a type of member interface that allows Players' Rewards members to interact using their computer, computer controlled device (XBOX®, NINTENDO Wii®, and PS3®) with the Players' Rewards servers.
A GUI consists of image icons, visual cues or image elements which enable the player to be able to easily navigate the software and its attendant features. The icons and images are used in conjunction with text, labels to fully represent the information and actions available to the member. Creating the visual image composition and behavior control of GUI is a crucial part of software application programming. The GUI main purpose is to enhance the efficiency and ease the usability for the members. Besides English, the GUI will also be available in modern high use languages such as Spanish, French, German, etc.
After software installation, the member can access the GUI simply by clicking on the appropriate icon. The GUI is a virtual shopping mall, designed to allow members to purchase a vast assortment of items found on a shopping portal which relies on the content harvested by the search engine employed in this invention.
The shopping portal is the main page (index) on the Internet that functions as a point of access and gateway for diverse sources in an easy to understand way. Those sources include but not limited to, information such as the number of points a member has collected, points lost, and points redeemed towards the purchase of online products and services.
The search engine will be integrated within a web portal to assist members in locating and acquiring items they desire. Merchant advertising (part of the White Labeling) can be incorporated into the search engine portal.
Within the portal used in conjunction with the present invention, members can access merchant ratings, submit comments, and review other member's commentary on merchants they have used points to redeem products and/or service from.
The index page can be dynamically updated, and give members real time access to their accounts. While the portal index page will be written in dynamic Internet languages (such as PHP, HTML, XLS, etc.), the utility itself is software that monitors the members game playing and forwards that information to the online database, where it can be recorded, analyzed and the appropriate points are then rewarded and their account updated and displayed to the member via the portal page.
Membership requires that a player have an account. It is this account that allows their play to be tracked and reward points awarded, via the downloadable software integrated with the online database.
The method of point distribution of this invention uses a system of checks and balances to ensure that a member's point total (active and passive) are valid, correct, and verifiable.
Every point issued to members (active and passive modes) is treated like individual assets, and each assigned point is issued a unique record number that incorporates a date and time stamp that is down to one ten thousand of a second.
Within the system every member is assigned a unique membership that is kept internally on the servers. Each time a monthly membership fee is collected, 2,000 active playing points are awarded to the member whose credit card has been successfully charged. The financial server will record the transaction and log the financial record onto the member's unique ID number. The financial server will also send a request to the server dedicated to tracking and assigning member points. The server dedicated to auditing, tracking, and verifying points will generate and assign 2,000 points into the member's point total.
Passive points are issued in this same manner, and additional safeguards can be implemented to identify any potential threat to our system, which include but are not limited to: (i) at no time should any two points contain the same ID record; and (ii) there should never be more total points in play than exceed a threshold of 39% of the total funds collected.
The following examples of the invention are merely illustrative of details of the invention, and are not meant to be limiting in any way.
Example 1
Patriots of Freedom Game
The following is a basic outline of the game entitled “The Patriots of Freedom,” which may be employed in one embodiment of this invention.
The setting is the present-day United States. After the attacks of Sep. 11, 2001, terrorism affects many nations and spreads with each passing day. If left unchecked dark and sinister forces will eventually consume the entire planet. The player begins his virtual life as a patriot by enlisting in one of the four branches of the U.S. military:
Army personnel report to Fort Bragg, North Carolina Navy personnel report to Indian Head NSWC, Maryland Air Force personnel report to Edwards AFB, California Marines report to Camp Lejeune MCB, North Carolina
Once enlisted, the player begins basic training to familiarize herself with how to control and operate the patriot. All experiences within the game will depend on which branch is chosen to serve in, how the player comports herself within the game, and how well the player can adapt to the changing environment.
The Patriots of Freedom (POF) represents the next wave of MMORPG video games. POF operates within the hierarchical structure of the U.S. military incorporating Real Time Play (“RTP”) that begins as a First Person Shooter (“FPS”) and evolves in complexity as the patriot begins to increase in rank, skill, character, knowledge. The patriot's experience begins by receiving direction and orders from higher ranking patriots and as higher ranks are obtained, transitioning begins from strictly a FPS towards directing and commanding the lower ranking patriots.
Individual patriots are encouraged to band together and form the best squad possible based upon player dossiers.
Individual Patriot—The player will go through basic training to learn how to operate the Patriot. Squad—9 to 10 Patriots. Typically commanded by a sergeant or staff sergeant, a squad or section is the smallest element in the Army structure, and its size is dependent on its function. Platoon—16 to 44 Patriots. A platoon is led by a lieutenant with an NCO as second in command, and consists of two to four squads or sections. Company—62 to 190 Patriots. Three to five platoons form a company, which is commanded by a captain with a first sergeant as the commander's principle NCO assistant. An artillery unit of equivalent size is called a battery, and a comparable armored or air cavalry unit is called a troop. Battalion—300 to 1,000 Patriots. Four to six companies make up a battalion, which is normally commanded by a lieutenant colonel with a command sergeant major as principle NCO assistant. A battalion is capable of independent operations of limited duration and scope. An armored or air cavalry unit of equivalent size is called a squadron. Brigade—3,000 to 5,000 Patriots. A brigade headquarters commands the tactical operation of two to five organic or attached combat battalions. Normally commanded by a colonel with a command sergeant major as senior NCO, brigades are employed on independent or semi-independent operations. Armored cavalry, ranger and Special Forces units these sizes are categorized as regiments or groups. Division—10,000 to 15,000 Patriots. Usually consisting of three brigade-sized elements and commanded by a major general, divisions are numbered and assigned missions based on their structures. The division performs major tactical operations for the corps and can conduct sustained battles and engagements. Corps—20,000 to 45,000 Patriots. Two to five divisions constitute a corps, which is typically commanded by a lieutenant general. As the deployable level of command required to synchronize and sustain combat operations, the corps provides the framework for multi-national operations. Army—50,000+ Patriots. Typically commanded by a lieutenant general or higher, an army combines two or more corps. A theater army is the ranking Army component in a unified command, and it has operational and support responsibilities that are assigned by the theater commander in chief. The commander in chief and theater army commander may order formation of a field army to direct operations of assigned corps and divisions. An army group plans and directs campaigns in a theater, and is composed of two or more field armies under a designated commander. Army groups have not been employed by the Army since World War II.
Once the player has achieved the highest rank possible (General in the Army or Air Force, Fleet Admiral in the Navy, or Commandant of the Marine Corps) the patriot's role within the experience transitions fully to a command and control mode of all the lower ranking patriots within the game. All patriots can still exercise the combat skills they have obtained throughout the experience, but as the patriot advances in rank, so does the complexity of each mission. High ranking patriots are at a premium, and should always occupy areas furthest from the battlefield based upon rank.
For the first release of The Patriots of Freedom the focus is on only up to Company level of troop formations. This makes Captain (in the Army, Air Force, and Marine Corps) or Lieutenant (in the Navy) the highest attainable rank possible within the first release of The Patriots of Freedom. Understanding and utilizing player dossiers become more vital as a virtual patriot moves up in rank. A good Captain or Lieutenant will choose good Sergeants or Petty Officers to help fulfill mission objectives because good Sergeants or Petty Officers will choose the better enlisted personnel to join their platoon.
The Patriots of Freedom offers genuine “in-game advertising” to legitimate companies. For example, billboards, car dealerships, stores, etc. that are elements comprising the game environment will be companies that exist today and their goods and services are available for players within the game to access and acquire.
For example, a known store could be one of the store fronts that a virtual patriot walks into during the course of play. The virtual patriot sees a car stereo system on sale in the store and elects to use his points to buy the system. The decision to by the car stereo system is confirmed by the member, and the total cost of the order less the available dollarized amount of reward points is then charged directly to the member's credit card account already on file used to pay for the monthly/yearly membership fee.
The Patriots of Freedom invokes genuine player networking and true team-building exercises to obtain better points and rewards. Using member dossiers to determine who the best players are that will increase the chances of mission success is a very integral part of the playing experience. The Patriots of Freedom has both a passive and active point collection area.
Within the passive points area players earn one point per hour, just like they normally would for playing any other online game. In the passive area the life of the virtual patriot is comparable to that of boot camp drills, military maneuvers, combat training, and war game simulations. These exercises are designed to improve on the virtual patriot's proficiency, network with other virtual patriots, and amass data with the member dossier to assess skills alongside other member dossiers accordingly.
During the course of training the virtual patriot may be killed. Exercises like capturing a flag, search and destroy, find and rescue, etc. require the engagement and elimination of other virtual patriots who are also increasing their skills. The death of a virtual patriot is not permanent during these passive point exercises, and the patriot may be reanimated and free to re-enter the combat area from a safe location.
Within passive play mode special one-time missions are offered that are loosely tied into current world events. For example, a world leader who is hostile towards the U.S., and who has been a known supporter of anti-US activities while funding terrorism, is scheduled to speak at the United Nations. Silencing this leader without implicating the U.S. government enables accumulation of a large amount of activity points for the squad or platoon able to successfully fulfill the mission without being detected.
For example, 250,000 points is offered to the squad (or platoon) that successfully completes the mission. The 250,000 points are divided up among the surviving members of the mission. The lower the number of surviving patriots, the greater percentage of reward points allotted to each surviving patriot. Items of great value (e.g., large-screen HDTV) become more accessible as the other patriots are eliminated during the mission. Conversely, the mission becomes more difficult and harder to complete as patriots are eliminated and the overall strength of the squad (or platoon) is reduced.
Only passive points are earned if a special one-time mission is not completed. Additionally, there are no retries if the patriot fails to complete a special one-time mission. Should no one complete the special one-time mission then the 250,000 points remain unallocated, and the mission is deemed incomplete.
Within the active play (or Campaign) mode the virtual patriot is required to fulfill a clearly defined large-scale live mission that requires the combined forces of all four branches of the military. Missions within active play have a specific start time and are real-time do-or-die situations for every virtual patriot entering the battlespace. Unlike special one-time missions within the passive play area, if the patriot is eliminated during a live action mission there is no reanimation.
Members will spend many hours developing their patriot, and being eliminated during a live action campaign will be a cause of great duress. Members may not want to start over by creating a brand new patriot and may instead pay a small charge to reanimate their virtual patriot eliminated during a live action mission. This reanimation fee is charged directly to the member's credit card information already on file for paying the membership fee.
A patriot reanimated for a fee is restored back with all attributes, experience, and assets intact. The only difference for the virtual patriot is that 25% of the total reward points have been lost. Even a virtual death must carry some consequences. Since the percentage of points available to each surviving patriot increases as other patriots are eliminated, there is a strong potential for a virtual patriot to display unethical, dishonorable characteristics by purposefully eliminating a squad member within a given live action mission. If a virtual patriot purposefully eliminates another member during a live mission, that patriot's “reputation” attribute is diminished and logged into their dossier. A patriot with a less than favorable reputation is more apt to be passed over by squad leaders, Lieutenants, and Captains for inclusion on a mission. Patriots with unfavorable reputations could band together and form splinter cells, death squads, or mercenary groups ideal for carrying out special one-time missions.
Should the virtual patriot be purposefully eliminated during a live action and elects to pay for reanimation, the option of purchasing a tracking beacon to locate the virtual patriot responsible for the demise is available. At any time during a live action the virtual patriot responsible for eliminating the member's patriot may be targeted. Additional points can be use to coerce and entice other virtual patriots to either attack or protect the member's patriot from other virtual patriots who have a locator fixed upon the member's virtual patriot. The amount of points needed to coerce or entice other virtual patriots is negotiated based solely upon what the member is willing to give up in exchange for security within the battlespace.
Example 2
Nuclear Jihad Game
The following is a basic outline of the game entitled “Nuclear Jihad,” which may be employed in one embodiment of this invention.
Scientists from America, England, Italy, and Israel have collaborated to discover the most powerful compound in the universe. The plan is for the four branches of the U.S. Military to take one of the four elements each to a designated area, an island that is controlled by the U.S. in the Atlantic Ocean. With minimal crew and under complete secrecy they plan to mix and test the new compound. Foreign governments sponsoring terrorists have discovered where the meeting will take place and stage a massive attack to steal the individual elements.
The surprise attack is successful and the individual elements are brought back separately to four different counties for analysis and processing. Their plan is to mass produce each element, then eventually meet up to combine their elements for use against the USA. As a safeguard a small portion of each element is shared amongst the terrorist cells within the four countries. Each country has the four elements and the ability to have an enormous bomb.
The U.S. government knows that once the four elements are successfully joined together a strike against high value targets within America will occur. Additionally, the U.S. government fears an information leak that could lead to widespread panic, so the decision is made to get the elements back using whatever force necessary. Each branch sends out teams to track down and take back each element. Each branch has a different mission and country they must invade:
Army—Syria
Marines—Germany
Air Force—Kuwait
Navy—Sri Lanka
Each branch must complete several objectives to seek out and recapture the elements. Patriots must work together in a coordinated effort to secure their area and complete the mission. If one branch has problems in recovering the element, other branches that are successful are required to provide support and help complete the mission. The mission is a failure if all four elements are not recovered and brought back to the U.S.
For virtual patriots who do not wish to join a platoon commanded by member, another option is to sign up with a platoon commanded by one of the CPU characters. CPU leaders are extremely proficient and are seldom eliminated from the battlespace. A mission is considered incomplete if the only surviving members are CPU controlled.
The four main CPU characters guiding the member through basic training are:
1. Slice—A machete-wielding warrior who has the ability to cut anyone in two. 2. Rick O'Shea—An expert marksman who can shoot from any angle and determine how to ricochet the bullet. 3. Torch—Scarred soldier who wields a flame-thrower as his defense. 4. Dutch—A cigar chomping berserker who is lethal in hand-to-hand combat and commands a mastery over almost any weapon or machinery.
In addition to all of today's standard issue firearms and weapons available for use, future weapons and systems are also be available for use based upon proficiencies and game play.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention. | A reward system for players of video games or computer games comprises:
(a) a gaming platform for participating in a video game or computer game; (b) a data collection module in communication with the platform, wherein the data collection module obtains and stores information received from the platform and assigns rewards points based upon the data and predetermined parameters; and (c) a purchasing module in communication with the data collection module, wherein the purchasing module receives information from the data collection module regarding the player's purchasing choices and arranges for the purchase items corresponding to the choices. | 6 |
BACKGROUND OF THE INVENTION
Compounds having the structural formula ##STR2## wherein R is hydrogen, alkyl or substituted alkyl and Y is hydrogen, alkyl, substituted alkyl, halogen, cyano or nitro are described in U.S. Pat. No. 3,501,286 as being herbicides.
A compound of the formula ##STR3## is taught by Pyman and Timmis, J. Chem. Soc., pp. 494-498 (1923). However, no utility for this compound is taught other than its use as an intermediate in the preparation of pharmaceuticals.
DESCRIPTION OF THE INVENTION
This invention relates to esters of 2-bromo-4-methyl-5-imidazole carboxylic acid as herbicides. The novel compounds of this invention have the following structural formula (A) ##STR4## wherein
R is C 1 -C 10 alkyl, preferably C 2 -C 5 alkyl, more preferably isopropyl, isobutyl, isopentyl or sec-pentyl; and most preferably isopropyl;
X is oxygen, sulfur, sulfoxide ##STR5## or sulfone ##STR6## and
Y is C 1 -C 6 alkyl, preferably C 1 -C 4 alkyl, phenyl, optionally substituted with halogen, preferably chlorine.
The structural formula (A) when R and Y are as defined is intended to define compounds of either of the following two structural isomers ##STR7## or mixtures of the two isomers in any proportion.
Both isomers are herbicidally active.
In the above description of the compounds of this invention alkyl includes both straight and branched configurations; for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, and tert-butyl, the amyls, the hexyls, the heptyls, the nonyls and the decyls; halogen includes chlorine, bromine, iodine and fluorine.
The compounds of this invention are active herbicides of a general type. That is, they are herbicidally effective against a wide range of plant species. The method of controlling undesirable vegetation of the present invention comprises applying an herbicidally effective amount of the above-described compounds to the area where control is desired.
The compounds of the present invention can be prepared by the following general method. ##STR8## wherein R is as defined and TEC is a transesterification catalyst such as Ti(O-alkyl) 4 , preferably Ti(isopropoxy) 4 . ##STR9## wherein R, X and Y are as defined.
Generally, for step (1) at least one mole of the alcohol is used for the reaction with the ethyl ester to prepare the imidazoles. Preferably, a slight mole excess of the alcohol is used. The reaction mixture is refluxed until completion of the reaction. The reaction product is recovered by removing the volatile materials. Atmospheric, subatmospheric or superatmospheric pressures can be used, depending on the boiling point of the solvent used. Ethanol is conveniently stripped at elevated temperatures and reduced pressure.
Reaction step (2) is run in a solvent such as tetrahydrofuran, at a temperature of about 25°-100° C., preferably room temperature, using equal mole amounts of the two reactants and the hydride base. Preferably, the hydride base is sodium hydride.
The reaction product is a mixture of (1) and (3) isomers and is worked up by conventional techniques.
The following example teaches the synthesis of a representative compound of this invention.
EXAMPLE I
Isopropyl ester of 2-Bromo-4-methyl-5-imidazolecarboxylic acid ##STR10##
To a suspension of 6.4 grams (g) (2.7×10 -2 moles) of ethyl 2-bromo-4-methyl-5-imidazole carboxylate in 70 milliliters (ml) isopropanol was added 0.6 ml (2.4×10 -3 moles) tetraisopropyl titanate. The resulting mixture was heated to reflux for 3 days, then concentrated in vacuo to one-half the original volume. The solution was cooled on ice and the precipitated crystalline solid was filtered and air dried to give 3.4 g of the desired product.
EXAMPLE II
Isopropyl ester of N-n-Butoxymethyl-2-bromo-4-methyl-5-imidazolecarboxylic acid ##STR11##
To a suspension of 293 milligrams (mg) (1.22 mM) of sodium hydride in 30 ml of anhydrous tetrahydrofuran was added, in portions, 3 g (1.22 mM) of isopropyl 2-bromo-4-methyl-5-imidazolecarboxylate. The resulting suspension was cooled to 0° C. and 1.5 g (1.22 mM) of chloromethyl-n-butyl ether was added dropwise. The reaction mixture was stirred overnight at room temperature. The precipitated sodium chloride was removed by filtration and concentration of the filtrate in vacuo gave 3.6 g (89%) of the desired product, isopropyl N-n-butoxymethyl-2-bromo-4-methyl-5-imidazolecarboxylate as a golden oil (89% yield).
EXAMPLE III
Isopropyl ester of N-Methylphenylsulfoxo-2-bromo-4-methyl-5-imidazolecarboxylic acid ##STR12##
To a suspension of 195 mg (8.13 mM) of sodium hydride in 20 ml of anhydrous tetrahydrofuran was added, in portions, 2 g (8.13 mM) of the isopropyl 2-bromo-4-methyl-5-imidazolecarboxylate. The resulting suspension was cooled to 0° C. and 1.4 g (8.13 mM) of chloromethylphenylsulfoxide was added by drop. The reaction mixture was stirred overnight at room temperature. The precipitated sodium chloride was removed by filtration and concentration of the filtrate in vacuo gave 3.1 grams of the desired product as a golden oil (100% yield).
The following is a table of certain selected compounds that are preparable according to the procedure described herein. Compound numbers are assigned to each compound and are used throughout the remainder of the application.
TABLE I______________________________________ ##STR13##CompoundNumber R X Y______________________________________1 isopropyl S methyl2 ethyl S methyl3 isopropyl SO.sub.2 methyl4 isopropyl SO methyl5 isopropyl S 4-chlorophenyl6 isopropyl S phenyl7 isopropyl SO phenyl8 isopropyl O methyl9 isopropyl O n-propyl10 isopropyl O n-butyl11 isopropyl O sec-butyl12 isopropyl O isopropyl______________________________________
Herbicidal Screening Tests
As previously mentioned, the herein described compounds produced in the above-described manner are phytotoxic compounds which are useful and valuable in controlling various plant species. Selected compounds of this invention were tested as herbicides in the following manner.
Pre-emergence herbicide test: On the day preceding treatment, seeds of eight different weed species are planted in loamy sand soil in individual rows using one species per row across the width of a flat. The seeds used are green foxtail (FT) (Setaria viridis), watergrass (WG) (Echinochloa crusgalli), wild oat (WO) (Avena fatua), annual morningglory (AMG) (Ipomoea lacunosa), velvetleaf (VL) (Abutilon theophrasti), Indian mustard (MD) (Brassica juncea), curly dock (CD) (Rumex crispus), and yellow nutsedge (YNG) (Cyperus esculentus). Ample seeds are planted to give about 20 to 40 seedlings per row, after emergence, depending upon the size of the plants.
Using an analytical balance, 600 milligrams (mg) of the compound to be tested are weighed out on a piece of glassine weighing paper. The paper and compound are placed in a 60 milliliter (ml) wide-mouth clear bottle and dissolved in 45 ml of acetone or substituted solvent. Eighteen ml of this solution are transferred to a 60 ml wide-mouth clear bottle and diluted with 22 ml of a water and acetone mixture (19:1) containing enough polyoxyethylene sorbitan monolaurate emulsifier to give a final solution of 0.5% (v/v). The solution is then sprayed on a seeded flat on a linear spray table calibrated to deliver 80 gallons per acre (748 L/ha). The application rate is 4 lb/acre (4.48 Kg/ha).
After treatment, the flats are placed in the greenhouse at a temperature of 70° to 80° F. and watered by sprinkling. Two weeks after treatment, the degree of injury or control is determined by comparison with untreated check plants of the same age. The injury rating from 0 to 100% is recorded for each species as percent control with 0% representing no injury and 100% representing complete control.
The results of the tests are shown in the following Table II.
TABLE II______________________________________Pre-Emergence Herbicidal ActivityApplication Rate - 4.48 kg/haCmpd.No. FT WG WO AMG VL MD CD YNG______________________________________1 25 50 25 85 80 100 70 02 0 0 0 0 0 0 0 03 50 65 0 90 60 100 50 04 60 60 15 80 20 80 85 05 25 80 0 0 0 0 0 06 50 25 40 0 25 50 35 07 85 75 100 100 85 95 75 08 95 100 60 100 100 100 95 09 75 65 75 65 75 100 50 010 60 60 0 25 75 85 60 011 100 100 80 100 100 100 75 --12 100 40 0 65 75 85 35 0______________________________________ -- = Not tested.
Post-Emergence Herbicide Test: This test is conducted in an identical manner to the testing procedure for the pre-emergence herbicide test, except the seeds of the eight different weed species are planted 10-12 days before treatment. Also, watering of the treated flats is confined to the soil surface and not to the foliage of the sprouted plants.
The results of the post-emergence herbicide test are reported in Table III.
TABLE III______________________________________Post-Emergence Herbicidal ActivityApplication Rate - 4.48 kg/haCmpd.No. FT WG WO AMG VL MD CD YNG______________________________________1 0 0 0 80 60 90 80 02 0 0 0 25 80 15 30 03 50 90 85 100 100 100 50 04 25 0 25 85 100 100 30 05 35 50 40 75 60 95 0 06 90 60 40 100 100 100 100 07 100 100 95 100 100 100 100 258 90 30 100 100 100 100 80 09 100 100 65 100 100 100 100 1010 100 100 85 100 95 100 85 011 60 60 0 75 100 100 75 012 100 70 50 100 95 100 100 0______________________________________ -- = Not Tested
The compounds of the present invention are useful as herbicides, and can be applied in a variety of ways at various concentrations. in practice, the compounds herein defined are formulated into herbicidal compositions, by admixture, in herbicidally effective amounts, with the adjuvants and carriers normally employed for facilitating the dispersion of active ingredients for agricultural applications, recognizing the fact that the formulation and mode of application of a toxicant may affect the activity of the materials in a given application. Thus, these active herbicidal compounds may be formulated as granules of relatively large particle size, as wettable powders, as emulsifiable concentrates, as powdery dusts, as solutions or as any of several other known types of formulations, depending upon the desired mode of application. Preferred formulations for pre-emergence herbicidal applications are wettable powders, emulsifiable concentrates and granules. These formulations may contain as little as about 0.5% to as much as about 95% or more by weight of active ingredient. A herbicidally effective amount depends upon the nature of the seeds or plants to be controlled and the rate of application varies from about 0.05 to approximately 25 pounds per acre, preferably from about 0.1 to about 10 pounds per acre.
Wettable powders are in the form of finely divided particles which disperse readily in water or other dispersants. The wettable powder is ultimately applied to the soil either as a dry dust or as a dispersion in water or other liquid. Typical carriers for wettable powders include fuller's earth, kaolin clays, silicas and other readily wet organic or inorganic diluents. Wettable powders normally are prepared to contain about 5% to about 95% of the active ingredient and usually also contain a small amount of wetting, dispersing, or emulsifying agent to facilitate wetting and dispersion.
Emulsifiable concentrates are homogenous liquid compositions which are dispersible in water or other dispersant, and may consist entirely of the active compound with a liquid or solid emulsifying agent, or may also contain a liquid carrier, such as xylene, heavy aromatic naphtha, isophorone and other non-volatile organic solvents. For herbicidal application, these concentrates are dispersed in water or other liquid carrier and normally applied as a spray to the area to be treated. The percentage by weight of the essential active ingredient may vary according to the manner in which the composition is to be applied, but in general comprises about 0.5% to 95% of active ingredient by weight of the herbicidal composition.
Granular formulations wherein the toxicant is carried on relatively coarse particles, are usually applied without dilution to the area in which suppression of vegetation is desired. Typical carriers for granular formulations include sand, fuller's earth, bentonite clays, vermiculite, perlite and other organic or inorganic materials which absorb or which may be coated with the toxicant. Granular formulations normally are prepared to contain about 5% to about 25% of active ingredients which may include surface-active agents such as wetting agents, dispersing agents or emulsifiers; oil such as heavy aromatic naphthas, kerosene or other petroleum fractions, or vegetable oils; and/or stickers such as dextrins, glue or synthetic resins.
Typical wetting, dispersing or emulsifying agents used in agricultural formulations include, for example, the alkyl and alkylaryl sulfonates and sulfates and their sodium salts; polyhydroxy alcohols; and other types of surface-active agents, many of which are available in commerce. The surface-active agent, when used, normally comprises from 0.1% to 15% by weight of the herbicidal composition.
Dusts, which are free-flowing admixtures of the active ingredient with finely divided solids such as talc, clays, flours and other organic and inorganic solids which act as dispersants and carriers for the toxicant, are useful formulations for soil-incorporating application.
Pastes, which are homogenous suspensions of a finely divided solid toxicant in a liquid carrier such as water or oil, are employed for specific purposes. These formulations normally contain about 5% to about 95% of active ingredient by weight, and may also contain small amounts of a wetting, dispersing or emulsifying agent to facilitate dispersion. For application, the pastes are normally diluted and applied as a spray to the area to be affected.
Other useful formulations for herbicidal applications include simple solutions of the active ingredient in a dispersant in which it is completely soluble at the desired concentration, such as acetone, alkylated naphthalenes, xylene and other organic solvents. Pressurized sprays, typically aerosols, wherein the active ingredient is dispersed in finely-divided form as a result of vaporization of a low boiling dispersant solvent carrier, such as the Freons, may also be used.
The phytotoxic compositions of this invention are applied to the plants in the conventional manner. Thus, the dust and liquid compositions can be applied to the plant by the use of power-dusters, boom and hand sprayers and spray dusters. The compositions can also be applied from airplanes as a dust or a spray because they are effective in very low dosages. In order to modify or control growth of germinating seeds or emerging seedlings, as a typical example, the dust and liquid compositions are applied to the soil according to conventional methods and are distributed in the soil to a depth of at least 1/2 inch below the soil surface. It is not necessary that the phytotoxic compositions be admixed with the soil particles since these compositions can also be applied merely by spraying or sprinkling the surface of the soil. The phytotoxic compositions of this invention can also be applied by addition to irrigation water supplied to the field to be treated. This method of application permits the penetration of the compositions into the soil as the water is absorbed therein. Dust compositions, granular compositions or liquid formulations applied to the surface of the soil can be distributed below the surface of the soil by conventional means such as discing, dragging or mixing operations. | A herbicidal compound having the structural formula ##STR1## where R is C 1 -C 10 alkyl; X is oxygen, sulfur, sulfoxide or sulfone; and Y is C 1 -C 6 alkyl, phenyl or substituted phenyl. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/395,608, filed on Mar. 24, 2003, entitled “Mortarless Wall Structure,” and published as US Publication No. 2003/0188497 on Oct. 9, 2003 which is a continuation in part of application Ser. No. 10/015,052, filed Dec. 11, 2001, entitled “Mortarless Wall Structure,” and issued as U.S. Pat. No. 6,691,471 on Feb. 17, 2004, which is a continuation in part of application Ser. No. 09/547,206, filed Apr. 12, 2000, entitled “Skirting Wall System,” and issued as U.S. Pat. No. 6,374,552 on Apr. 23, 2002. This application is also a continuation in part of application Ser. No. 10/363,999, filed Apr. 12, 2001, entitled “Mortarless Wall Structure,” and published as US Publication No. 2004/0006945 on Jan. 15, 2004, which is a continuation in part of application Ser. No. 09/547,206, filed Apr. 12, 2000, entitled “Skirting Wall System,” and issued as U.S. Pat. No. 6,374,552 on Apr. 23, 2002. This application also claims priority to PCT application Serial No. PCT/US01/11957 filed on Apr. 12, 2001, entitled “Wall Structure,” and PCT application Serial No. PCT/US00/25791 filed on Sep. 20, 2000, entitled “Wall Structure,” and all of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to decorative and structural blocks designed to be installed as exterior and interior walls for buildings. More particularly, the present invention relates to a system that uses specifically designed and manufactured masonry blocks that are used in conjunction with specifically designed support beams and/or brackets to provide durable, attractive, easy to assemble surfaces to a wide variety of buildings, structures, and structural elements.
BACKGROUND OF THE INVENTION
[0003] Transportable structures such as mobile homes, trailer homes, modular homes and recreational vehicles, by their very nature, are usually not intended to be built upon a conventional foundation. Rather, they are brought or driven to a location where they may remain for indeterminate periods of time. Often, over an extended period at a particular site, such structures may start to settle differentially onto or in the ground due to factors such as deflating tires or local variations in soil bearing capacities. Additionally, factors such as erosion and freeze-thaw cycles may also cause such structures to shift and/or tilt. In order to prevent such unwanted movement and ensure that a structure is level regardless of the ground's topography, the structures are often placed on stilts that extend from the structure or upon piles that extend from the ground, or even on isolated footings that distribute the weight of a structure over a relatively large surface area. While this solves the aforementioned problem of shifting/or sinking it often results in an unsightly visible gap in the area between the ground and the bottom of the structure.
[0004] Various attempts to cover the unsightly gap have included the use of plants, natural material such as rocks and wood and manmade products such as cement, masonry and plastics. These attempts have proven to be either prohibitively expensive, difficult to install and/or disassemble, or unattractive and unable to withstand sustained exposure to nature's elements. Attempts that tend to be prohibitively expensive or difficult to install include, for example, wall structures constructed of large, custom-made, cement slabs having decorative faces, and standard masonry blocks held together with mortar. Attempts that fall into the latter category include such relatively fragile and easily breakable products as wooden or plastic lattices, and synthetic panels designed to simulate stones or bricks.
[0005] Consequently, there is a need for an easy to assemble and/or dissemble, lightweight and sturdy, inexpensive wall structure for covering the gap between the ground and an elevated structure such as a mobile home.
[0006] In other applications, where brick, stone, or concrete is used as veneer or fascia, for fencing, and as load-bearing and non load-bearing walls, etc., these structures are constructed with an eye towards permanence. That is, the structures are not meant to be easily dismantled. This means that the component parts are often able to interconnect with each other and/or with a support framework in some fashion. This usually entails the use of robust connections such as mechanical fasteners, adhesives, cement, or the like. For example, many types of veneers are typically coated with adhesive or cementitious material to enable them to be securely and directly bonded to a structure. Or, as another example, walls may be constructed in a conventional manner with blocks and mortar.
[0007] Alternatively, wall structures may comprise heavy, interlocking blocks that rely on size and weight to achieve some measure of permanence. As one may well imagine, each of the aforementioned structures would be difficult and time consuming to reconfigure, remove, or repair should the need arise. And while the construction of some of these structures typically requires specialized knowledge, skills, and tools to achieve, it will be appreciated that disassembly may require other, additional specialized knowledge, skills, and tools to achieve. In light of these shortcomings, there is an additional need for a wall structure that may be easily assembled, disassembled and rebuilt or reconfigured by an unskilled user without damage to the constituent parts of the wall structure and which may be used as a veneer, fascia, cladding, fence, or as a load-bearing or non load-bearing wall.
[0008] The present invention provides a solution to these needs and other problems, and offers other advantages over the prior art.
SUMMARY OF THE INVENTION
[0009] Generally, the present invention provides a system by which structures may be provided with durable, easy to assemble externally facing surfaces, which are generally vertical and which may be used in a wide variety of applications. The system utilizes a series of particularly configured blocks that may be operatively connected to the structures by beams and/or brackets. One embodiment of the present invention provides a block wall system for use in skirting elevated structures. The blocks are shaped to be stacked in vertically independent, self-supporting columns, strengthened and linked together by specially shaped, lightweight, lateral support beams positioned between adjacent columns, and which may be stabilized by one or more inverted u-shaped brackets which are attached at or near the bottom of an elevated structure. In an alternative embodiment, a u-shaped bracket is provided with an arm that is rotatably attached thereto and which is movable into a position that facilitates attachment to a generally vertical surface. In another embodiment, the blocks are configured so that lateral support beams may be positioned not only between adjacent columns but also at intermediate positions along the block as well. In another embodiment, the lateral support beam is configured so that it can be movably coupled to a bracket, which may be attached to an existing structure.
[0010] One embodiment of the block comprises a front face, a rear face, top and bottom surfaces, and side surfaces, and each side surface includes an outwardly opening, vertically oriented groove for receiving a portion of a support beam. The top and bottom surfaces are configured to facilitate a stacking relationship between adjacent courses of blocks such that they are generally coplanar. This relationship is most easily achieved by making the top and bottom surfaces substantially collateral, planar and relatively perpendicular to rear and/or front faces. Another embodiment of the block includes the provision of externally formed channels that are configured and arranged to prevent moisture from forming and collecting at the rear face of the block. Another embodiment of the block includes at least one through hole or aperture that is substantially aligned with outwardly opening, vertically oriented grooves in the side surfaces of a block. As will be explained later, the through holes or apertures facilitate use with support beams in a variety of applications. Another embodiment of the block has viewable surfaces or facings that are angled with respect to each other and which facilitate the formation of closed structures.
[0011] One purpose of the beams is to keep vertically stacked, self-supporting columns of blocks from buckling when subjected to a force normal to the plane of the column. This strengthening is accomplished providing the beams with lateral extensions or ribs that are configured to be received in aligned grooves at the sides of the vertically stacked blocks. Another purpose of the beams is to link adjacent columns of blocks together in a colonnade-like arrangement to form a wall structure. This is also achieved with the aforementioned lateral extensions and grooves. As may be expected, the beams provide very little, if any, support in a vertical direction. The columns so constructed are considered independent because, unlike conventionally constructed masonry or stone walls, the joints between adjacent blocks are in alignment with each other rather than being offset as in a running bond. This enables the columns of blocks to move up and down relative to each other, without appreciably altering the inherent continuity of a wall structure. As will be appreciated, the rigidity of the blocks provides enough support to prevent a column from failing in the vertical direction. When a more robust wall structure is desired, blocks that have appropriately configured apertures and rearwardly facing slots may be stacked in a running bond arrangement and strengthened and linked together by support beams. Although the beams can be fabricated form a variety of materials such as metals and plastics, extruded aluminum, nylon, and polyvinyl chloride (PVC) are preferred.
[0012] It will be appreciated that the use of the lateral support beams also eliminates and/or substantially reduces the need for mortar to stabilize and unify the blocks. This wall structure system is advantageous over traditional brick and mortar walls for obvious reasons. First, fewer materials are required to build a wall. Second, the materials are easier to handle and manipulate, and no special tools or skills are required. Third, a wall can be constructed under conditions that would not be possible using traditional brick and mortar construction and a person need not be concerned about time constraints imposed by drying mortar. Fourth, the joints formed between adjacent blocks allow the wall to appear monolithic or seamless at a surprisingly close distance. Moreover, by providing blocks that have had their marginal areas modified, it is also possible to create walls that have the appearance of conventional block and mortar construction. Fifth, the block wall system can be constructed on a variety of surfaces, including sand, gravel, dirt, or building elements such as H-beams, flooring, base blocks, etc. It is not necessary to pour a foundation.
[0013] The lateral support beams also allow the blocks to be substantially thinner than conventional masonry blocks. These thin, lightweight blocks are not only easier to handle and ship, but require less material and time to fabricate. The blocks are generally about 1 to 4 inches (2.5-10 cm.) thick, about 6 to 12 inches (15-30 cm.) in height and about 6 to 24 inches (15-60 cm.) in width, and preferably have a thickness on the order of around 2½ inches (6.0 cm.). As one may appreciate, the combination of the thin blocks and the support beams facilitates construction of masonry wall structures in locations and configurations that were heretofore not possible using thin blocks alone. The resulting wall structure of this system is surprisingly strong and it may even be used to provide support to an elevated structure. When a wall structure is installed about an elevated structure, such as a portable home, the elevated structure may be lowered onto the blocks of the wall. Alternatively, the block wall system may serve as a skirt, which improves the aesthetics of the structure and keeps animals, litter, snow, etc. from intruding or being otherwise introduced beneath the structure. Or, the block wall system may be used with existing structures such as elevated decks and retaining walls. With these embodiments, it is not necessary that the blocks make actual contact with the structure.
[0014] The block wall system also allows the wall to be easily disassembled and reassembled. This not only gives flexibility during initial construction, but also allows later renovations to be made quickly and inexpensively. For instance, it may be desirable or required to vent elevated structures having skirting walls, to prevent the buildup of moisture or condensation between the ground and the elevated structure. Such vents can be easily installed into an existing wall, especially if they are of similar dimensions and configurations as the blocks. The blocks of a given column are simply removed and reinstalled, replacing one of the blocks with the vent. Other auxiliary items, such as an access door or lights, could be installed in a similar manner.
[0015] The wall block system of the present invention is not confined to linear structures. As will be appreciated, the system also allows walls to intersect to form angled or closed structures. In one embodiment, two intersecting walls are simply aligned to form a butt joint and fasteners such as pegs, or screws, and plastic inserts are used to fasten one wall to the other. Alternatively, construction mastic, or a similar type of adhesive, may be applied instead of or in combination with the abovementioned fasteners. In another embodiment, blocks are preformed as angled intersecting wall units that have been provided with outwardly opening, vertically oriented side grooves configured to receive portions of support beams, which may be further linked to other wall blocks as described above. As will be appreciated, such blocks may be combined together to form hollow columnar structures, or may be used to clad an existing structure such as a support post. Again, ease of installation is greatly improved by the block wall system of the present invention.
[0016] Another embodiment of the wall structure uses a differently configured bracket than the aforementioned u-shaped bracket. It, too, is used to operatively connect the wall structure to a support. The bracket of this embodiment, however, attaches in a slightly different manner than the u-shaped bracket. Instead of straddling the upper portion of a top-most block as with the u-shaped bracket of the aforementioned embodiment, this bracket has one end that is configured to be positioned within space defined by opposing vertical grooves of adjacent blocks. That is, the bracket is designed to be installed at or near the sides of a column. The other end of the bracket is configured to be attached at or near the bottom of a structure. An advantage with this bracket it that it is able to provide support for the wall structure in two directions, while allowing movement of wall components relative thereto in a third direction. As will be appreciated, this bracket may be easily installed and removed without the need for special training or tools. Preferably, the bracket of this embodiment is L-shaped, although it is envisioned that other shapes are possible. For example, the bracket may be linear, or it may be linear and have an axial twist in it. Or, the structure-engaging portion may be provided with a u-shape or even its own integral fastener.
[0017] An assembly of blocks may be operatively connected to a support using yet another embodiment of the wall skirting system. With this embodiment, the support beam is configured to be movably coupled to one or more brackets that, in turn, may be attached to the support. This allows the beam to move relative to the bracket(s) without sacrificing the strength of the assembled blocks, and also allows the beams to be connected to the structure at different locations along its length. For example, at the top, at the bottom, or anywhere in between. As will be understood, in order for the support beam and bracket to operate in such a constrained manner the bracket(s) need to be configured so that they are able to slidingly retain the beam. Thus, differently configured beams may require specially configured brackets.
[0018] In another embodiment of the block wall system, blocks are operatively connected to a structure with one or more brackets, which are configured to be able to engage the side grooves of adjacent blocks, and which may be directly attached to the structure. As will be appreciated, the brackets of this embodiment will permit the blocks to move relative thereto, but not to the degree that is available with the aforementioned support beam and bracket combination. As with the aforementioned support beams, the brackets can be fabricated form a variety of materials such as metals and plastics. However, steel, extruded aluminum, nylon, and polyvinyl chloride (PVC) are preferred.
[0019] It will be appreciated that wall structures other than linear structures are possible. For example, support beams and blocks may be used to construct circular, or sinuous structures by providing curved blocks or blocks with one curved viewable surface (when viewed cross-sectionally from a point above the top surface of the block) that are operatively connected to support beams that are similarly arranged. Alternatively, a wall structure may be constructed in a zigzag or erose form with the support beams collaterally arranged relative to each other in a zigzag manner. To reduce vertical gaps between forwardly facing viewable surfaces of adjacent blocks in such a wall structure, it would be a matter of providing support beams with ribs that are angled with respect to the web and mitering or beveling the opposing sides of the blocks, or using a combination of both angling and mitering the ribs and sides, respectively. A similarly configured wall may also be constructed using support beams arranged in a coplanar or staggered fashion relative to each other and blocks having a predetermined, angular viewable surface (when viewed cross-sectionally from a point above the top surface of the blocks). For example, a “V”, “L”, or a “W”. Such blocks may have parallel front and rear faces, if desired. With such a construction, neither the support beams nor the opposing fingers need to be modified. In a related construction, it is envisioned that blocks be constructed having angles of ninety degrees so that they may be used as inner or outer corners. With such blocks, the opposing sides and their fingers would be perpendicular to each other.
[0020] In one method of constructing a freestanding, low wall structure of the present invention, a person would prepare or otherwise select an appropriate location in which to construct a wall. The construction would begin by placing a first block having opposing side grooves in a desired position and orientation. Then, a second, similar block would be placed directly on top of the first block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks would be operatively connected to each other along their respective sides by inserting at least one rib of first and second support beams into the aligned grooves of the respective sides of the first and second blocks and seating them securely. A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is much the same, except now the third block is positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages at least one other rib of one of the already positioned support beams. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages at least one other rib of one of the already positioned support beam. After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by inserting at least one rib of a third support beam into their aligned vertical groove of the respective sides of the first and second blocks and seating them securely. And so on.
[0021] Another, alternative method of constructing a wall structure of the present invention according to the present invention would be as follows. A person would prepare or otherwise select an appropriate substructure on which to construct a wall structure. The construction would begin by operatively connecting a first elongated support beam to the substructure. Then using the first support beam as a reference, a series of additional support beams would be operatively connected to the substructure, with all of the support beams in vertical and collateral alignment, and with the distance between adjacent support beams sufficient to enable the ribs of adjacent beams to engage opposing side grooves of a block. Once the dimensions of the wall structure have been established, the blocks with opposing side grooves may be positioned by sliding the blocks along the length of and between adjacent support beams. This may be done course by course, column by column, or in a mixture of both columns and courses, as desired.
[0022] In a variation of the aforementioned methods of construction, a person would begin by operatively connecting a first elongated support beam to the substructure in a vertical orientation. Then a first block having opposing side grooves would be placed in a desired position and orientation against the first elongate support beam so that at least one of the ribs of the first beam is seated within one of the side grooves of the block. Then, a second, similar block would be placed directly on top of the first block so that the at least one rib of the first beam is also seated within one of the side grooves of the second block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks are operatively connected to each other along their other respective sides by aligning the grooves of the respective sides of the first and second blocks, and inserting at least one rib of a second support beam into the aligned grooves and seating it securely therein. After the second support beam is seated, it is attached to the substructure. A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is the same, with the third block positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages another rib of the already positioned second support beam. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages another rib of the already positioned second support beam. After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by aligning the grooves of the respective sides of the third and fourth blocks, and inserting at least one rib of a third support beam into the aligned grooves and seating it securely therein. After the third support beam is seated, it is attached to the substructure. And so on.
[0023] Additional advantages and features of the invention will be set forth in part in the description which follows, and in part, will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a partial, perspective view of two embodiments of the block wall system, with one preferred embodiment of blocks arranged below an elevated first (upper level) deck structure and another embodiment of blocks arranged about the perimeter of an adjacent, elevated second (lower level) deck structure;
[0025] FIG. 2 is a partial, exploded, perspective view of the block arrangement below the elevated first (upper level) deck structure of FIG. 1 ;
[0026] FIG. 2 a is a top plan view of the block arrangement of FIG. 1 , taken generally along lines 2 a - 2 a;
[0027] FIG. 3 is a side elevational, cross-sectional view of the block arrangement about the perimeter of the elevated second (lower level) deck structure of FIG. 1 taken generally along lines 3 - 3 ;
[0028] FIG. 3 a is a partial, side elevational, cross-sectional view of an alternative support for the block arrangement of FIG. 3 ;
[0029] FIG. 4 is a perspective view of an elevated structure skirted with an embodiment of the blocks of the present invention arranged in a wall structure;
[0030] FIG. 5 is a side elevational view the wall structure of FIG. 4 taken generally along lines 5 - 5 ;
[0031] FIG. 6 is a partial, perspective view of an embodiment of blocks arranged to provide a facia wall for a retaining wall;
[0032] FIG. 6 a is a partial, side elevational, cross-sectional view of the block arrangement of FIG. 6 taken generally along lines 6 a - 6 a;
[0033] FIG. 7 is a perspective view of another embodiment of a block of the present invention;
[0034] FIG. 7 a is a perspective view of another embodiment of a block of the present invention;
[0035] FIG. 7 b is a bottom plan view of the block of FIG. 7 a;
[0036] FIG. 8 is a partial, cross-sectional, plan view of an embodiment of a corner construction of a wall structure of the present invention;
[0037] FIG. 9 is a perspective view of another embodiment of a block of the present invention;
[0038] FIG. 10 is a bottom plan view of the block of FIG. 9 ;
[0039] FIG. 11 is a partial, perspective view of an embodiment of a support beam of the present invention;
[0040] FIG. 11 a is a partial, perspective view of an alternative embodiment of a support beam of the present invention;
[0041] FIG. 12 is a partial, perspective view of an alternative embodiment of a support beam;
[0042] FIG. 13 is a partial, perspective view of an alternative embodiment of a support beam;
[0043] FIG. 14 is a plan view of an alternative embodiment of a block engagement portion of a vertical support beam similar to that of FIG. 11 a , with the remainder of the support beam shown in phantom;
[0044] FIG. 15 is a plan view of an alternative embodiment of a block engagement portion of a support beam similar to that of FIG. 11 a , with the remainder of the support beam shown in phantom;
[0045] FIG. 16 is a partial, perspective view of an embodiment of a support beam of the present invention;
[0046] FIG. 17 is a partial, perspective view of another embodiment of a support beam in conjunction with a bracket, with the bracket configured to be attached to a sub structure;
[0047] FIG. 18 is a partial, perspective view of another embodiment of a support beam in conjunction with another embodiment of a bracket, with the bracket configured to be attached to a sub structure;
[0048] FIG. 19 is a partial, perspective view of another embodiment of a support beam in conjunction with another embodiment of a bracket with the bracket configured to be attached to a substructure;
[0049] FIG. 20 is a partial, perspective view of an embodiment of a support beam having an integrally formed aperture and an integrally formed bracket, with the support beam able to be used with the support beam of FIG. 19 to construct/form a double sided wall structure;
[0050] FIG. 21 a partial, perspective view of another embodiment of a support beam;
[0051] FIG. 22 is a partial, top plan view, taken generally along lines 22 - 22 of FIG. 4 , of showing adjacent blocks of the present invention in conjunction with a support beam;
[0052] FIG. 23 is a partial, top plan view of the two blocks abutted with a support beam of FIG. 22 , but with the support beam arranged in an alternative configuration;
[0053] FIG. 23 a is a partial, top plan view of the blocks of FIG. 23 as they may be assembled into a wall structure, or as a wall structure is disassembled;
[0054] FIG. 24 is a partial, top plan view of two blocks, a support beam, and a support bracket that have been assembled into a wall structure;
[0055] FIG. 24 a is a partial, top plan view of a portion of the blocks, support beam, and bracket of FIG. 24 , as they may be assembled into a wall structure, or as a wall structure is disassembled;
[0056] FIG. 25 is a partial, top plan view of two blocks of the present invention in conjunction with an alternative embodiment of a support beam;
[0057] FIG. 26 is a partial, top plan view of two blocks of the present invention in conjunction with another alternative embodiment of a support beam;
[0058] FIG. 27 is a partial, top plan view of the support beams shown in FIGS. 12 and 13 in conjunction with blocks of the present invention;
[0059] FIG. 28 is a partial, top plan view of two blocks of FIG. 7 a that are operatively connected to the support beam of FIG. 11 a;
[0060] FIG. 29 is a partial, top plan view of the support beam of FIG. 16 as it may be used to operatively connect blocks of the present invention to a substructure;
[0061] FIG. 30 is a perspective view of a wall structure construction using another preferred embodiment of support beams and blocks of the present invention;
[0062] FIG. 31 is a partial, top plan view of the support beam and bracket of FIG. 17 as they may be used to operatively connect blocks to a substructure;
[0063] FIG. 32 is a partial, top plan view of the support beam and bracket of FIG. 18 as they may be used to operatively connect blocks to a substructure;
[0064] FIG. 33 is a partial, top plan view of the support beam and bracket of FIG. 19 as they may be used to operatively connect blocks to a substructure;
[0065] FIG. 34 is a partial, top plan view of an alternative embodiment of the support beam of FIG. 21 as it may be used to operatively connect blocks to a substructure;
[0066] FIG. 35 is a partial, top plan view of the support beam of FIG. 21 as it may be used operatively connect blocks to a substructure;
[0067] FIG. 36 is a partial, top plan view of the support beam of FIG. 20 and the support beam of FIG. 19 as they may be used to operatively connect differently sized blocks together in a dual-sided wall structure;
[0068] FIG. 37 is a partial, top plan view of the blocks of FIG. 7 in conjunction with another embodiment of a support beam, with the support beam operatively connecting the blocks to an existing structure;
[0069] FIG. 37 a is a partial, top plan view of the blocks of FIG. 7 in conjunction with another alternative embodiment of a support beam with the support beam operatively connecting the blocks to an existing structure;
[0070] FIG. 37 b is a partial, top plan view of blocks of FIG. 7 in conjunction with another alternative embodiment of a support beam with the support beam operatively connecting the blocks to an existing structure;
[0071] FIG. 38 is a partial, top plan view of a free standing dual wall structure wherein the respective walls of the wall structure are connected to each other in a spaced relation by an alternative embodiment of a support beam;
[0072] FIG. 39 is a partial, top plan view of blocks of FIG. 7 in conjunction with an alternative embodiment of the support beam of FIG. 20 , wherein the aperture is configured to received a post;
[0073] FIG. 40 is a partial, perspective view of an embodiment of a wall structure of the present invention and a preferred attachment bracket;
[0074] FIG. 41 is a perspective view of the attachment bracket of FIG. 40 ;
[0075] FIG. 42 is a side elevational view of the bracket of FIG. 41 attached to a lower surface of a structure, and as it may be attached to an upper surface of the structure (shown in phantom);
[0076] FIG. 43 is a perspective view if the attachment bracket of FIG. 41 as it may be used in conjunction with the support beam of FIG. 11 ;
[0077] FIG. 44 is an exploded, perspective view of an attachment bracket and the support beam of FIG. 11 a;
[0078] FIG. 45 is a rear perspective view of the attachment bracket and support beam of FIG. 44 after they have been operatively connected to each other;
[0079] FIG. 46 is a perspective view of an alternative embodiment of an attachment bracket suitable for use with a support beam as depicted in FIG. 11 a;
[0080] FIG. 47 is a plan view of the attachment bracket of FIG. 46 as it may be operatively connected to a support beam as depicted in FIG. 11 a;
[0081] FIG. 48 is a perspective view of an alternative embodiment of an attachment bracket having an arm that is rotatably connected thereto, and which is in a first position;
[0082] FIG. 49 is a perspective view of the attachment bracket of FIG. 48 in which the arm has been rotated to a second position;
[0083] FIG. 50 is a perspective view of an embodiment of an attachment bracket;
[0084] FIG. 51 is a partial, perspective view of a wall structure in which blocks of the present invention are operatively connected to a substructure by the vertically oriented support beams and brackets of FIGS. 2 and 2 a;
[0085] FIG. 52 is another partial perspective view of a wall structure in which blocks of the present invention are operatively connected to a substructure by horizontally oriented support beams and brackets of FIGS. 2 and 2 a;
[0086] FIG. 53 is a side elevation view of a block wall structure that is operatively connected to a structure;
[0087] FIG. 54 is an edge view of a sealing element that is used in the construction of the wall structure of FIG. 53 ;
[0088] FIG. 55 is a perspective view of the sealing element of FIG. 54 ;
[0089] FIG. 56 is an enlarged view of a portion of FIG. 53 , which depicts the sealing element of FIGS. 54 and 55 as it resides between structural elements;
[0090] FIG. 57 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention;
[0091] FIG. 58 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention;
[0092] FIG. 59 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention; and,
[0093] FIG. 60 is a plan view of the brackets of FIGS. 57 and 59 operatively connecting blocks of the present invention to a substructure.
DETAILED DESCRIPTION
[0094] FIG. 1 illustrates several embodiments of the wall block system of present invention, as practiced with an elevated first (upper level) deck d 1 and an adjacent, elevated second (lower level) deck structure d 2 . The first embodiment is an elevated upper level deck structure d 1 , which is supported by a plurality of vertical posts that have been provided with an external sheathing of blocks that are operatively connected to the posts by support beams and brackets.
[0095] As depicted, the blocks used to sheath the post are angled blocks, such as depicted in FIGS. 2 and 2 a . The blocks, which are provided with grooves at their side edges, are configured to be operatively connected to a post by one or more support beams 716 , which will be discussed later in greater detail. As depicted, the support beams may be directly attached to the post. Alternatively, the blocks may also be operatively connected to the post by a support beam and a bracket 354 (see, for example, FIG. 2 a , which will be discussed later in greater detail), or by brackets alone (see FIGS. 57, 58 , 59 and 60 ). While it will be understood that a post sheathing will be relatively robust, it may be desirable to create a more permanent structure. This can be achieved, for example, by providing the horizontal and/or vertical edge surfaces of the blocks with a suitable adhesive 58 (vertical edge surfaces shown in phantom). Alternatively, the blocks may be secured by one or more circumferential bands of material (not shown).
[0096] Referring again to FIGS. 1, 2 and 2 a , it will be apparent that gaps may exist between the blocks and the post, and that moisture and debris may infiltrate the gaps from above, and/or between the joints between adjacent blocks. As will be understood, such infiltration may be substantially reduced by providing the sheathed post with cap stones, flashing gaskets or other construction elements that serve to effectively close the gaps from above. Infiltration reduction may also be achieved by providing the horizontal and vertical edge surfaces with caulking material.
[0097] The second embodiment of the block wall system of FIG. 1 depicts another application of the present invention, where blocks are used to skirt an elevated, lower level, second deck structure d 2 . In this application, the wall structure comprises several block embodiments. Starting from the left corner, the upper and lowermost courses comprise blocks that are similar to the corner blocks of FIGS. 2 and 2 a. The middle course, while it could comprise a block of FIGS. 2 and 2 a , is constructed using two linear blocks that are connected to each other by fastening element such as pins and/or adhesive material (see, for example, FIG. 8 ).
[0098] Continuing towards the right, the next block embodiments, which will be discussed later in greater detail, are generally linear and as will be discussed later, configured to be operatively connected to the deck frame. Continuing on to the right corner, the arrangement of the blocks is similar to the arrangement of the blocks depicted at the left corner. The right corner differs, however, in that the corners formed by the blocks are not ninety degrees. Instead, the corner formed by the intersection of two walls is obtuse.
[0099] As will be discussed later in greater detail, the skirting structure blocks may be operatively connected to the deck frame in a manner similar to the previously discussed post sheathing. That is, through the use of support beams, support beams and bracket, or brackets. The wall structure depicted in FIG. 5 uses a support beam that is attached directly to the deck frame. As will be discussed later, the support beam serves to maintain and align a plurality of blocks. As depicted, the blocks of FIG. 5 are supported by a longitudinal L-shaped support bar that is also attached to the deck frame. With this operative connection, the blocks are not subject to external forces such as frost heave, and are generally static.
[0100] In the partial depiction wall structure of FIG. 5 a , the support beam is indirectly connected to the deck frame by one or more brackets. In this instance, the beam and bracket combination is similar to the beam and bracket combination of FIG. 2 a . This combination allows the beam (and blocks), which rest on a footing, to move in response to external forces such as frost heave. In this regard, the operative connection can be considered dynamic.
[0101] FIG. 3 is a perspective view of an elevated structure “S” skirted with a wall system 10 of the present invention. Generally, the wall structure 10 comprises of a plurality of blocks 12 forming columns 14 (see also, FIG. 4 ) partially spaced apart and held in place by vertically oriented, lateral support beams (see, for example, FIGS. 5, 11 , 22 , and 23 ). Downward opening brackets 18 (see FIGS. 5 and 22 ) that are attached to the bottom of the structure “S” being skirted, are configured to engaged the top block 12 of selected columns 14 to help prevent the wall structure 10 from tipping rearwardly or forwardly. As used herein, the term “forward” means away from the center of the elevated structure “S” and the term “rearward” means toward the center of the elevated structure “S”.
[0102] FIGS. 4 and 7 show an arrangement of blocks 12 that form a plurality of columns 14 . Referring particularly to FIG. 7 , each block 12 is generally panel-shaped and includes a front face 20 , a rear face 22 , a top surface 24 , a bottom surface 26 and pairs of side surfaces 28 a , 29 a and 28 b , 29 b , respectively. The side surface pairs 28 a , 29 a and 28 b , 29 b , respectively, are preferably somewhat perpendicular to the rear face 22 and/or the front face 20 . Side surface 28 a is spaced from side surface 28 b by a distance (taken along a “x” direction in a three-dimensional coordinate system relative to the blocks 12 ) to define a width 33 of the block 12 . Additionally, each pair of side surfaces 28 a and 29 a , 28 b and 29 b , include a substantially vertical groove 34 therebetween, which is configured to receive a portion of a lateral support beam 16 (See, for example, FIG. 11 ).
[0103] Note that while the top and bottom surfaces 24 , 26 of adjacent blocks 12 are configured to contact each other without thick layers of mortar or binding material therebetween, it is envisioned that the use of thin layers of intermediate materials, which may serve to strengthen and/or provide resistance to moisture may be practiced without departing from the spirit and scope of the invention. Moreover, it will be apparent that thin or no intermediate layers will minimize the spacing between blocks and allow the marginal areas 23 c , 23 d of adjacent blocks 12 to combine and simulate horizontally oriented splitting recesses.
[0104] As will be understood, the brackets 18 (see FIGS. 4 and 22 ) prevent rearward or forward movement of the column 14 and also work in conjunction with the beam 16 to prevent columns 14 not in direct contact with the bracket 18 from tipping over rearwardly or forwardly. It is envisioned that the beams 16 may be directly attached to the wall structure 10 (similar to FIG. 29 ) or alternatively, the bracket 18 may be solely responsible for preventing the wall structure 10 from tipping over. While it will be understood that the bracket 18 can be of any suitable material, synthetic, more preferably poly-vinyl chloride (PVC) or other durable plastic is preferred.
[0105] The bracket 18 comprises a front wall 44 , a rear wall 46 spaced apart from front wall 44 and a top wall 48 joining the front wall 44 to the rear wall 46 in a generally inverted “U”-shape. The front wall 44 and the rear wall 46 define an opening 50 , which is configured and arranged to receive an uppermost portion of the top block 12 of a column 14 . In practice, the bracket 18 is attached at or near the underside of a structure “S” to be skirted so that the opening 50 can receive the upper portion of the top block 12 of a column 14 . Preferably, the bracket 18 is positioned such that it may straddle the central region of an uppermost block 12 . It may be desired to make rear wall 46 of a greater vertical dimension than the front wall 44 to provide additional support. It may also be desired to provide a bracket 18 with a rear wall 46 , width that extends in a lateral direction further than the front wall 44 width. Furthermore, it is envisioned that the bracket 18 can be formed into a variety of lengths. For instance, the bracket 18 can be as short as one inch or as long as the entire skirted structure “S”.
[0106] While the top wall 48 of the bracket 18 is depicted in FIG. 4 as being in contact with the top surface 24 of the uppermost block 12 of the column 14 , it should be understood that this need not always be the case. In situations where the wall structure 10 is not a load bearing wall, or where the terrain shifts or changes due to climate, settling, animals, roots, etc., it may be desirable to provide a gap between the top wall 48 and the top surface of the wall structure 10 . Thus, individual columns 14 will be able to move vertically in small increments without destroying the integrity of the wall structure 10 or the skirted structure (not shown). In that regard, it should be appreciated that the beams 16 slidingly grip portions of the blocks 12 . That is to say, the beams 16 do not grip the blocks 12 with so much force as to preclude relative movement of the blocks 12 therealong in a longitudinal direction.
[0107] FIGS. 6 and 6 a show an embodiment of another application of the present invention, where blocks are used to provide a facia wall in front of an existing retaining wall. The facia wall is formed using support beams and brackets similar to the beams and brackets depicted in FIGS. 2 and 2 a . That is, the support beam 716 , as shown, comprises an elongated spine or web 718 and plurality of ribs 720 and 722 , 724 and 726 , which are arranged in a substantially coplanar and collateral relation so that the first pair of ribs 720 , 722 , which are substantially coplanar and extend away from each other. The first pair of ribs 720 , 722 are designed to engage the grooves of one or more blocks of a structure (see, for example, FIG. 6 a ).
[0108] In addition, the web 718 also includes a second pair of ribs 724 , 726 , which are also substantially coplanar and which extend away from each other. Note that the pairs of ribs 724 and 726 are in substantially collateral or parallel relation with respect to each other and are spaced apart from each other by a distance defined by the web 718 . As better shown in FIGS. 51 and 52 , he support beam 716 also includes a pair of pair of leg structures 730 having leg portions 732 a , 732 b that they extend rearwardly away from ribs 724 , 726 and which form a generally U-shaped channel therewith. One of the leg portions 732 b includes a foot 734 . that extends laterally away from the leg portion 732 b and is generally parallel with ribs 724 , 726 . As with the embodiment of FIGS. 2 and 2 a , the foot may be connected directly or indirectly to a support structure. However, as depicted, the beams of FIGS. 6 and 6 a are operatively connected to a structure by a plurality of brackets 354 , which are attached to blocks of the retaining wall. With such an arrangement the beams, which are slidingly constrained by the brackets, permit blocks to move without destroying the integrity of the structure.
[0109] The brackets 354 used to operatively connect the beams 718 to the retaining wall blocks generally comprise a structure engaging portion, a web, and a support beam engaging portion. As shown in FIG. 50 , the structure engaging portion 356 of bracket 354 comprises a single or first member 357 that is provided with an aperture 360 , which is used to facilitate attachment to the retaining wall with fastening elements such as nails, threaded fasteners, or anchor bolts. It will be appreciated, however, that an aperture or apertures need not be present in order to attach the bracket to a structure. The fastening element(s) may be driven through the first member, if desired. Additionally, it will also be appreciated that attachment may also be achieved with suitable adhesives, in lieu of, or in addition to, fastening elements. The support beam engaging portion 358 comprises a web 362 and a pair of legs 364 , 366 , which are angled with respect to the web to form a generally “L”-shape. The web 362 includes an aperture 368 that is accessible through a slot 370 defined by edges 372 and 374 of legs 366 and 364 , respectively. The aperture 368 and slot 370 are configured to slidingly receive a leg portion 732 b and foot 734 of a support beam (see also, FIGS. 50, 51 and 52 ).
[0110] Attention is now directed to the individual components of a wall structure 10 . FIG. 7 depicts a preferred embodiment of a block 12 . It can be seen that the block 12 is generally panel-shaped and includes a front face 20 , a rear face 22 , a top surface 24 , a bottom surface 26 and pairs of side surfaces 28 a , 29 a and 28 b , 29 b , respectively. The block 12 is preferably made of a composite masonry material in a dry-cast molding operation. Though the general shape of the blocks 12 is more important than the material used in order to practice the present invention, composite masonry material provides the most desirable combination of strength, appearance, economy, and ease of manufacturing. It is envisioned, however, that other materials can be used, such as concrete, fiberglass, ceramics, hard plastics, dense foam, or even wood.
[0111] The front face 20 is spaced from the rear face 22 by a predetermined distance herein defining the thickness or depth 30 (generally about 1 to 4 inches (2.5 to 10.0 cm)) of the block 12 . As shown in FIG. 7 , the front face 20 is formed to have a roughened or rustic surface. Such surfaces commonly result during block fabrication, where a mold is cast and the casting is later split or fractured into two blocks along a predetermined plane, with the plane of separation between the two blocks defining a pair of opposing front faces. Splitting is not necessary to carry out the spirit of the invention, however, and the block 12 may be formed by other known methods. Moreover, the front face 20 can be dressed, modified, or otherwise worked in any desired manner.
[0112] A vertically oriented splitting recess 21 may be provided on the front face 20 of the block 12 to enable the block 12 to be fashioned into predetermined shapes. In FIG. 7 , the splitting recess 21 is depicted as bisecting the block 12 . However, it is understood that the splitting recess can be located and oriented elsewhere on the block. That is, the splitting recess can be off-center, horizontal, diagonal, etc. Moreover, it is also understood that the block can be provided with more than one splitting recess, if desired.
[0113] The front face 20 includes marginal areas 23 a , 23 b , 23 c , and 23 d . As may be expected, the number of marginal areas corresponds to the number of edges of the front face 20 . These marginal areas may be worked or modified, if desired, to produce different visual effects. Here, the desired effect is for the marginal areas 23 a , 23 b , 23 c , and 23 d to simulate splitting recesses 21 . Thus, the marginal areas 23 a , 23 b , 23 c , and 23 d are formed so that when blocks 12 are positioned in contact with each other in a wall structure 10 , the cross-sectional profiles of their marginal areas 23 a , 23 b , 23 c , and 23 d , when combined, simulate splitting recesses 21 . As depicted the splitting recesses 21 have a cross-sectional profile that is somewhat circular, and the marginal areas 23 a , 23 b , 23 c , and 23 d have cross-sectional areas that are fluted or arced. As can be appreciated, the splitting recesses 21 and marginal areas 23 a , 23 b , 23 c , and 23 d may be configured with other cross-sectional profiles, if desired. For example, a “V”-shaped cross-sectional profile.
[0114] As mentioned above, tight or thin joints 31 (See FIG. 3 ) between adjacent blocks 12 enables a wall structure to appear monolithic or seamless. This feature may be used in combination with splitting recesses 21 and marginal areas 23 a - d of the blocks 12 to create different visual effects. For example, it is envisioned that a wall structure may simulate running bonds by having the blocks of each column alternate between a block with no splitting recess and worked marginal areas and a block having a splitting recess and worked horizontal marginal areas (see, for example, FIG. 40 ). Or, it is envisioned that the splitting recesses and marginal areas be selected to enable the wall structure to simulate an ashlar block wall (not shown).
[0115] Referring again to FIG. 7 , the top surface 24 is spaced from the bottom surface 26 by a distance (taken along a “y” direction in a three-dimensional coordinate system relative to the block 12 ) to define the height 32 (about 6 to 12 inches (15 to 30 cm)) of the block 12 . When blocks 12 are arranged vertically to form a column 14 (see FIG. 4 ), the bottom surface 26 of any block 12 other than the bottom block of a column 14 (not shown) rests on the top surface 24 of the block therebelow. It is therefore preferred that the top surface 24 and the bottom surface 26 be configured to facilitate a stacking relationship between two blocks 12 . A stacking relationship is most easily achieved by making the top and bottom surfaces 24 , 26 substantially collateral, planar, and relatively perpendicular to the rear face 22 and/or the front face 20 , as best shown in FIGS. 4 and 5 . Alternatively, it is envisioned that top and bottom surfaces 24 , 26 may be complementarily shaped, and not perpendicular to the rear face and/or the front face, but which permit upper and lower blocks to be stacked in a vertical relationship (not shown). For example, the surfaces could be non-planar and/or irregular. Alternatively, the surfaces can have compound curves or even interlocking segments (not shown).
[0116] The side surface pairs 28 a , 29 a and 28 b , 29 b , respectively, are preferably somewhat perpendicular to the rear face 22 and/or the front face 20 . Side surface 28 a is spaced from side surface 28 b by a distance (taken along a “x” direction in a three-dimensional coordinate system relative to a block 12 ) to define the width 33 (6 to 24 inches (15 to 60 cm)) of block 12 . Additionally, each pair of side surfaces 28 a and 29 a , 28 b and 29 b , include a substantially vertical groove 34 therebetween that is configured to receive a portion of a lateral support beam 16 (see, for example, FIG. 11 ). While a pair of side grooves for each block is preferred, it is envisioned that one side surface be provided with a groove and the other side surface have a tongue configured to mate with the groove, thereby obviating the need for beams 16 . However, in order to maintain the vertically independent characteristics of columns 14 , the use of beams 16 is preferred.
[0117] Referring now to FIGS. 7 a and 7 b , another embodiment of the block of the present invention is depicted. The block 112 is generally panel-shaped and includes a front face 120 , a rear face 122 , a top surface 124 , a bottom surface 126 and pairs of side surfaces 128 a , 129 a , and 128 b , 129 b , respectively.
[0118] The front face 120 is spaced from the rear face 122 by a predetermined distance defining the thickness or depth 130 (generally about 1 to 4 inches (2.5 to 10.0 cm)) of the block 112 . As shown in FIG. 7 a , the front face 120 is formed to having a roughened or weathered surface. However, it is understood that the front face 120 could, be dressed, modified, or otherwise worked in any desired manner.
[0119] Vertically oriented splitting recesses may be provided on the front face of the block to enable the block to be fashioned into predetermined shapes. Here, the splitting recesses 121 are depicted as quartering the block 112 and forming front face segments 125 a , 125 b , 125 c , and 125 d . However, it is understood that the splitting recesses 121 may be located and oriented elsewhere on the block 112 . That is, the splitting recesses 121 could be off center, horizontal, diagonal, etc. Moreover, it is also understood that a block splitting recesses 121 may be omitted, if desired.
[0120] The front face 120 includes marginal areas 123 a , 123 b , 123 c , and 123 d . As may be expected, the number of marginal areas corresponds to the number of edges of the front face 120 . The marginal areas 123 a - d may be worked or modified, if desired, to produce different visual effects. In FIG. 7 a , the desired visual effect is for the marginal areas to simulate splitting recesses. Thus, the marginal areas 123 a - d are formed so that when blocks 112 are positioned in contact with each other in a wall structure 10 (See FIG. 3 , for example), the cross-sectional profiles of their marginal areas 123 a - d , when combined, simulate splitting recesses at the joints formed by the block. As depicted, the splitting recesses 121 have a cross-sectional profile that is somewhat circular, and the marginal areas 123 a - d have cross-sectional areas that are fluted or arced. As can be appreciated, the splitting recesses and marginal areas 123 a - d may be configured with other cross-sectional profiles, if desired. For example, a “V”-shaped cross-sectional profile.
[0121] Referring again to FIG. 7 a , the top surface 124 is spaced from the bottom surface 126 by a distance (taken along a “y” direction in a three-dimensional coordinate system relative to the block 112 ) to define the height 132 (about 6 to 12 inches (15 to 30 cm)) of the block 112 . When the blocks 112 are arranged vertically to form a column 14 (see, for example, FIGS. 4 and 5 ), the bottom surface 126 (not shown) of any block 112 other than the bottom block of a column 14 (See FIG. 5 ) rests on the top surface 124 of the block 112 therebelow. It is therefore preferred that the top surface 124 and the bottom surface 126 be configured to facilitate a stacking relationship between two blocks 112 . A stacking relationship is most easily achieved by making the top and bottom surfaces 124 , 126 substantially collateral, planar and relatively perpendicular to the rear face 122 and/or the front face 120 , as shown in FIGS. 4 and 5 . Alternatively, it is envisioned that the top surface 124 and the bottom surface 126 (see FIG. 7 b ) may be complementarily shaped, and not perpendicular to the rear face 122 and/or the front face 120 , as long as the upper and lower blocks 112 can be stacked in a vertical relationship. For example, the surfaces 124 , 126 (not shown) can be non-planar and/or irregular. Or, the surfaces 124 , 126 (not shown) can have compound curves or interlocking segments (not shown).
[0122] Referring to FIG. 7 b , the side surface pairs 128 a , 129 a and 128 b , 129 b , respectively, are preferably somewhat perpendicular to the rear face 122 and/or the front face 120 . The side surface 128 a is spaced from the side surface 128 b by a distance (taken along the “x” direction in a three-dimensional coordinate system relative to the block 112 ) to define the width 133 (6 to 24 inches (15 to 60 cm)) of the block 112 . Additionally, each pair of side surfaces 128 a , 129 a , 128 b and 129 b , include a substantially vertical groove 134 located therebetween that is configured to receive a portion of a lateral support beam (see, for example, the lateral support beam depicted in FIGS. 11 , and 23 - 36 ).
[0123] The block 112 is that it is additionally provided with one or more substantially vertical apertures or through holes 150 a , 150 b , and 150 c . As can be seen, apertures 150 a , 150 b , and 150 c , which are in substantial alignment with the grooves 134 located on either side of the block 112 . This enables for use with support beams 270 such as those shown in (See FIG. 12 ), to be used, if desired. The vertical apertures 150 a - c also allow a plurality of blocks 112 to be positioned in a running bond (again using support beams 270 such as those shown in FIG. 12 , for example). The aperture 150 b may be provided with a slot 152 , which that provides an opening to the rear face 122 . In addition, the block 112 may now be split into smaller predetermined sizes, with each smaller block (not shown) having a set of side grooves 134 . Although not depicted, it will be understood that apertures 150 a and 150 c may also be provided with slots (as with aperture 150 b ), if desired.
[0124] Another feature of block 112 is the provision of recesses 127 a and 127 b on the rear surface 122 adjacent the side surfaces 129 a and 129 b . The recesses come into play during, and aid in, the manufacturing of the block. After a large block (not shown) is molded and split into two smaller blocks and the smaller blocks are removed from the conveyor on which they rest by a pusher bar (not shown) that impacts the rear surfaces of the blocks and moves them in a desired direction. This works if the blocks are substantially parallel to the pusher bar. However, if the blocks are not substantially parallel to the pusher bar, the bar has a tendency to chip and break the side segments. The recesses provide clearance so that if the block is somewhat askew relative to the pusher bar, the bar will not contact the side segments and thereby reducing chipping and breakage.
[0125] FIG. 8 shows a preferred corner configuration using the blocks 12 of the present invention. The design of the block 12 lends itself to the formation of corners without the need for mortar, corner braces, or other supports. Two blocks 12 a and 12 b are simply aligned to form a corner butt joint 51 . Preferably, block 12 b is broken along its splitting recess to form a new split face, which roughly matches split front face of block 12 a . Holes 54 are drilled through the blocks 12 a and 12 b so that a fastener 56 may be inserted therein. Generally, the fastener may be any suitable fastener, and preferably, an appropriately sized pin, peg, or screw, and the like. Alternatively, glue, preferably construction mastic, may be applied instead of or, more preferably, in combination with fasteners to secure the blocks to each other.
[0126] Referring now to FIGS. 9 and 10 , another embodiment of a block 156 of the present invention is depicted. The block 156 is generally angularly-shaped and includes a front face 158 , a rear face 160 , a top surface 164 , a bottom surface 166 and pairs of side surfaces 168 a , 169 a , and 168 b , 169 b , respectively. As with the previously described blocks 112 , the side surfaces 168 a , 169 a , and 168 b , 169 b are provided with grooves 170 a and 170 b that are configured to receive portions of lateral support beams, and will not be discussed here in detail. An alternate embodiment of the block 156 ′ is illustrated in FIGS. 1-2 a . As shown in FIGS. 9-10 , front face 158 is formed with a roughened or weathered surface or facing segments 159 a - b and is provided with marginal areas 163 a - d . These features are not necessary to carry out the spirit of the invention, however. The front face 158 may be dressed, modified, or otherwise worked in any desired manner. The block 156 may also be provided with recesses 167 a and 167 b , located on the rear face segments 161 a and 161 b , adjacent the side surfaces 169 a and 169 b . As discussed previously, the recesses 167 a - b prevent and/or reduce chipping during the manufacturing process.
[0127] As depicted, the block 156 is configured so that the front face segments 159 a and 159 b , and the rear face segments 161 a and 161 b are oriented so that they intersect each other at a predetermined angle 172 . The angle of intersection 172 can vary from about 15 degrees to about 165 degrees. Preferably, though, the angle of intersection is about 90 degrees so that the block may be used to construct rectilinear structures. In that regard, it will be appreciated that the blocks 156 may be used with or without linearly shaped blocks to form columnar structures of varying shapes and sizes (see, for example FIG. 1 ). Moreover, it is envisioned that the blocks may be formed with more than two front and rear face segments 159 a - b , 161 a - b , and/or that the block could be formed in a generally arcuate shape.
[0128] Referring now to FIG. 11 , an embodiment of a beam of the present invention generally comprises an elongated spine or web and at least one rib, which is substantially coextensive therewith. More specifically, a preferred embodiment of beam 16 , as shown, includes a plurality of ribs that are arranged in a substantially coplanar and collateral relation. That is, there is a first pair of ribs 38 a , which are substantially coplanar and extend away from each other. And, there is a second pair of ribs 38 b , which are also substantially coplanar and extend away from each other. Note that the pairs of ribs 38 a and 38 b are in substantial collateral relation with each other and are spaced apart from each other by a distance defined by the web 36 . This configuration of two pairs of ribs 38 a and 38 b attached to each other by web 36 forms somewhat of an I-beam configuration. It is preferred that at least one set of ribs 38 a be resiliently deformable and, even more preferred, that they converge slightly towards and then diverge slightly away from the other ribs 38 b in a somewhat “V”-shaped configuration towards the ends of the ribs 38 . A “V”-shaped configuration is preferred because it allows a segment 35 of a block 12 to be gripped between the ribs 38 a - b (see, for example, FIGS. 23 and 24 ). As will be appreciated, in order for the desired amount of gripping force to occur, the distance or span 42 between a rib 38 b and the apex of the “V” of an unflexed rib 38 a should be slightly less than the thickness of segment 35 (see FIG. 24 ). It will also be appreciated that the distance or span 43 between the leading edge of flange 40 of the unflexed rib 38 a and the rib 38 b should be slightly greater than the thickness of segment 35 (See, again FIG. 24 ). Thus, when a beam 16 is attached to a block 12 the rib 38 a is deflected from its unstressed state to a stressed state and a segment 35 of a block may be gripped between ribs 38 a and 38 b . As depicted in FIG. 23 the ribs 38 a and 38 b are preferred because they prevent unwanted movement and misalignment between blocks 12 of a given column 14 and they are able to compensate for variations in dimensions that sometimes occur during manufacture of the blocks.
[0129] Beam 16 may be attached at its upper ends to a structure being skirted (see, for example, FIG. 1 ) if desired, preferably at or near the lowermost edge or bottom of the structure, and using conventional fastening techniques and technologies. Such attachments may be used in conjunction with or without a bracket 18 to provide support and stability to the independent columns 14 (see FIG. 5 ) by preventing them from leaning or falling forwardly or rearwardly. The beams aligns the blocks 12 of a given column), by preventing lateral movement therebetween (that is, movement along the “x” direction in a three-dimensional coordinate system relative to the blocks 12 ).
[0130] Another embodiment of a lateral support beam 116 is depicted in FIG. 11 a . Here, the beam 116 generally comprises a body having block-engaging portion and a bracket-engaging portion. More specifically, the beam 116 comprises a first web 180 and a second web 181 that are generally aligned with each other. Projecting from the webs 180 , 181 are pairs of ribs 182 a , 182 b , and 182 c . The first pair of ribs 182 a , which form the block-engaging portion, extend away from each other in a generally coplanar relation. The second pair of ribs 182 b is generally collaterally aligned with the first pair of ribs 182 a and is separated therefrom by a predetermined span 188 . The third pair of ribs 182 c is generally collaterally aligned with the second pair of ribs 182 b and is separated therefrom by a predetermined span 190 . The outer ends of ribs 182 a are provided with resilient flanges 184 that are configured and arranged such that the ribs 182 a are able to be received by the vertical grooves on the blocks. With this beam embodiment, segments of the sides of a block are not gripped between adjacent pairs of ribs. Rather, engagement with blocks is achieved through the first set of ribs 182 a that substantially span the depth of the vertical grooves of the blocks, where depth is taken along the “z” axis in the three dimensional coordinate system (see, for example, FIG. 7 a ). It will be appreciated that the block engaging portion, i.e., the first pair of ribs 182 a , need not be restricted to a flange configuration. A frictional engagement, for example, can be achieved with other configurations.
[0131] Alternative embodiments of support beams 270 , 287 and blocks 312 are illustrated in FIGS. 12, 13 and 27 . With regard to the support beam 270 depicted in FIG. 12 , support beam 270 comprises a pair of webs 272 , 274 , which are generally parallel to each other and that terminate in opposing ribs. A third web 276 extends from the. surface formed by opposing ribs in general alignment with webs 272 , 274 and terminates in opposing ribs 278 c . The ends of opposing ribs 278 a and 278 b may be provided with flanges and coupling elements 280 , 282 , respectively. As will be appreciated, two webs 272 , 274 (versus a single web) increases the overall strength of the beam 270 so that the beam resists bending and warping more than beams that have only single webs that connect their opposing ribs.
[0132] The support beam 287 of FIG. 13 is similar to the support beam 270 of FIG. 12 . Instead of having opposed ribs that engage a block, however, the block engagement section 288 of the beam is configured so that it is able to substantially span the depths of the grooves of two opposing blocks, or the depth of the aperture 350 in the interior section of a block 312 (see FIG. 27 ) (where depth is taken along the “z” axis in the three dimensional coordinate system as shown in FIG. 7 a ). As depicted, the engagement section 288 of the support beam 287 is generally “T”-shaped and substantially spans the depth of the aperture 350 (i.e. see FIG. 27 ) where depth is taken along the “z” axis in the three dimensional coordinate system as shown in FIG. 7 a (see FIG. 45 , for example), and generally spans the width of the slot 352 of a block (see, FIG. 27 ). As shown, the engagement section 288 is hollow, however, it is understood that the engagement section 288 may be solid, if desired. The base of the “T”-shaped engagement section 288 is provided with a web 276 and a pair of opposing ribs 278 c to enable the support beam 287 to be connected to a bracket such as those depicted in FIGS. 44-45 . With regard to FIG. 27 , it will be appreciated that the depiction of the support beams 270 and 287 relative to the blocks 312 are for illustrative purposes only, and that they may be interchanged if desired.
[0133] A frictional engagement may be desired and this could be achieved with other configurations. For example, in FIG. 14 the block-engaging section 288 may take the form of generally planar opposing planar sections 192 each having resilient spurs 194 projecting therefrom. Or, as seen in FIG. 15 , the block-engaging section 288 may take the form of a preformed resilient body 196 having an aperture 198 . Note that in FIGS. 14 and 15 , the bracket-engaging portions 290 are shown in phantom.
[0134] With reference to FIG. 16 , the support beam 116 is similar to the support beam of prior embodiments in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. In a departure from previous embodiments, the support beam 116 of this embodiment includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 510 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 and 506 . This arrangement serves several purposes. As explained above, not only does the extension 508 create spaces between a wall structure and a substructure that may be used as plenums, conduits, or for retaining insulative, fire-retardant or other building materials, but it also facilitates attachment of the support beam 116 to a substructure. Preferably, the attachment member 512 comprises feet 516 and 518 that extend laterally in opposite directions from the extension 508 to provide a point or points of connection which may be used with adhesive or fastening elements, such as nails or screws, in attaching a support beam to a substructure (see also, FIG. 29 ).
[0135] Referring now to FIG. 17 , the support beam 116 , again, has an extension 508 , which terminates in an attachment member 512 having feet 516 , 518 . However, in this embodiment, the extension 508 and the feet 516 , 518 are foreshortened. Note that the support beam 116 is not directly connected to a substructure but is operatively connected to a bracket 534 that is, in turn, operatively connected to a substructure. The bracket 534 includes a substructure engaging portion 536 , a span 538 and an attachment member with a support beam engaging portion 542 . The support beam engaging portion 542 is sized to be snuggly received and frictionally retained within a channel 530 or 532 formed by a rib and a foot 505 , 516 ; 506 , 518 , respectively, of the beam 116 . Note that the support beam 116 need not extend along the length of the bracket 534 , and more particularly, the support beam 116 need not be coextensive with the side of a block 112 (see FIG. 7 a ) to which it may be operatively connected. The reason for this is that a block need not be retained along its entire length of its grooves to be adequately retained as part of a wall structure. Instead, it is only necessary for a block to retained at several points. Thus, the support beams 116 may take the form of clips that attach to the bracket 534 , and a block 112 can be retained at a plurality of predetermined locations (i.e. such as upper and lower ends). It will be appreciated that such support beam clips may be used to operatively connect a pair of blocks to a support bracket by positioning the clips so that they span the interface between two adjacent blocks. It will also be appreciated that the support beam clip may be longer than a side of a block to which it is operatively connected so that it may operatively connect more than two blocks to a bracket.
[0136] The span 538 of the bracket 534 serves to position the support beam 116 a predetermined distance from a substructure while the substructure engaging portion 536 serves to attach the bracket 534 to a substructure. As with the aforementioned embodiment, the bracket 534 may be operatively connected to a substructure using a variety of fastening elements. It will be appreciated that both channels 530 , 532 of the support beam 116 of this embodiment may be used with oppositely facing brackets, if desired, to form a more robust connection between the wall structure and a substructure.
[0137] Referring now to FIG. 18 , the support beam 116 terminates at an attachment member 512 that includes two spaced apart resilient walls 550 , 552 having confronting arms 554 , 556 , which define a slot 558 and channel 560 , which are sized to admit and retain a second attachment member.
[0138] With this embodiment, the support beam 116 is not directly connected to a substructure but is operatively connected to a bracket 562 that is, in turn, operatively connected to a substructure (see, for example, FIG. 32 ). The bracket 562 includes substructure engaging portions 564 , 566 , a span 538 and a first attachment member 570 . Preferably, the first attachment member 570 is a dart-shaped head 572 having shoulders 574 , 576 that are configured to engage arms 554 , 556 of the support beam 116 in a constrained relation. That is, the attachment member 512 of the support beam is sized to slidingly receive the head 572 within a slot 558 and a channel 560 formed by the resilient walls 550 , 552 and their confronting arms 554 , 556 . Thus, the support beam 116 may be connected to a bracket 562 in a constrained manner. It will be appreciated that the support beam 116 can be operatively connected to the bracket 562 in several ways. For example, by positioning the bottom of the channel 560 and the slot 558 over the top of the dart shaped head 572 and the span 568 of bracket 562 and then sliding the support beam 116 down along the bracket 562 and interconnecting with an already positioned block, or sliding the support beam down along the bracket 562 and later interconnecting with a block, which is slid into position in a similar manner. Alternatively, a support beam 116 may be operatively connected to a bracket 562 by aligning the slot 558 of the attachment member 512 opposite the apex of the dart shaped head 572 and then pushing the support beam 116 towards the dart shaped head 572 until the arms 554 , 556 of the attachment member 512 engage the shoulders 574 , 576 of the dart shaped head 572 .
[0139] As will be appreciated, the support beam 116 of FIG. 18 need not extend along the length of the bracket 562 and, more particularly, the support beam need not be co-extensive with the side of a block to which it is operatively connected. The span 538 of bracket 562 serves to position the support beam 116 a predetermined distance from a substructure and the substructure engaging portion 564 , 566 serves to attach the bracket 562 onto a substructure. Bracket 562 may be operatively connected to a substructure using a variety of fastening elements 578 (see also, FIG. 32 ).
[0140] Referring now to FIG. 19 , the operative connection is reversed from that shown in FIG. 18 . That is, support beam 116 includes an extension that terminates in a first attachment member 570 having a head 594 with shoulders 596 , 598 . The bracket 580 now includes two spaced-apart resilient walls 582 , 584 having confronting arms 586 , 588 , which define a slot 590 and a channel 592 , which are sized to admit and retain the attachment member 594 in a constrained relation, as discussed above. As with the aforementioned embodiments, the support beam 116 need not extend along the length of the bracket 580 . The bracket may be operatively connected to a substructure using a variety of fastening elements.
[0141] Referring now to FIG. 20 , another preferred embodiment depicts a post 600 which has been provided with a plurality of connectors to enable the post 600 to support a plurality of wall structures. In this embodiment, the post 600 includes front and rear surfaces 602 , 604 and opposing sides, with a web 606 that extends from the front surface 602 , and an attachment bracket 612 that extends from the rear surface 604 . A pair of ribs 608 , 610 extend laterally in opposite directions from the web 606 in the same manner as the ribs 38 of support beam 16 in FIG. 11 , while the attachment bracket 612 includes a slot 614 and channel structure 616 similar to the slot 558 , 590 and channel 560 , 592 structures described and shown in FIGS. 18 and 19 , respectively. Thus, with this embodiment, blocks may be directly connected to the post 600 at side 602 or connected indirectly at side 604 via an appropriately configured support beam (such as beam 116 of FIG. 19 ).
[0142] Although not shown, other combinations of operative connections may also be used. For example, the post 600 may be provided with two direct connectors (webs with laterally extending ribs) or the post may be provided with two indirect connectors (attachment members, such as channels). As will be appreciated, the post 600 may be operatively connected to a substructure such as a footing or foundation, or be set into the ground using known techniques and technologies. While the post 600 is depicted as having a hollow cross-section, it is understood that the post may also be a solid in cross section or may have a reinforcing structure such as a pipe or a rod received therein.
[0143] With reference to FIG. 21 , the support beam 116 is similar to the support beam of prior embodiments, in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. The support beam 116 includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 510 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 and 506 . In FIG. 21 , the attachment member 512 is depicted as feet 516 and 518 , however it is understood that the attachment member may take other forms. Note that ribs 503 , 504 , 505 and 506 are reversed relative to each other so that the pair of opposing ribs 505 and 506 are now forward, relative to the opposing pair of ribs 503 and 504 (similar to the rib arrangement as depicted in FIGS. 23 and 24 ). Note also, that the pair of forwardly facing opposing ribs 505 and 506 are somewhat thicker than the pair of opposing ribs 503 and 504 . This feature allows the support beam 116 to have a viewable surface 507 , which may form part of an observed wall structure (see FIG. 35 ).
[0144] Referring now to FIG. 22 , a partial horizontal section of the wall structure 10 of FIG. 4 is depicted. As shown, a beam 16 operatively connects two adjacent blocks 12 of adjacent columns 14 to each other. Here, the “V”-shaped ribs 38 a are positioned within grooves 34 of adjacent blocks 12 and ribs 38 b are positioned against the rear faces 22 of adjacent blocks 12 . In this configuration, the beam 16 remains hidden from view and provides support along several axes (taken along the “z” and “x” directions in a three-dimensional coordinate system relative to a block 12 ). With the beam 16 of this embodiment, the grooves 34 may be considerably larger than the thickness of the ribs 38 a , without affecting the gripping ability of the beam 16 . Thus, there may be quite a large space in front of the ribs 38 a . Note that the distance between side surfaces 29 a and 29 b of block 12 is less than the distance between side surfaces 28 a and 28 b of block 12 to allow the side surfaces 28 a , 28 b of adjacent blocks 12 to be brought into intimate contact with each other while providing enough space to accommodate the web 36 of the beam 16 (see FIGS. 24 and 24 a ). Note that a bracket 18 is shown (in dashed lines) as it would be positioned relative to an uppermost block 12 of a column 14 .
[0145] FIGS. 23 and 24 show a preferred beam arrangement in which the beam 16 shown in FIGS. 11 and 22 is reversed with respect to blocks 12 to which the beam is connected. That is, the ribs 38 b are positioned within opposing grooves 34 and ribs 38 a are positioned against the rear faces 22 of blocks 12 . This arrangement does not significantly change the function and gripping ability of the beam 16 as discussed above.
[0146] As with to the embodiment depicted in FIG. 22 , the distance between side surfaces 29 a and 29 b of the blocks is less than the distance between side surfaces 28 a and 28 b to allow side surfaces 28 a , 28 b of adjacent blocks 12 to be brought into intimate contact with each other while providing enough space to accommodate the web 36 of the beam 16 . Note that when two adjacent blocks 12 are brought into contact with each other, their corresponding margins 23 a and 23 b combine to form a profile that is substantially the same as the profile of a splitting recess 21 (as shown in FIGS. 22 and 24 ). It will be appreciated that the splitting recess 21 and may have other profiles, such as a “V”-shape and that the corresponding margins would be more beveled or chamfered.
[0147] Referring now to FIGS. 23, 23 a , 24 and 24 a , operatively connecting blocks together to form a wall structure 10 begins with connecting a block 12 to a beam 16 . As depicted in FIGS. 23 a and 24 a , the leading edge of flange 40 allows the rib 38 a to be displaced as it encounters the block segment 35 . As the beam 16 is connected to the block 12 , block segment 35 is gripped by ribs 38 a and 38 b.
[0148] In a preferred method to operatively connect a wall to a structure using the aforementioned bracket, a person would prepare or otherwise select an appropriate location in which to construct a wall. The construction would begin by placing a first block having opposing side grooves in a desired position and orientation. Then, a second, similar block would be placed directly on top of the first block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks would be operatively connected to each other along one of their respective sides by inserting a rib of first support beam into the aligned grooves and seating it securely.
[0149] Next, a bracket is positioned so that its wall engaging portion is collaterally aligned and in contact with the support beam such that it extends therewith along the groove in the block. The structure engaging portion of the bracket is then brought into position for attachment to a structure by sliding or otherwise manipulating the bracket in a direction towards the point of attachment on the structure (this is generally above and co-planar with the wall). The bracket is than attached to the structure using conventional techniques and technologies. The rib of a second support beam is then inserted into the aligned grooves of the opposite sides of the blocks, and a second bracket is used to operatively connect this portion of the wall to a structure using the aforementioned steps.
[0150] A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is much the same, except now the third block is positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages at least one other rib of one of the already positioned support beams. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages at least one other rib of one of the already positioned support beam and the wall engaging portion of the already installed bracket.
[0151] After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by inserting at least one rib of a third support beam into their aligned vertical groove of the respective sides of the first and second blocks and seating them securely, and that support beam would be operatively connected to a support by yet another bracket. And so on. It will be appreciated that other methods of constructing a wall structure using the aforementioned components are possible.
[0152] FIG. 25 illustrates an alternative embodiment of a beam 16 having two ribs 38 a , 38 b but only one resiliently deformable rib 38 a . FIG. 26 shows yet another embodiment of a beam 16 comprising one pair of opposed ribs 38 b such that the support beam 16 is essentially an elongate spline. It should be understood that for purposes of clarity, the ribs 38 b as depicted in FIGS. 25 and 26 are substantially thinner than the grooves 34 in which they are positioned, and that in actuality ribs 38 a - b and grooves 34 would be configured to effectively maintain blocks 12 in a coplanar relation with little or no play.
[0153] Alternative embodiments of support beams and blocks are shown in FIG. 27 . As depicted in FIG. 27 , a support beam 270 may be operatively connected to one or more blocks 312 , at grooves 334 a and 334 b. Note that the blocks 312 include a front face 320 , a rear face 322 , a top surface 324 , a bottom surface (not shown), and side surfaces 328 a and 329 a , and 328 b and 329 b . The blocks 312 also include marginal areas 323 and notches 327 , which will not be discussed here in detail. As can be seen, the side surfaces 329 a and 329 b are foreshortened to accommodate the increased width of the support beam 270 . The support beam 270 may be operatively connected to a block 312 when the ribs 278 a and 278 b grip side segments 335 a , 335 b . The support beam 287 can be operatively connected to a block 312 by sliding a block engagement section 288 into the aperture 350 .
[0154] Another embodiment of a lateral support beam is depicted in FIG. 28 . Here, the beam 116 generally comprises a body having block-engaging portion and a bracket-engaging portion. More specifically, the beam 116 comprises a first web 180 and a second web 181 that are generally aligned with each other. Projecting from the webs 180 , 181 are pairs of ribs 182 a , 182 b , and 182 c . The first pair of ribs 182 a form block-engaging portions, which extend away from each other in a generally coplanar relation. The second pair of ribs 182 b is generally collaterally aligned with the first pair of ribs 182 a and is separated therefrom by a predetermined span 188 .
[0155] The third pair of ribs 182 c is generally collaterally aligned with the second pair of ribs 182 b and is separated therefrom by a predetermined span 190 . The outer ends of ribs 182 a are provided with resilient flanges 184 that are configured and arranged such that the ribs 182 a are able to be received by the vertical grooves on the blocks of the present invention. With this embodiment, segments of the sides of a blocks re not gripped between adjacent pairs of ribs.
[0156] Now referring to FIG. 29 , a support beam 116 , similar to the support beam of prior embodiments, includes a web 500 from which a plurality of ribs 503 , 504 , 505 and 506 extend. The support beam 116 of this embodiment includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 500 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 , and 506 . The extension 508 not only creates spaces between a wall structure and a substructure that may be used as plenums, conduits, or for retaining insulative, fire-retardant or other building materials, and also facilitates attachment of the support beam 116 to a substructure “S” (partially shown). Preferably, the attachment member 512 comprises feet 516 , 518 that extend laterally in opposite directions from the extension 508 to provide a point or points of connection which may be used with adhesive or mechanical fastening elements, such as nails or screws 522 , in attaching a support beam to a substructure “S”.
[0157] FIG. 30 illustrates a partially assembled wall structure 410 comprising a plurality of blocks 412 retained in place by a plurality of vertically oriented, elongated support beams 416 that are operatively connected to a substructure “S” (shown in dashed lines). The support beams 416 allow the blocks 412 of adjacent horizontal courses to be substantially superposed one above the other and not laterally offset from each other in a bond pattern, as one may expect of such a wall structure. Thus, the wall structure 410 is comprised of a plurality of adjacent columns 414 a - d that may be operatively connected to each other in a serial fashion. Each block 412 of the wall structure 410 includes a front face 420 , a rear face 422 , a top surface 424 , a bottom surface 426 and opposing sides 427 a , 427 b . Each opposing side 427 a , 427 b includes opposing grooves 434 , 436 defined by plurality of outwardly extending fingers 428 a , 428 c and 428 b , 428 d , with outwardly facing surfaces 430 a , 430 c and 430 b , 430 d.
[0158] Preferably, the blocks 412 are symmetrically formed, so that either the front or rear face 420 , 422 , respectively, may face forwardly. This feature allows a block which has been damaged or had its surface otherwise altered to be easily removed and reinstalled by merely turning the block around (or over) so that other good or undamaged sides now being the viewable surface of the block. In other words, the blocks are reversible. The front and rear faces need not have the same surface treatment. That is, a block 412 may have a smooth front face and a roughened rear face 422 . Or, a block 412 may have roughened front face and a decorated or non-planar rear face. For example, in FIG. 30 , the lower most blocks 412 of column 414 c and column 414 d, respectively, have forwardly facing rear faces 422 while the remaining blocks in the partially assembled wall structure 410 have forwardly facing front faces. As depicted, the viewable front faces 420 of the blocks 412 of the wall structure 410 are smooth and the viewable rear faces 422 of the blocks of the wall structure 410 are roughened or otherwise decorated. Note that the leftmost beam 416 may be used to form the base and a cap of a horizontally oriented wall structure.
[0159] Referring now to FIG. 31 , a support beam 116 , has an extension 508 , which terminates in an attachment member 512 -with feet 516 , 518 . However, in this embodiment the extension 508 and the feet 516 , 518 are foreshortened. Note that the support beam 116 is not directly connected to a substructure “S” but is operatively connected to a bracket 534 that is, in turn, operatively connected to a substructure “S” (shown in dashed lines). The bracket 534 includes a substructure engaging portion 536 , a span 538 and an attachment member with a support beam engaging portion 542 . The support beam engagement portion 542 is sized to be snuggly received and frictionally retained within a channel 530 or 532 formed by a rib and a foot ( 505 , 516 ; 506 , 518 , respectively) of the beam 116 . Note that the support beam 116 need not extend along the length of the bracket 534 , and more particularly the support beam need not be coextensive with the side of a block to which it is operatively connected. The reason for this is that a block 112 need not be retained along its entire length of its grooves to be adequately retained as part of a wall structure. Instead, it is only necessary for a block to retained at several points. Thus, the support beams 116 may take the form of clips that attach to the bracket 534 , and a block 112 may be retained at a plurality of predetermined locations such as its upper and lower ends. It will be appreciated that such support beam clips may be used to operatively connect a pair of blocks to a support bracket 534 by positioning the clips so that they span the interface between two adjacent blocks. It will also be appreciated that the support beam clip may be longer than a side of a block to which it is operatively connected so that it may operatively connect more than two blocks to a bracket.
[0160] The span 538 of the bracket 534 serves to position the support beam 116 a predetermined distance from a substructure “S” while the substructure engaging portion 536 serves to attach the bracket 534 onto a substructure “S”. As with the aforementioned embodiment, the bracket 534 may be operatively connected to a substructure “S” using a variety of fastening elements. It will be appreciated that the support beam 116 of this embodiment may be used with oppositely facing brackets; if desired, to form a more robust connection between the wall structure and a substructure “S”.
[0161] Referring now to FIGS. 32 and 18 , the support beam 116 does not have an extension. Rather, as best shown in FIG. 18 , the beam 116 terminates at a first attachment member 512 that includes two spaced apart resilient walls 550 , 552 having confronting arms 554 , 556 , which define a slot 558 and channel 560 that are sized to admit and retain a second attachment member 570 .
[0162] With this embodiment, the support beam 116 is not directly connected to a substructure “S” but is operatively connected to a bracket 562 that is, in turn, operatively connected to a substructure “S” (shown in dashed lines). The bracket 562 includes substructure engaging portions 564 , 566 , a span 538 and an attachment member 570 . As best shown in FIG. 18 , the attachment member 570 is dart-shaped head 572 having shoulders 574 , 576 , which are configured to engage confronting arms 554 , 556 in a constrained relation. That is, the attachment member 570 of the support beam is sized to slidingly receive the dart shaped head 572 within a slot 558 and channel 560 formed by the resilient walls 550 , 552 and their confronting arms 554 , 556 . Thus, the support beam 116 may be connected to the bracket 562 in a constrained manner. It will be appreciated that the support beam 116 may be operatively connected to a bracket 562 in several ways. For example, by positioning the bottom of the channel 560 and the slot 558 over the dart shaped head 572 of the bracket 562 , the support beam 116 may be slid down along the bracket 562 to interconnect with an already positioned block 112 . Alternatively, the beam 116 may be slid down along the bracket 562 and later interconnecting with a block 112 , which is slid into position in a similar manner. Alternatively, a support beam 116 may be operatively connected to a bracket 562 by aligning the slot 558 of the attachment member 512 opposite the apex of the dart shaped head 572 and then pushing the support beam 116 towards the dart shaped head 572 until the confronting arms 554 , 556 of the attachment member 512 engage the shoulders 574 , 576 of the dart shaped head 572 .
[0163] The support beam 116 need not extend along the length of the bracket 562 , and, more particularly, the support beam need not be co-extensive with the side of a block to which it is operatively connected. The reasons for this have been discussed in conjunction with the description of FIG. 31 , and for purposes of brevity will not be repeated. The span 538 of the bracket 562 serves to position the support beam 116 a predetermined distance from a substructure “S” and the substructure engaging portion 564 , 566 serves to attach the bracket 562 to a substructure “S”.
[0164] Referring now to FIGS. 33 and 19 , the operative connection is reversed from FIG. 32 . That is, the support beam 116 includes an extension 508 that terminates in an attachment member 570 having a dart-shaped head 594 with shoulders 596 , 598 . The bracket 580 includes two spaced-apart resilient walls 582 , 584 having confronting arms 586 , 588 , which define a slot 590 and channel 592 that are sized to admit and retain the dart-shaped attachment member 594 in a constrained relation, as discussed above. As with the aforementioned embodiments, the support beam 116 need not extend along the length of the bracket 562 , and the bracket 562 may be operatively connected to a substructure “S” using a variety of fastening elements.
[0165] With reference to FIGS. 34 and 35 , support beam 116 depicted is similar to the support beam of prior embodiments in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. In a departure from this previous embodiment, the support beam 116 includes an extension 500 that terminates with an attachment member 512 . Preferably, the extension 500 is aligned with, and extends from the web 510 so as to position the attachment member 512 is a predetermined distance from the plurality of ribs. Note that the ribs 503 , 504 , 505 and 506 are reversed relative to each other so that the pair of opposing ribs 505 and 506 are now forward relative to the opposing pair of ribs 503 and 504 . In FIG. 34 , the attachment member 512 is depicted as having feet 516 and 518 , however it is understood that the attachment member may take other forms such as those depicted in FIGS. 18-20 . Note also, that the pair of forwardly facing opposing ribs 505 , 506 are somewhat thicker than the pair of opposing ribs 503 , 504 . This feature allows the support beam 116 to have a viewable surface 507 , which may form part of an observed wall. As depicted in FIGS. 34 and 35 , ribs 505 and 506 may be coplanar or collateral relative to the viewable faces 320 , 322 of blocks in a wall structure.
[0166] Referring again to FIGS. 34 and 35 , the blocks 312 that are used with the aforementioned beam 116 are similar to the blocks 112 depicted in the wall construction 110 of FIG. 30 . That is, each block 312 has a front face 320 , a rear face 322 , a top surface, a bottom surface and opposing sides.
[0167] Each block 312 differs from the block 112 depicted in FIG. 30 in several respects. First, block 312 has only one pair of opposing fingers 328 a ′, 328 b ′ instead of the pair of opposing fingers depicted in FIG. 33 . Thus, each block 312 does not have a groove that obscures a support beam rib. Instead of a groove, each block 312 has opposing ledges 334 , 336 defined by pairs of side surfaces 330 a , 330 b , 330 c , 330 d and fingers 328 a ′, 328 b ′, respectively. Preferably, the thickness of the ledges 336 , 338 will be substantially the same as the thickness of opposing ribs 505 , 506 to enable the viewable surface of a wall structure to be substantially contiguous. However, it is understood that the thicknesses of the ledges 336 , 338 and/or opposing ribs 505 , 506 need not be substantially the same. For example, the thickness of the ribs 505 , 506 may be greater than the thickness of the ledges 336 , 338 of the blocks so that the viewable surface 507 of a support beam projects outwardly with respect to the viewable surface of the blocks of the wall structure (as in FIG. 35 ), or the thickness of the ribs 505 , 506 may be less than the thickness of the ledges 336 , 338 of the blocks so that the viewable surface 507 of the support beam is recessed with respect to the viewable surface.
[0168] Another difference between block 312 and block 112 is that the opposing laterally extending, aligned fingers 328 a ′, 328 b ′ are offset from the center plane of the block 312 . As seen in FIGS. 34 and 35 this allows blocks to be operatively connected to a support beam in several configurations. In FIG. 34 , for example, blocks 312 are operatively connected to a support beam so that front face 320 (left side) and rear face 322 (right side) are substantially flush with the viewable surface 507 of the support beam 116 . As with the aforementioned blocks of FIG. 30 , the front and rear faces may have the same surface or different surfaces. Here, the front face 320 on the left side of FIG. 34 is depicted as being smooth, while the rear face 322 on the left side of FIG. 34 is depicted as being roughened. The viewable surfaces on the right side of FIG. 34 are reversed. In FIG. 35 , the blocks 312 have been rotated so that when they are operatively connected to the support beam 116 they are set back from the viewable surface 507 . It will be appreciated that the blocks 312 need not be all coplanar or set back with respect to the viewable surface 507 of the support beam 116 . Combinations of setback blocks and coplanar blocks are possible to create a myriad of wall surfaces. It is contemplated that such combinations may be arranged into identifiable forms or patterns and may also be arranged to display alphanumeric characters and the like. Note that the viewable surface 507 may be provided with a textured or otherwise decorated surface, which matches the surfaces of adjacent blocks. Alternatively, as depicted in FIG. 34 , the forward facing surface of the support beam can be provided with a cap or strip 145 of material with a viewable surface 147 , which may be textured or otherwise decorated as desired and which may be affixed or attached to the viewable surface 147 in a conventional manner.
[0169] Referring now to FIG. 36 , another preferred embodiment depicts a post 600 , which has been provided with a plurality of connectors to enable the post to support a plurality of wall structures. In this embodiment, the post 600 includes opposing sides 602 , 604 from which extend a web 606 and a bracket 612 , respectively. A pair of ribs 608 , 610 extend laterally in opposite directions from the web 606 , while the bracket 612 includes the slot 614 and channel structure 616 similar to the slot and channel structures described and shown in FIG. 18 , respectively. Thus, with this embodiment, blocks may be directly connected to the post 600 at side 602 or connected indirectly at side 604 via an appropriately configured support beam.
[0170] Other combinations of operative connections may also be used. For example, the post 600 may be provided with two direct connectors (webs with laterally extending ribs) or the post may be provided with two indirect connectors (attachment members, such as channels). As will be appreciated, the post 600 may be operatively connected to a substructure such as a footing or foundation, or be set into the ground using known techniques and technologies. While the post 600 is depicted as having a hollow cross-section, it is understood that the post may also be a solid in cross-section or may have a reinforcing structure such as a pipe or a rod received therein (see, for example, FIG. 39 ).
[0171] FIGS. 37-37 b illustrate additional embodiments of the present invention. FIG. 37 shows a support beam 16 having a pair of leg structures 654 that are constructed and arranged to secure a wall comprising columns 14 of blocks 12 to an existing support structure 658 . The support structure 658 may be a building or any other type of structure that may support a wall structure 10 according to the present invention. Legs or leg portions 656 of the leg structures 654 extend rearwardly from the support beam 16 and are preferably secured to ribs 38 b thereof. The leg structures 654 may also be formed as part of the web 36 of the support beam 16 . The leg portions 656 have a foot 660 , which extends laterally therefrom to provide a point of connection for the support beam 16 to the existing support structure 658 . Nails, screws, or other appropriate fasteners 662 may be driven through the feet 660 of the support beam 16 and into the sheathing 664 of the typical wall of the wall of the existing structure 658 . The sheathing 664 is typically supported by a plurality of horizontal girts 666 . Once the support beam 16 has been secured to the existing structure 658 , blocks 12 are stacked between respective support beams 16 as illustrated in FIG. 37 such that ribs 38 a of the support beam 16 reside in grooves 34 in the sides of the blocks 12 .
[0172] In order to prevent the inflow of water into the wall structure 10 , it may be desirable to apply a bead of a waterproof material 670 , such as mastic or caulk, along the horizontal surfaces of the blocks 12 . The bead of waterproof material 670 forms a seal between the upper surface 24 of the lower block 12 upon which the waterproof material 670 has been applied and the lower surface 26 of the block 12 immediately above the lower block 12 . It will be appreciated that mastic or caulk may also be applied to the vertical side surfaces of the blocks (not shown).
[0173] Legs or leg portions 656 of support beam 16 preferably extend rearwardly from the ribs 38 b in a perpendicular relationship thereto. Similarly, it is preferred that the feet 660 of the support beam 16 extend laterally perpendicular to the leg portions 656 . The perpendicular relationship of the feet and legs to the remainder of the support beam 16 is the preferred embodiment thereof since the purpose of the leg portions 656 and the feet 660 to provide an offset for the wall structure from the existing structure 658 . This offset allows a wall structure 10 to be secured over uneven surfaces such as corrugated steel siding 668 , as illustrated in FIG. 37 . As can be seen, legs or leg portions 656 of support beam 16 are sufficiently long such that the support beam 16 clears ridge 673 of the steel siding 668 . As can be appreciated, steel siding 668 typically presents a plurality of vertically flat attachment surfaces. Where a wall structure 10 is to be applied to a wall of an existing structure 658 that is not vertically smooth, furring strips or blocking may be fastened to the wall of exterior of the existing structure 658 as needed. As support beams 16 provide no vertical support for the blocks 12 , the blocks must be provided with some sort of foundation. Examples of suitable foundation include, but are not limited to, a concrete pad or footing that is sunk into the ground, and a cantilever ledge or bracket which is securely affixed to the wall of the existing structure.
[0174] FIG. 37 a illustrates a support beam 16 having two pairs of ribs 38 a and 38 b separated by a web 36 and only a single leg structure 654 comprising a leg portion 656 and a foot 660 . The embodiment of FIG. 37 a is particularly useful when an obstruction, such as ridge 673 of steel siding 668 would prevent one of the leg structures 654 illustrated in FIG. 37 from securely contacting the wall of the structure 658 . Fasteners 662 are sufficient to provide the requisite lateral support for the wall structure 10 . The support beam 16 having only a single leg structure 654 may be rotated end-for-end depending on the offset location of an obstruction such as ridge 673 .
[0175] Preferably, the support beams of the present invention will be extruded or molded from a material such as a plastic, a fiber reinforced resin, or a metal such as aluminum. In addition to forming embodiments of support beams 16 having the respective profiles of the support beams illustrated in FIG. 37 a , it is possible that one leg structure 654 could be removed from a support beam 16 such as the support beam 16 of FIG. 37 having two leg structures 654 , thereby resulting in the support beam 16 embodiment illustrated in FIG. 37 a . However, where a single leg structure 654 would be sufficient to provide the needed lateral support for a wall structure 10 , it would be more economical to manufacture support 16 having only a single leg structure 654 . As used herein, the term “forward” means away from the center of the elevated structure (and along the “z” direction in a three-dimensional coordinate system relative to a block) and the term “rearward” means toward the center of the elevated structure (also along the “z” direction in a three-dimensional coordinate system relative to a block).
[0176] FIG. 37 b illustrates a support beam 16 that is constructed and arranged to provide lateral support to a wall structure 10 as described in conjunction with FIGS. 37 and 37 a . The main difference here being that the support beam 16 of FIG. 37 b has a pair of ribs 38 a and only a single rib 38 b extending from the web 36 . A leg structure 654 extends rearwardly from the rib 38 b preferably in a perpendicular relation thereto. While it is preferred that the leg or leg portion 656 and foot 660 be arranged at right angles to each other and to the ribs 38 b of the support beam 16 , these structures may be arranged at any angle to one another provided, of course, that there is a sufficient offset from the wall of the existing structure 658 to allow installation of the blocks 12 of the wall structure 10 and that the foot 660 of leg structure 654 may be securely fastened to an supporting structure 658 .
[0177] FIG. 38 illustrates a double-ended support beam 80 b , which is useful for constructing a dual wall structure 10 having a front face 74 and a rear face 76 . The space between the front and rear faces 74 , 76 of the wall structure 10 may remain hollow or may be filled. Each end of the double-ended support beam 80 b comprises a support beam or block engagement structure having a cross-sectional profile similar to the support beam illustrated in FIG. 11 arranged back-to-back in a spaced apart relation and connected by a spacer web 82 b . Spacer web 82 b is connected to the base pair of ribs 38 b of each of the support beam portions in a perpendicular fashion. In this manner, support beam 80 b couples dual walls of the wall structure 10 to provide mutual lateral support. Further support can be had by backfilling the space between the front and rear sides of the dual wall structure 10 with gravel, earth, sand, concrete or insulative material 79 . Preferably, it will be appreciated that a cap 81 , such may be placed over the top of the dual wall structure 10 to prevent the ingress of water, debris, or nuisance animals. It will also be appreciated that such a cap 81 may be secured to the dual wall structure by known technologies and techniques, if desired. See, for example, the use of adhesive material depicted in FIG. 37 .
[0178] FIG. 39 illustrates a single-sided wall structure 10 comprising columns 14 of blocks 12 supported by a post-like support beam 84 . Support beam 84 comprises a post 85 having extending therefrom a web 36 . A pair of ribs 38 a extend laterally from the web 36 in the same manner as the ribs 38 a of support beams 16 described in conjunction with FIG. 11 . As installed, post 85 is preferably rigidly seated in a footing or foundation set into the ground below the wall structure 10 . As can be appreciated, blocks 12 are stacked between respective post support beams 84 as described above. The post 85 preferably has a hollow cross-section. However, post 85 may also be solid in cross-section or be provided with a reinforcing structure such as a pipe or a rod received therein. An alternate embodiment for the post or support beam 84 involves securely seating a plurality of rods or members in footings or a foundation beneath the wall structure 10 and sliding the post or beam 84 of the type illustrated in FIG. 39 thereover. Blocks 12 would then disposed between respective pairs of post support beams 84 as described above.
[0179] Now turning to FIG. 40 , a wall structure 10 is depicted as it may be used in conjunction with an elevated structure “S.” As with the wall structure generally depicted in FIGS. 4 and 22 , this wall structure 10 is comprised of a plurality of blocks 12 arranged in columns 14 , having the columns 14 held in place by vertically oriented, lateral support beams 16 , and with each beam 16 operably connecting adjacent columns 14 together. The brackets 19 used in this embodiment, however, differ from the “U”-shaped brackets 18 of the previously described embodiment in several respects. First, the brackets 19 are shaped differently than the bracket 18 of FIGS. 4 and 22 . Instead of having an inverted “U”-shaped configuration as with bracket 18 , the bracket 19 of this embodiment has a single, downwardly extending portion. Another difference is that rather than positioning a portion of a block 12 within an opening 50 defined by a pair of walls 44 , 46 , the bracket 19 of the embodiment has a wall engaging portion 62 that extends downwardly into vertical grooves 34 at the sides of blocks 12 . Another difference between brackets 18 and 19 is that bracket 18 connects to a column 14 in a generally central location, whereas the brackets 19 of this embodiment connect at the sides of column 14 . As with the previously described brackets 18 , brackets 19 help to stabilize and prevent the wall structure 10 from tipping rearwardly or forwardly. The brackets 19 also prevent the structure from shifting from side to side.
[0180] For purposes of illustration, the size of the wall structure 10 of this embodiment has been limited three columns 14 and four courses, with the two uppermost blocks of the left column 14 removed to reveal the juxtaposition between the brackets 19 , beams 16 and blocks 12 . Note that the wall structure 10 depicted in this embodiment also includes a plurality of footings or support pads 80 a that are positioned beneath the columns 14 at the junction where they connect to the beams 16 . Preferably, each footing or support pad 80 a may be provided with a setting channel 82 a that is configured and arranged to receive the bottom edges of one or more columns of blocks in a constrained relation. Note that the footing or support pad 80 a for the middle and right columns 14 has been removed and replaced with an “L”-shaped support base or angle iron (see, for example, the support base in FIGS. 3 and 53 ) that spans the bottom of the middle and right columns 14 . This construction can be used when the use of individual, regularly spaced footings 80 a is not possible or desirable. Also note that the wall structure 10 is depicted as having a running bond on its three lowermost courses. As can be seen, the bottom and third courses of blocks do not have splitting recesses. They do, however, have their perimeter marginal areas 23 a - d worked. The second course of blocks, on the other hand, have splitting recesses 21 and have only their horizontal marginal areas worked. Thus, each column 14 will have blocks with alternating front faces. When the columns of blocks are positioned adjacent each other in the normal assembly procedure some of the blocks 12 will form tight joints 31 and some of the blocks will form joints that appear substantially thicker. Thus, from a distance, the wall structure 10 will give the impression that it was constructed of blocks and mortar in a conventional manner. It will be appreciated that the externally viewable surface of the wall structure depicted in FIG. 40 is merely one example of an externally viewable surface, and that many other externally viewable surfaces are possible.
[0181] Turning now to FIGS. 41-43 , a preferred embodiment of bracket 19 depicted in FIG. 40 will now be discussed. As can be seen in FIGS. 41 and 42 , the bracket 19 comprises a structure engaging portion 60 and a wall engaging portion 62 . The wall engaging portion 62 of the bracket 19 includes opposing surfaces 64 , 66 , which are arranged and configured to contact a portion of a beam 16 and a portion of a block, respectively. If desired, the wall engaging portion 62 may be provided with strengthening creases 67 . As will be appreciated, the wall engaging portion 62 of the bracket 19 has a width 77 and a length 78 whose dimensions correspond to the particular blocks that are being used to construct a wall, and will be discussed only in general terms. Thus, the width 77 may range from a distance roughly equivalent to the depth of a single groove 34 in one block, to a distance roughly equivalent to the depth of two grooves 34 of opposing blocks. The width may also be roughly equivalent to the width of the web 36 of the beam 16 so that the wall engaging portion of the bracket may be oriented transversely to the wall structure. The length 78 may also vary depending upon the requirements of the wall structure (not shown). A typical width and length for a wall engaging portion 62 may be on the order of about two inches by about four inches, and a typical width and length for a structure engaging portion 60 may be on the order of about two inches by about one-and-a-half inches. It will be appreciated that the bracket 19 may be formed from material that may be modified or otherwise altered to fit a particular application. Thus, for example, the width and/or length of the wall engaging portion may be cut-to-length length or otherwise tailored at a jobsite without appreciably delaying or hindering construction.
[0182] The structure engaging portion 60 of the bracket 19 also includes opposing surfaces 68 , 70 . However, in this embodiment, only opposing surface 68 is configured to contact a portion of a structure (See, FIGS. 40 and 42 ). As depicted, the structure engaging portion 60 is attached to a lower surface of a structure “S” by an upwardly extending fastener or fastening element 73 . It is understood, however, that the attachment surface of the structure can be an upper surface, in which case the opposing surface 70 would contact the surface of the structure “S” and the fastener would extend downwardly from surface 68 (shown in dashed lines). As shown in FIG. 42 , the structure engaging portion 60 and the wall engaging portion 62 are planar and substantially orthogonal with respect to each other. It is understood, however, that the wall engaging portion 62 and the structure engaging portion 60 need not be orthogonal to each other. They may be linearly aligned, for example. It is also envisioned that the wall and structure engaging portions may be formed in other configurations. For instance, either portion 60 , 62 may be formed with U-shaped profiles that enable the portions 60 , 62 to straddle sections of the structure and/or wall. That is the structure engaging portion may be formed so that it may straddle the bottom and side edges of a structure and the wall engaging portion may be formed to engage a wall structure at its front and/or rear surfaces. The structure engaging portion 60 is provided with an aperture 72 that may be used with a conventional fastener 73 . For purposes of this application, the term “fastening element” or “fastener” may include mechanical fasteners such as screws, nails, bolts, rivets, or their equivalents, and/or adhesives, weldments, or the like. Alternatively, the structure engaging portion 60 may be provided with an integral fastening element so that the portion 60 may be driven into or otherwise attached to a support.
[0183] Another embodiment of a bracket is depicted in FIGS. 44 and 45 . As can be seen, the bracket 200 generally comprises a structure engaging portion 202 and a support beam engaging portion 203 . More specifically, the structure engaging portion 202 comprises a first member 204 and a second member 206 , which are angled with respect to each other to form a generally “L”-shaped form. The first and second members may be provided with apertures 208 that permit attachment to a structure with fastening elements such as nail and threaded fasteners. It will be appreciated, though, that attachment may also be achieved with suitable adhesives used in lieu of or in addition to fastening elements. The support beam engaging portion 203 comprises a web 210 and a pair of legs 212 , 214 , which are angled with respect to the web 210 to form a generally “L”-shaped form. The web 210 includes an aperture 220 that is accessible through a slot 222 defined by edges 216 and 218 of legs 212 and 214 , respectively. The aperture 220 and slot 222 are configured to slidingly receive a pair of ribs and a portion of a web of a support beam. As depicted in FIGS. 44 , and 45 , when a support beam is attached to the bracket, the support beam is able to move in a constrained manner relative thereto. This feature allows, the bracket to be attached at different points along a structure as well as different points along a beam. Moreover, it allows a wall construction to be self-adjusting. An application of bracket 200 , a support beam 116 , and a plurality of brackets 112 as can be seen in FIG. 53 .
[0184] Another embodiment of a bracket is depicted in FIGS. 46 and 47 . The bracket 230 of this embodiment comprises a structure engaging portion 232 , a connecting web 234 , and a support beam engaging portion 235 that comprises a rib 236 and a coupling element 238 . The bracket 230 is configured and arranged to operatively connect a support beam (such as the support beams depicted in FIGS. 11 a, 28 , 44 , and 45 ) to a support. As with the previously described bracket embodiment ( 200 ), the structure engaging portion 232 may be provided with apertures 240 that permit the bracket to be attached to a structure with conventional fastening elements. Alternatively, the bracket may be attached to a support using other known technologies and techniques. When the bracket 230 is used to operatively connect a beam to a support, the coupling element 238 of the beam engaging portion 235 is slidingly retained between one of the coupling elements 186 and one of the pairs of ribs 182 a . Thus configured, a support beam is able to move in a constrained or sliding manner relative thereto. This feature allows the bracket to be attached at different points along a structure as well as along different points along a beam. The bracket also permits a wall structure to be self-adjusting.
[0185] Referring now to FIGS. 48 and 49 , an alternative embodiment of an attachment bracket 90 is depicted. Here, the bracket 90 is similar to earlier discussed bracket 18 (see FIGS. 4 and 22 ) in that it has opposing walls 92 , 94 that are connected to each other by a top wall or span 96 , and which retain a portion of a block in a constrained relation. However, in this embodiment, the shorter of the two walls 94 is provided with an arm 98 that is movably attached thereto by a connector 100 , such as a rivet. As depicted in FIG. 48 , the arm 98 is in a first position where it extends towards a block (not shown). In this position, the bracket 90 resembles bracket 18 (see FIG. 4 ) and may be attached at or near the underside of a structure in the usual manner, via the span 96 .
[0186] In situations where it is not possible to easily attach the bracket 90 to the underside of a structure, a user of the bracket 90 need only rotate the arm 98 to a second position so that it extends away from a block (not shown) as depicted in FIG. 49 . In this position, the bracket may be attached to a vertical surface via the arm by a conventional fastener, such as a nail or screw, which extends through an aperture 102 . Alternatively, the bracket may be secured to a vertical surface by a suitable adhesive. As will be appreciated, the bracket 90 may be oriented so that either one of the walls 92 , 94 may be in confronting relation with the front or rear face of a block.
[0187] FIGS. 50-52 illustrate brackets and beams as shown in FIGS. 2 and 2 a as they may be used in conjunction with blocks to form alternative structures. Starting with FIG. 50 , bracket 354 is depicted. The bracket 354 is similar to previously described bracket 200 shown in FIGS. 44 and 45 in that it generally comprises a structure engaging portion and a support beam engaging portion. However, there are differences. Instead of having a structure engaging portion that comprises a first member and a second member, structure engaging portion 356 of bracket 354 comprises a single or first member 357 . As depicted, the first member 357 is provided with an aperture 360 that facilitates attachment to a structure with fastening elements such as nails, threaded fasteners, or rivets. It will be appreciated, however, that an aperture or apertures need not be present in order to attach the bracket to a structure. The fastening element(s) may be driven through the first member, if desired. Additionally, it will also be appreciated that attachment may also be achieved with suitable adhesives, in lieu of, or in addition to, fastening elements. Continuing on, the support beam engaging portion 358 comprises a web 362 and a pair of legs 364 , 366 , which are angled with respect to the web to form a generally “”-shaped form. The web 362 includes an aperture 368 that is accessible through a slot 370 defined by edges 372 and 374 of legs 366 and 364 , respectively. The aperture 368 and slot 370 are configured to slidingly receive a leg portion 732 b and foot 734 of a support beam 716 of FIGS. 51 and 52 .
[0188] Generally, the bracket of FIG. 50 may be used with beams and blocks as shown in FIGS. 51 and 52 to form wall structures similar to wall structures previously discussed. More specifically, support beam 716 , as shown, comprises an elongated spine or web 718 and plurality of ribs 720 and 722 , 724 and 726 , which are arranged in a substantially coplanar and collateral relation so that the first pair of ribs 720 , 722 , which are substantially coplanar, extend away from each other in a manner similar to other embodiments already described. As shown, a first pair of ribs 720 , 722 are designed to engage the grooves 728 of one or more blocks of a structure. As shown in FIG. 51 , the support beams 716 may be oriented in a generally vertical direction, or as in FIG. 52 , a generally horizontal direction. Note that in either orientation, the blocks would essentially be self-supporting.
[0189] In addition, the web also includes a second pair of ribs 724 , 726 which are also substantially coplanar and which extend away from each other. Note that the pairs of ribs 720 , 722 and 724 , 726 are in substantially collateral or parallel relation with respect to each other and are spaced apart from each other by a distance defined by the web 718 . The support beam 716 also includes a pair of pair of leg structures 730 having leg portions 732 a - b that are similar to the leg structures of FIG. 37 in that they extend rearwardly away from ribs 724 , 726 and which form a generally U-shaped channel therewith. The support beam differs, however, in that only one of the leg portions 732 b includes a foot 734 . As depicted, the foot 734 extends laterally away from the leg portion 732 b and is generally parallel with ribs 720 , 722 . As with the embodiment of FIGS. 2 and 2 a , the foot may be connected directly or indirectly to a support structure. However, as depicted, the beams of FIGS. 51 and 52 are operatively connected to a structure by a plurality of brackets 354 , which are attached to suitable structural members. With such an arrangement the beams, which are slidingly constrained by the brackets, permit blocks to move without destroying the integrity of the structure.
[0190] As shown in FIG. 53 , a bracket 200 is used as part of a wall system to operatively connect a support beam 116 to a structure “S”. Note that the lowermost course of blocks is supported by a horizontally oriented, elongated base, preferably in the form of an angle iron 83 , which can be used with one or more support pads or footings 80 a , if desired. The angle iron 83 includes an upper surface 86 , that is configured to receive one or more blocks thereon and a sidewall 88 that prevents the block(s) from being shifted backwards. Optionally, the upper surface and/or the sidewall of the angle iron 83 may be provided with adhesive material to enable the block(s) to be secured thereto, which increases the strength and stability of the wall structure. Often, a completed wall structure will terminate in an upper course of blocks that is offset from the structure “S”. In these situations, one or more capstones or sills 113 may be used to provide a finished look, with the sills being positioned upon the upper course of blocks. As will be understood, the sills may be attached to the upper course of blocks using known technologies and techniques, such as adhesives. Sometimes, there is a gap between a capstone or sill 113 and the structure “S”, through which moisture, debris, insects, etc. may pass. This gap can be effectively closed using a sealing element 250 as depicted in FIGS. 54 and 55 .
[0191] The sealing element 250 of the present invention generally comprises a body having a plurality of flexible, resilient strips that provide an effective seal between the sills or finish moldings and the structure. More specifically the sealing element 250 comprises a sealing panel 251 that is formed by first and second strips 252 and 254 and an attachment portion 255 that is formed by third and fourth strips 256 and 258 . The attachment portion 255 is operatively connected to the panel 251 such that the third and fourth strips extend therefrom in a generally radial relation. As can be seen in FIGS. 54 and 55 , the sealing element is in an unflexed state and the third and fourth strips 256 and 258 define an angle 262 , which can range from about 15 degrees to about 165 degrees. The preferred range of the angle however is in the range of about 45 degrees to about 75 degrees. The third and fourth strips 256 and 258 may include beads or wales 260 that enable the sealing element to anchor itself into position. In use, the third and fourth strips 256 and 258 of the attachment portion 255 are pinched together and inserted into the gap between the wall and a structure, as shown in FIGS. 53 and 56 . As the attachment portion 255 is seated, the first and second strips 252 , 254 of the panel 251 contact the surfaces of the sill 113 and the structure “S” and exert normal forces there against. Thus, effectively seals the gap. As will be appreciated, the sealing element is maintained in position by the beads 260 that, due to the resilient nature of the strips, tend to catch against irregularities in the surfaces of the sill and the structure “S” and resist movement. As will be appreciated, the sealing element 250 may be oriented so that the first and third strips 252 , 256 contact the sill 113 and the second and fourth strips 254 , 258 contact the structure “S”, if desired.
[0192] There may be times when it is not possible, practical, or desirable to use beams or the combination of beams and brackets, as previously described to operatively connect blocks to a structure. In such cases, blocks may be attached to a structure using only brackets. Generally, as shown in FIGS. 57-59 , each bracket comprises a structure engagement portion and a block engagement portion that are spaced from each other by a web. In one preferred embodiment, shown in FIG. 57 , the bracket 754 comprises a structure engagement portion 756 that is similar to previously described structure engagement portions in that it is configured and arranged to act as a point of attachment to a structure, and comprises a member 766 having an aperture 768 , with the aperture configured to be used in conjunction with a fastening element such as a nail, screw or rivet. The bracket also comprises a web 762 and a panel 760 , which collectively serve to connect the structure engagement portion 756 to a block engagement portion 758 , and which serve to position a block a predetermined distance from a structure to which it may be attached. While the structure engagement portion 756 and the web 762 form a generally 90 degree angle therebetween, it will be understood that the angle may be modified depending upon the configuration of the structure to which it is attached. Thus, for example, the angle could be acute or obtuse. The block engagement portion 758 , which is connected to the web, comprises a plurality of generally planar sections 759 a, 759 b, 759 c, 759 d, and which are configured to cooperatively engage portions of one or more blocks such that forward and rearward movement of the blocks relative to the structure, is limited. This is achieved by forming some sections so that they are substantially coplanar with each other and forming some sections so that they are substantially parallel to each other (when viewing the bracket on edge). Note that those sections that are coplanar with each other extend away from the web in opposite directions, while those sections that are parallel to each other and spaced from each other by a panel, need not be so restricted. Note also, that the sections are configured and arranged so that when viewed from front, the sections do not overlap or superimpose upon each other. As will be appreciated, this permits to bracket to be manufactured from material such as metal and formed into the desired configuration with a series of cuts and bends. It will be understood, however, that the bracket may be manufactured from different materials (eg. plastics) and formed using different techniques (eg. molding) without departing from the spirit and scope of the invention. In use, as shown in FIG. 60 (right side), the bracket 754 operatively connects two blocks to a structure “S”.
[0193] Alternative embodiments of bracket 754 are depicted in FIGS. 58 and 59 . As with the previously described bracket, these brackets 754 ′ and 754 ″, respectively, comprise a structure engagement portion, a web, and a block engagement portion. The structure engagement portions are similar to the structure engagement portion of FIG. 57 in that they are configured and arranged to act as a point of attachment to a structure, and comprises a member 766 ′, 766 ″ having an aperture 768 ′, 768 ″ respectively, with the aperture configured to be used in conjunction with a fastening element such as a nail, screw or rivet. Likewise, the brackets also comprise a web 762 ′, 762 ″ which serve to connect the structure engagement portion 756 ′, 756 ″ to a block engagement portion 758 ′, 758 ″, respectively, and which serve to position a block a predetermined distance from a structure to which it may be attached. In a departure from the web structure of FIG. 57 , the webs of FIGS. 58 and 59 include an additional aperture 764 ′, 764 ″ that is configured and arranged to act as a point of attachment to a structure (see, for example, the left side of FIG. 60 ). As with the previously describe embodiment of FIG. 57 , the angle formed by the structure engagement portion and the web (shown generally as 90 degrees) may be modified depending upon the configuration of the structure to which it is attached. The block engagement portions 758 ′, 758 ″, which are connected to respective webs, each comprise a plurality of sections 759 a ′ and 759 b ′, 759 a ″ and 759 b ″, which are configured to cooperatively engage portions of one or more blocks such that forward and rearward movement of the blocks relative to the structure, is limited. This is achieved by forming the sections so that they are generally coplanar to each other (when viewing the bracket on edge) and able to engage opposing surfaces in one or more blocks. A feature common to each of the sections 758 a ′ and 758 b ′, 758 a ″ and 758 b ″ is that they have a thickness 776 ′, 776 ″ that effectively spans the distance between the opposing surfaces into which they are positioned, such that forward and rearward movement of the blocks relative to the structure, is limited. In particular, the effective thickness of each section 776 ′, 776 ″ of bracket 754 ′, 754 ″ is achieved by forming creases 772 in each section to form darts 770 , whose ends define the extent of the effective thickness 776 ′. A strengthening rib 774 may be provided for each section, if desired. The effective thickness 776 ′ of the sections 770 of bracket 754 ′ is achieved by forming the sections so that they have high and low block contacting areas, preferably by curving the sections and more preferably by forming the sections into the shape of arcs. FIG. 60 is a plan view of the brackets of FIGS. 57 and 59 operatively connecting blocks of the present invention to a substructure.
[0194] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | The present invention relates to decorative and structural blocks designed to be installed as skirting structures for buildings, elevated structures and structural elements such as posts. More particularly, the present invention relates to a system that uses specifically designed and manufactured masonry blocks that are used in conjunction with specifically designed support beams and/or brackets to provide durable, attractive, easy to assemble surfaces or skirting structures. The blocks are shaped to be stacked in vertically independent, self-supporting columns, strengthened and linked together by specially shaped, lightweight, lateral support beams positioned between adjacent columns, and which may be attached directly or indirectly to a sub-structure. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The disclosure of Japanese Patent Application No. 2006-13349 filed on Jan. 23, 2006 including specification, drawings and claims is incorporated herein by reference in its entirely.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to a method of manufacturing a semiconductor device, and more particularly, to a method of manufacturing a power semiconductor device such as an insulating gate bipolar transistor.
[0004] 2. Description of the Related Art
[0005] FIG. 4 and FIGS. 5A through 5D show steps for manufacturing a conventional semiconductor device, at which the back surface of a semiconductor wafer is polished and back surface metal is disposed. FIG. 4 is a top view of a semiconductor wafer 1 , while FIGS. 5A through 5D are cross sectional views of FIG. 4 taken along the IV-IV direction. The conventional manufacturing steps shown in FIGS. 5A through 5D include the following steps 1 through 4.
[0006] Step 1: As shown in FIGS. 4 and 5A , a semiconductor element 2 is formed on the semiconductor wafer 1 of silicon or the like. The film thickness of the semiconductor wafer 1 is t 1 (before polishing).
[0007] Step 2: As shown in FIG. 5B , for reduction of the resistance of the semiconductor element 2 , the semiconductor wafer 1 is polished at its back surface into the film thickness of t 2 (after polishing).
[0008] Step 3: As shown in FIG. 5C , a first metal layer 3 of Al or Al—Si alloy for instance is formed on the back surface of the semiconductor wafer 1 . Following this, a barrier metal layer 4 of Ti, Mo or V for instance, a second metal layer 5 of Ni for instance, and a third metal layer 6 of Au, Ag or Au—Ag alloy for instance are formed one after another by vapor deposition, sputtering, etc.
[0009] Step 4: The semiconductor wafer 1 now seating on its back surface the four layers of the metal films is loaded into a furnace which is kept at the temperature of approximately from 300 to 470° C. and sintered. This causes the semiconductor wafer 1 and the first metal layer 3 to diffuse into each other, which creates an excellent ohmic contact (JPA 04-072764).
SUMMARY OF THE INVENTION
[0010] However, there is a problem as shown in FIG. 5D that the semiconductor wafer 1 bends as if it were pulled at its back surface after sintered.
[0011] FIG. 6 shows a relationship between the thickness and the amount of bending of a silicon wafer of six inches whose back surface seats 200 nm of the first metal layer (Al) 3, 100 nm of the barrier metal layer (Ti) 4, 500 nm of the second metal layer (Ni) 5 and 200 nm of the third metal layer (Au) 6 . In FIG. 6 , the mark represents the relationship before sintering and the mark □ represents the relationship after sintering.
[0012] For example, when the thickness of the silicon wafer is 200 μm, the amount of bending X after sintering is 1.7 mm, when the thickness is 130 μm, the amount of bending X is 3.8 mm, and when the thickness is 60 μm, the amount of bending X is 16 mm.
[0013] Bent in this fashion, the semiconductor wafer 1 get caught inside an apparatus while being transported, thereby causing a transportation error, interrupted processing, etc. In addition, soldering will become insufficient during die bonding the semiconductor wafer 1 which is cut into a chip to a substrate or the like, thereby causing defective bonding.
[0014] Through intensive research, the inventors found that the nature of the film constituting the second metal layer 5 of Ni would alter while thermally treated and influence bending of the semiconductor wafer 1 , and made this invention.
[0015] Accordingly, an object of the present invention is to provide a method of manufacturing a semiconductor device which reduces the amount of bending of a semiconductor device which is attributable to thermal processing.
[0016] The present invention is directed to a method of manufacturing a semiconductor device having a back surface electrode, including: a step of preparing a semiconductor wafer having a front surface and a back surface; a thermal processing step of forming a first metal layer on the back surface of the semiconductor wafer and executing thermal processing, thereby creating an ohmic contact between the semiconductor wafer and the first metal layer; and a step of forming a second metal layer of Ni on the back surface of the semiconductor substrate after the thermal processing step.
[0017] As described above, use of the semiconductor device manufacturing method according to the present invention makes it possible to reduce the amount of bending of a semiconductor wafer and prevent a transportation error and the like related to the semiconductor wafer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A through 1E show cross sectional views of steps of manufacturing a semiconductor device according to an embodiment 1 of the present invention;
[0019] FIGS. 2A through 2E show cross sectional views of steps of manufacturing a semiconductor device according to an embodiment 2 of the present invention;
[0020] FIGS. 3A through 3E show cross sectional views of steps of manufacturing a semiconductor device according to an embodiment 3 of the present invention;
[0021] FIG. 4 is a top view of a conventional semiconductor device;
[0022] FIGS. 5A through 5D show cross sectional views of conventional steps of manufacturing a semiconductor device; and
[0023] FIG. 6 shows a relationship between the wafer thickness and the amount of bending in a semiconductor device fabricated in accordance with a conventional manufacturing method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
[0024] FIGS. 1A through 1E show cross sectional views of steps of manufacturing a semiconductor device according to the embodiment 1, generally denoted at 100 . The cross sectional views in FIGS. 1A through 1E show the semiconductor device 100 as it is viewed from the same direction as the IV-IV direction which is shown in FIG. 4 . This manufacturing method includes the following steps 1 through 5.
[0025] Step 1: As shown in FIG. 1A , a semiconductor element 2 such as an insulating gate bipolar transistor (IGBT) is formed on a semiconductor wafer 1 of silicon or the like. The film thickness of the semiconductor wafer 1 is t 1 (before polishing).
[0026] Step 2: As shown in FIG. 1B , for reduction of the resistance of the semiconductor element 2 , the semiconductor wafer 1 is polished at its back surface into the film thickness of t 2 (after polishing).
[0027] Step 3: As shown in FIG. 1C , a first metal layer 3 of Al or Al—Si alloy for instance is formed on the back surface of the semiconductor wafer 1 . The first metal layer 3 is formed by vapor deposition, sputtering, etc.
[0028] Prior to the step of forming the first metal layer 3 on the back surface of the semiconductor wafer 1 , B, As or other ions may be implanted from the back surface of the semiconductor wafer 1 and thus implanted ions may be activated by heating.
[0029] Step 4: The semiconductor wafer 1 is loaded into a furnace which is kept at the temperature of approximately from 300 to 470° C. and thermally processed (sintering). This causes the semiconductor wafer 1 and the first metal layer 3 to diffuse into each other, which creates an excellent ohmic contact. As shown in FIG. 1D , the semiconductor wafer 1 scarcely bends during this thermal processing.
[0030] Step 5: As shown in FIG. 1E , a barrier metal layer 4 of Ti, Mo or V for instance, a second metal layer 5 of Ni for instance, and a third metal layer 6 of Au, Ag or Au—Ag alloy for instance are formed one after another by vapor deposition, sputtering, etc. No thermal processing is executed after forming these metal layers.
[0031] The second metal layer 5 is intended for favorable soldering during die bonding. The third metal layer 6 is intended for prevention of oxidization of the second metal layer 5 .
[0032] In the event that a silicon wafer whose diameter is six inches and film thickness t 2 is 60 μm is used as the semiconductor wafer 1 , the amount of bending X after forming the first metal layer 3 of 200 nm in thickness and performing thermal processing is 1 mm or less.
[0033] After forming the barrier metal layer 4 of 100 nm in thickness, the second metal layer 5 of 500 nm in thickness and the third metal layer 6 of 200 nm in thickness, the amount of bending X is 2 mm or less.
[0034] As the thermal processing step (sintering) is not executed after forming the second metal layer 5 of Ni for instance, it is possible to reduce bending of the semiconductor wafer 1 . In short, the second metal layer 5 is not subjected to thermal processing at a high temperature such as 300° C. or more, which reduces bending of the semiconductor wafer 1 .
[0035] Where the manufacturing method according to the embodiment 1 is used therefore, it is possible to create an excellent ohmic contact by thermal processing and reduce bending of the semiconductor wafer.
[0036] In the step 5, the substrate temperature of the semiconductor wafer 1 during the formation of the second metal layer 5 and the third metal layer 6 is preferably 80° C. or lower. When the second metal layer 5 and the third metal layer 6 are formed at a low temperature of 80° C. or less, it is possible to further reduce the amount of bending X of the semiconductor wafer 1 down to 1 mm or less.
Embodiment 2
[0037] FIGS. 2A through 2E show cross sectional views of steps of manufacturing a semiconductor device according to the embodiment 2, generally denoted at 200 . The cross sectional views in FIGS. 2A through 2E show the semiconductor device 200 as it is viewed from the same direction as the IV-IV direction which is shown in FIG. 4 . In FIGS. 2A through 2E , the same reference symbols as those used in FIGS. 1A through 1E are the same or corresponding portions. This manufacturing method includes the following steps 1 through 5.
[0038] Steps 1 and 2: The steps 1 and 2 shown in FIGS. 2A and 2B are similar to the steps 1 and 2 according to the earlier embodiment 1.
[0039] Step 3: As shown in FIG. 2C , the first metal layer 3 of Al or Al—Si alloy for instance and the barrier metal layer 4 of Ti, Mo or V for instance are formed on the back surface of the semiconductor wafer 1 . The first metal layer 3 and the barrier metal layer 4 are formed vapor deposition, sputtering, etc.
[0040] Prior to the step of forming the first metal layer 3 on the back surface of the semiconductor wafer 1 , B, As or other ions may be implanted from the back surface of the semiconductor wafer 1 and thus implanted ions may be activated by heating.
[0041] Step 4: The semiconductor wafer 1 is loaded into a furnace which is kept at the temperature of approximately from 300 to 470° C. and thermally processed (sintering). This causes the semiconductor wafer 1 and the first metal layer 3 to diffuse into each other, which creates an excellent ohmic contact. As shown in FIG. 2D , the semiconductor wafer 1 scarcely bends during this thermal processing.
[0042] Step 5: As shown in FIG. 2E , the second metal layer 5 of Ni for instance and the third metal layer 6 of Au, Ag or Au—Ag alloy for instance are formed one after another by vapor deposition, sputtering, etc. No thermal processing is executed after forming these metal layers.
[0043] In the event that a silicon wafer whose diameter is six inches and film thickness t 2 is 60 μm is used as the semiconductor wafer 1 , the amount of bending X is 1 mm or less after forming the first metal layer 3 having the film thickness of 200 nm and the barrier metal layer 4 having the film thickness of 100 nm and performing thermal processing.
[0044] After forming the second metal layer 5 of 500 nm in thickness and the third metal layer 6 of 200 nm in thickness, the amount of bending X is 2 mm or less.
[0045] As the thermal processing step (sintering) is not executed after forming the second metal layer 5 of Ni for instance, it is possible to reduce bending of the semiconductor wafer 1 . Where the manufacturing method according to the embodiment 2 is used therefore, it is possible to create an excellent ohmic contact by thermal processing and reduce bending of the semiconductor wafer.
[0046] Use of the method according to the embodiment 2 in particular achieves better adhesion between the first metal layer 3 and the barrier metal layer 4 .
[0047] In the step 5, the temperature of the semiconductor wafer 1 during the formation of the second metal layer 5 and the third metal layer 6 is preferably 80° C. or lower. When the second metal layer 5 and the third metal layer 6 are formed at a low temperature of 80° C. or less, it is possible to further reduce the amount of bending X of the semiconductor wafer 1 down to 1 mm or less.
Embodiment 3
[0048] FIGS. 3A through 3E show cross sectional views of steps of manufacturing a semiconductor device according to the embodiment 3, generally denoted at 300 . The cross sectional views in FIGS. 3A through 3E show the semiconductor device 300 as it is viewed from the same direction as the IV-IV direction which is shown in FIG. 4 . In FIGS. 3A through 3E , the same reference symbols as those used in FIGS. 1A through 1E are the same or corresponding portions. This manufacturing method includes the following steps 1 through 5.
[0049] Steps 1 through 4: The steps 1 through 4 shown in FIGS. 3A through 3D are similar to the steps 1 through 4 according to the embodiment 2 described above.
[0050] Step 5: As shown in FIG. 5E , a barrier metal layer 7 of Ti, Mo or V, the same material as that of the barrier metal layer 4 is further formed. As the barrier metal layer 7 made of the same material as that of the barrier metal layer 4 is formed after sintering, adhesion between the barrier metal layer 7 and the overlying second metal layer 5 improves.
[0051] Following this, the second metal layer 5 of Ni for instance and the third metal layer 6 of Au, Ag or Au—Ag alloy for instance are formed one after another by vapor deposition, sputtering, etc. No thermal processing is executed after forming the barrier metal layer 7 and these metal layers 5 and 6 .
[0052] In the event that a silicon wafer whose diameter is six inches and film thickness t 2 is 60 μm is used as the semiconductor wafer 1 , the amount of bending X is 1 mm or less after forming the first metal layer 3 having the film thickness of 200 nm and the barrier metal layer 4 having the film thickness of 100 nm and performing thermal processing.
[0053] After forming the barrier metal layer 7 , the second metal layer 5 of 500 nm in thickness and the third metal layer 6 of 200 nm in thickness, the amount of bending X is 2 mm or less.
[0054] As the thermal processing step (sintering) is not executed after forming the second metal layer 5 of Ni for instance, it is possible to reduce bending of the semiconductor wafer 1 . Where the manufacturing method according to the embodiment 3 is used therefore, it is possible to create an excellent ohmic contact by thermal processing and reduce bending of the semiconductor wafer.
[0055] In the step 5, the temperature of the semiconductor wafer 1 during the formation of the barrier metal layer 7 , the second metal layer 5 and the third metal layer 6 is preferably 80° C. or lower. When the barrier metal layer 7 , the second metal layer 5 and the third metal layer 6 are formed at a low temperature of 80° C. or less, it is possible to further reduce the amount of bending X of the semiconductor wafer 1 down to 1 mm or less. | A method of manufacturing a semiconductor device having a back surface electrode, including: a step of preparing a semiconductor wafer having a front surface and a back surface; a thermal processing step of forming a first metal layer on the back surface of the semiconductor wafer and executing thermal processing, thereby creating an ohmic contact between the semiconductor wafer and the first metal layer; and a step of forming a second metal layer of Ni on the back surface of the semiconductor substrate after the thermal processing step. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 61/272,511, filed in the U.S. Patent and Trademark Office on Oct. 1, 2009, and entitled “RECHARGEABLE BATTERY AND BATTERY MODULE,” which is incorporated by reference herein in its entirety and for all purposes.
BACKGROUND
1. Field of the Invention
Embodiments relate to a rechargeable battery and a battery module.
2. Description of the Related Art
A rechargeable battery differs from a primary battery in that it can be repeatedly charged and discharged, while the latter makes only the irreversible conversion of chemical to electrical energy. The low-capacity rechargeable battery is used as the power supply for small electronic devices, such as cellular phones, notebook computers and camcorders, while the high-capacity rechargeable battery is used as the power supply for driving motors in hybrid vehicles and the like.
A high-power rechargeable battery using a non-aqueous electrolyte with a high energy density has been recently developed. For example, the high-power rechargeable battery is constructed with a high-capacity rechargeable battery having a plurality of rechargeable cells coupled to each other in series such that it can be used as the power supply for driving motors in electric vehicles requiring high power.
The above information disclosed in this Background section is only for enhancement of understanding of the related art and may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY
Embodiments are therefore directed to a rechargeable battery and a battery module, which substantially overcome one or more of the problems due to the limitations and disadvantages of the related art.
It is therefore a feature of an embodiment to provide a rechargeable battery with an improved terminal structure, and a battery module including the same.
It is therefore another feature of an embodiment to provide a rechargeable battery that includes provisions for preventing galvanic corrosion, and a battery module including the same.
At least one of the above and other features may be realized by providing a battery, including a battery case, an electrode assembly in the battery case, the electrode assembly including a first electrode, a first terminal exposed to an exterior of the battery case, the first terminal being electrically connected to the first electrode, a first fixing member mechanically coupling the first terminal to the battery, the first fixing member forming at least part of an electrical path from the first terminal to the first electrode, and a corrosion resistance member providing an electrical path from the first terminal to the first fixing member and being in direct contact with each of the first terminal and the first fixing member.
The corrosion resistance member may prevent the first terminal from directly contacting the first fixing member.
The first terminal may have a surface formed of a metal having a first ionization tendency, the first fixing member may have a surface formed of a metal having a second ionization tendency, and the corrosion resistance member may have a surface formed of a metal having a third ionization tendency that is between the first ionization tendency and the second ionization tendency.
The first terminal may serve as the positive terminal.
The first terminal may serve as the cathode terminal during discharge of the battery.
The metal forming the surface of the first terminal may be copper, and the metal forming the surface of the first fixing member may be aluminum.
The first electrode may include aluminum, and the first fixing member may electrically contact the first electrode.
The metal forming the surface of the corrosion resistance member may be nickel, stainless steel, nickel-plated copper, or a clad metal of Al—Cu, Ni—Cu, or Al—Ni.
The first terminal may serve as the negative terminal.
The first terminal may serve as the anode terminal during discharge of the battery.
The metal forming the surface of the first terminal may be aluminum, and the metal forming the surface of the first fixing member may be copper.
The first electrode may include copper, and the first fixing member may electrically contact the first electrode.
The metal forming the surface of the corrosion resistance member may be nickel, stainless steel, nickel-plated copper, or a clad metal of Al—Cu, Ni—Cu, or Al—Ni.
The corrosion resistance member may be separate from the first terminal and the first fixing member.
The corrosion resistance member may be integral with the first terminal.
The corrosion resistance member may be a layer deposited on the first terminal.
The corrosion resistance member may be a plating layer on the first terminal.
The electrode assembly may further include a second electrode and a separator, the separator separating the first electrode from the second electrode.
The first fixing member may be a rivet.
At least one of the above and other features may also be realized by providing a battery module, including a first battery, and a second battery electrically connected to the first battery, each of the first and second batteries including a battery case, an electrode assembly in the battery case, the electrode assembly including a first electrode, a first terminal exposed to an exterior of the battery case, the first terminal being electrically connected to the first electrode, a first fixing member mechanically coupling the first terminal to the battery, the first fixing member forming at least part of an electrical path from the first terminal to the first electrode, and a corrosion resistance member providing an electrical path from the first terminal to the first fixing member and being in direct contact with each of the first terminal and the first fixing member.
The corrosion resistance member may prevent the first terminal from directly contacting the first fixing member.
The first battery and the second battery may be electrically connected to one another in series, the first terminals of the respective first and second batteries serving as positive terminals, and the positive terminal of the first battery may be electrically connected to a negative terminal of the second battery by a connection member that is welded to each of the positive terminal of the first battery and the negative terminal of the second battery.
Outer surfaces of the positive terminal of the first battery, the negative terminal of the second battery, and the connection member may each be formed of a same metal.
The first fixing member may be a rivet, the rivet having an outer surface formed of a metal different from an outer surface of the positive terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages will become more apparent to those of ordinary skill in the art by describing in detail example embodiments with reference to the attached drawings, in which:
FIG. 1 illustrates a perspective view of a rechargeable battery according to a first example embodiment,
FIG. 2 illustrates a cross-sectional view of the rechargeable battery taken along the II-II line of FIG. 1 ,
FIG. 3 illustrates an exploded perspective view of the rechargeable battery according to the first example embodiment, illustrating the process of installing a fixture at a first terminal,
FIG. 4 illustrates an exploded perspective view of a battery module according to a second example embodiment,
FIG. 5 illustrates a cross-sectional view of the battery module taken along the V-V line of FIG. 4 , and
FIG. 6 illustrates a partial sectional view of a battery module according to a third example embodiment.
DESCRIPTION OF REFERENCE NUMERALS INDICATING ELEMENTS IN THE DRAWINGS
100 : rechargeable battery,
110 : electrode assembly,
111 : positive electrode,
111 a : positive electrode uncoated region,
112 : negative electrode,
112 a : negative electrode uncoated region,
113 : separator,
115 : first lead member,
115 a : first lead member upper plate,
115 b : first lead member attachment plate,
116 : second lead member,
120 : cap plate,
121 : first fixture (rivet),
121 a : first fixture pillar portion,
121 b : first fixture top head portion,
121 c : first fixture bottom head portion,
122 : second fixture (rivet),
122 a : second fixture pillar portion,
122 b : second fixture top head portion,
122 c : second fixture bottom head portion,
123 : terminal insulating member,
124 : case,
125 : electrolyte injection hole plug (cork),
126 : vent,
127 : lower gasket,
130 : first terminal (positive terminal),
140 : second terminal (negative terminal),
131 : protrusion,
132 : first hole,
134 : second hole,
141 : protrusion,
150 : corrosion resistance member,
151 : corrosion resistance member tube portion,
153 : corrosion resistance member head portion,
156 : corrosion resistance member hole,
160 : connection member,
162 : connection member groove,
165 : welded portion,
175 : welded portion,
180 : first terminal (positive terminal),
181 : first terminal protrusions, and
185 : corrosion resistance layer.
DETAILED DESCRIPTION
Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings, however, they may be embodied in 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.
In the drawing figures, dimensions may be exaggerated for clarity of illustration. It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element, or one or more intervening elements may also be present. It will also be understood that when an element is referred to as being “under” another element, it can be directly under, or one or more intervening elements may also be present. It will also be understood that when an element is referred to as being “between” two elements, it can be the only element between the two elements, or one or more intervening elements may also be present. Like reference numerals refer to like elements throughout.
As used herein, the term “anode” refers to the electrode at which oxidation occurs. As used herein, the term “cathode” refers to the electrode at which reduction occurs. The terminal that is coupled to the anode (“anode terminal”) is the negative terminal (−) of the electrochemical cell (or unit battery) while the electrochemical cell is discharging. The anode terminal provides electrons to the load circuit during discharge of the electrochemical cell. The terminal that is coupled to the cathode is the positive terminal (+) of the electrochemical cell while the electrochemical cell is discharging. The cathode terminal receives electrons from the load circuit during discharge of the electrochemical cell. While the battery is being charged, energy is input to the battery to regenerate the electrochemical potential of the battery. Thus, the oxidation and reduction locations interchange (or swap), such that the positive terminal of the electrochemical cell is the anode while the battery is being charged and the negative terminal of the electrochemical cell is the cathode while the battery is being charged.
FIG. 1 illustrates a perspective view of a rechargeable battery according to a first example embodiment, and FIG. 2 illustrates a cross-sectional view of the rechargeable battery taken along the II-II line of FIG. 1 .
Referring to FIG. 1 and FIG. 2 , the rechargeable battery 100 may be a prismatic battery. The rechargeable battery 100 may include an electrode assembly 110 . The electrode assembly 110 may include positive and negative electrodes 111 and 112 wound together with a separator 113 interposed therebetween as an insulator. The rechargeable battery 100 may also include a case 124 having the electrode assembly 110 therein, first and second terminals 130 and 140 electrically connected to the electrode assembly 110 , and a cap plate 120 fitted to an opening of the case 124 (the opening not being shown in the drawings, which illustrate the case 124 as being closed by the cap plate 120 ). As described in greater detail below, terminals may be electrically connected to the electrode assembly 110 and protruded to the outside of the case 124 .
The positive electrode 111 may include a current collector, e.g., a thin metal foil plate, and a positive active material. The positive electrode 111 may include a coated region, where the positive active material is coated, and an uncoated region 111 a , where active material is not coated. The thin metal foil plate of the positive electrode 111 may be aluminum or may include aluminum. The negative electrode 112 may include a current collector, e.g., a thin metal foil plate, and a negative active material. The negative electrode 112 may include a coated region, where the negative active material is coated, and an uncoated region 112 a , where active material is not coated. The uncoated regions 111 a and 112 a may be formed at the lateral ends of the positive and the negative electrodes 111 and 112 in the longitudinal direction of the positive and the negative electrodes 111 and 112 . The positive and the negative electrodes 111 and 112 may be spiral-wound by interposing the separator 113 therebetween as an insulator so as to form a jellyroll-shaped electrode assembly 110 .
In another implementation, the electrode assembly 110 may be structured such that a plurality of positive and negative electrodes 111 and 112 are alternately deposited while interposing the separator 113 therebetween.
A first terminal 130 may be electrically connected to the positive uncoated region 111 a of the electrode assembly 110 via a first lead member 115 , and a second terminal 140 may be electrically connected to the negative uncoated region 112 a via a second lead member 116 .
The case 124 may be formed to have a hexahedral-shaped prismatic case having an inner space and the top opening. In another implementation, the case may be formed with various shapes such as a cylinder, a pouch, etc.
The case 124 may be formed to have a hexahedral-shaped prismatic case having an inner space and the top opening 124 a . In another implementation, the case may be formed with various shapes such as a cylinder, a pouch, etc.
The cap plate 120 may be formed with a thin plate, and may be provided with a vent 126 having a notch capable of opening at a predetermined inner pressure. A plug 125 may be provided for sealing an electrolyte injection hole.
The first and the second terminals 130 and 140 may be plate-shaped, and may be disposed parallel to the cap plate 120 . The first terminal 130 may be fixed to the cap plate 120 by way of a first fixture 121 , and the second terminal 140 may be fixed to the cap plate 120 by way of a second fixture 122 . In an implementation, the fixtures 121 and 122 may be formed with rivets. By using the fixtures 121 and 122 , the first and second terminals 130 , 140 may be secured against vibration and loosening, which may increase contact resistance. In contrast, where terminals are fixed to a cap plate by way of nuts, the nuts may be liable to release due to continuous external vibration or impact. If the nuts are released, the contact resistance between the electrode assembly and the terminals may increase so that the output of the rechargeable battery is deteriorated, and the cycle life of a battery module is reduced.
The fixtures 121 and 122 may have pillar portions 121 a and 122 a inserted into the cap plate 120 , top head portions 121 b and 122 b laterally protruding from the top ends of the pillar portions 121 a and 122 a , and bottom head portions 121 c and 122 c laterally protruding from the bottom ends of the pillar portions 121 a and 122 a.
A first lead member 115 may be attached, e.g., by welding, to the bottom side of the bottom head portion 121 c positioned at the bottom end of the first fixture 121 . The first lead member 115 may be, or may include, aluminum. Similarly, the first fixture 121 may be, or may include, aluminum. The first lead member 115 may have an upper plate 115 a welded to the first fixture 121 , and an attachment plate 115 b protruding downward from the upper plate 115 a and fixed to the positive uncoated region 111 a.
A second lead member 116 may be attached, e.g., by welding, to the bottom side of the bottom head portion 122 c positioned at the bottom end of the second fixture 122 . The second lead member 116 may be, or may include, copper. Similarly, the second fixture 122 may be, or may include, copper. The second lead member 116 may include an upper plate 116 a welded to the second fixture 122 , and an attachment plate 116 b protruding downward from the upper plate 116 a and fixed to the negative uncoated region 112 a.
In another implementation, the lead members 115 and 116 may be fixed to the cap plate 120 , together with the terminals 130 and 140 , by way of the fixtures 121 and 122 , rather than being welded to the fixtures.
Respective terminal insulating members 123 may be installed between the cap plate 120 and the terminals 130 and 140 so as to insulate the cap plate 120 from the terminals 130 , 140 . Respective lower gaskets 127 may be disposed between the cap plate 120 and the fixtures 121 and 122 so as to insulate the cap plate 120 from the fixtures 121 and 122 .
The terminal insulating member 123 may be wider than the terminals 130 and 140 , and may be tightly adhered to the top surface of the cap plate 120 . The terminal insulating members 123 may have central through-holes for receiving the fixtures 121 and 122 .
The terminals 130 and 140 of the rechargeable battery 100 according to the present example embodiment may be fixed to the cap plate 120 by way of the rivet-shaped fixtures 121 and 122 , which may endure under vibration better than a nut-coupled structure.
FIG. 3 illustrates an exploded perspective view of the rechargeable battery according to the first example embodiment, illustrating the process of installing a fixture at a first terminal.
An example of installation of the first fixture 121 (and the second fixture 122 , which may be installed in substantially the same manner) will now be described with reference to FIG. 2 and FIG. 3 . As shown in FIG. 3 , the pillar-shaped fixture 121 ( 122 ) may be inserted into the terminal 130 ( 140 ) and the cap plate 120 . In this state, the fixture 121 ( 122 ) may be pressed from the top and the bottom ends so that top head portion 121 b ( 122 b ) and bottom head portion 121 c ( 122 c ) are formed by deforming the pillar shaped fixture 121 ( 122 ). In another implementation, a fixture with a pre-formed bottom head portion may be inserted into a terminal and cap plate, and the top end of the fixture may be pressed from the top end so as to form a top head portion at the top end of the rivet.
The terminals 130 and 140 may be tightly adhered to the cap plate 120 during the process of pressing the fixtures 121 and 122 so that the terminals 130 and 140 can be prevented from being released due to vibration.
It is most important with the rechargeable battery 100 to reduce the contact resistance. Excessively high contact resistance may degrade the output of the rechargeable battery 100 , and may generate resistance heating from high current flow so that the temperature of the rechargeable battery 100 is elevated. When the temperature of the rechargeable battery 100 is elevated, an abnormal reaction may occur internally, and, accordingly, the cycle life of the rechargeable battery 100 may be reduced. However, with the present example embodiment, the fixtures 121 and 122 may be less susceptible to being loosened by vibration, and, hence, the contact resistance may be minimized.
As shown in FIG. 1 , the first and the second terminals 130 and 140 may be generally formed in the shape of a rectangular plate, which has a short side with a relatively small length, and a long side with a length greater than the short sides.
Upward protrusions 131 and 141 may be formed at both ends of the long side, respectively, and a connection member 160 (described in detail below) may be fitted between the protrusions 131 and 141 .
The first and the second terminals 130 and 140 may be formed with the same material. The first and second terminals 130 , 140 may be, or may include, copper. The rechargeable battery 100 may be a lithium battery, a lithium ion battery, etc. In an embodiment, the positive current collector, the first lead member 115 , and the first fixture 121 may be, or may include, aluminum. The negative current collector, the second lead member 116 and the second fixture 122 may be, or may include, copper.
As described in detail below, the rechargeable battery 100 according to an embodiment may reduce or eliminate galvanic corrosion. In this regard, where the first and the second terminals 130 and 140 are formed with copper, galvanic corrosion may be generated between the copper first terminal 130 and the first fixture 121 , which may be, or may include, aluminum. Meanwhile, if the first and the second terminals 130 and 140 are formed with aluminum, galvanic corrosion may be made between the second terminal 140 and the second fixture 122 , which may be, or may include, copper. Moreover, the galvanic corrosion between dissimilar metals may be further worsened when the potential difference is large, and the copper metal having a low ionization tendency is used as the negative electrode 112 , while the aluminum metal having a high ionization tendency is used as the positive electrode 111 . As copper and aluminum are largely differentiated in ionization tendency from each other, the possibility of galvanic corrosion is increased at the aluminum metal.
If galvanic corrosion is made between the terminals 130 and 140 and the fixtures 121 and 122 , the contact resistance between the terminals 130 and 140 and the fixtures 121 and 122 may increase. Accordingly, the output of the rechargeable battery 100 may be deteriorated.
In accordance with the present example embodiment, the case where the first and the second terminals 130 and 140 are formed with copper will now be described with reference to FIG. 2 and FIG. 3 .
A corrosion resistance member 150 may be installed between the first terminal 130 and the first fixture 121 in order to prevent galvanic corrosion. In an implementation, the corrosion resistance member 150 may be omitted from the second terminal 140 , as the materials connected at the second terminal 140 may all be the same, e.g., copper or including copper. The corrosion resistance member 150 may have a tube portion 151 , and a head portion 153 formed at the top end of the tube portion 151 and having a cross section larger than the tube portion 151 . The first terminal 130 may have a first hole 132 at a central region for receiving the tube portion 151 , and a second hole 134 communicating with the first hole 132 with a diameter greater than the first hole 132 to receive the head portion 153 .
The corrosion resistance member 150 may have a hole 156 , for receiving the first fixture 121 , that is formed along the whole of the tube portion 151 and the head portion 153 .
The pillar-shaped first fixture 121 may be inserted into the hole 156 and the cap plate 120 , and pressed so as to form the top head 121 b and the bottom head 121 c.
The corrosion resistance member 150 may be formed of a material having an ionization tendency that is between that of the material for the first terminal 130 and that of the material for the first fixture 121 . With a difference in ionization tendency between the first terminal 130 and the corrosion resistance member 150 , as well as between the first fixture 121 and the corrosion resistance member 150 , each being smaller than the difference in ionization tendency between the corrosion resistance member 150 and the first terminal 130 , the galvanic corrosion occurring at the first terminal 130 and the corrosion resistance member 150 may be reduced.
In an implementation, taking as an example a case where the first terminal 130 is formed with copper and the first fixture 121 is formed with aluminum, the corrosion resistance member 150 may be formed with, e.g., nickel, stainless steel, nickel-plated copper, or a clad metal of Al—Cu, Ni—Cu, or Al—Ni, etc., having ionization tendencies between the copper and the aluminum metals. As particular examples, nickel and stainless steel are higher in ionization tendency than copper but lower than aluminum, and have excellent corrosion resistance.
As described above, with the present example embodiment, even in case the first terminal 130 and the first fixture 121 are formed with different materials, the galvanic corrosion occurring between the first terminal 130 and the first fixture 121 can be reduced. Furthermore, by forming the first terminal 130 and the first fixture 121 with different materials, it is possible to form the first terminal 130 and the second terminal 140 with the same material. This may substantially simplify the electrical connection of multiple batteries in a battery module.
FIG. 3 illustrates an enlarged view of the first terminal 130 . It will be appreciated that the second terminal 140 can be formed using the same structures for preventing galvanic corrosion, if necessary or desired as a result of the materials used for the second terminal 140 and corresponding fixing member and electrode. Accordingly, a detailed description of such galvanic corrosion preventing structures will not be repeated for the second terminal 140 .
FIG. 4 illustrates an exploded perspective view of a battery module according to a second example embodiment, and FIG. 5 illustrates a cross-sectional view of the battery module taken along the V-V line of FIG. 4 .
Referring to FIG. 5 , the battery module 200 according to the present example embodiment may include a plurality of rechargeable batteries 100 . Respective connection members 160 may be used to electrically interconnect the rechargeable batteries 100 . The rechargeable batteries 100 may be arranged in parallel as a stack of batteries. The rechargeable batteries 100 may be electrically coupled to each other in series by way of the connection members 160 . In another implementation, the rechargeable batteries 100 may be electrically coupled to each other in parallel.
A high-capacity rechargeable battery module may be formed using a plurality of rechargeable batteries 100 electrically coupled to each other in series and/or parallel. The rechargeable batteries 100 may have a cylindrical shape, a prismatic shape, etc.
In the battery module, the connection members 160 may be attached to the positive and the negative terminals by way of resistance welding. Preferably, the positive and negative terminals are formed of a same material. For example, terminals 130 and 140 may each be, or may each include, copper. This may allow for a simple resistance welding process to be used, as it may be hard otherwise to weld dissimilar metals to each other where the positive and the negative terminals are formed with different materials. In this regard, if the connection member is formed with a material different from the positive and/or negative terminals, the melting points of the connection member and the positive and/or negative terminals may be different from each other so that it becomes hard to attach the connection member and the terminals to each other through welding. Further, if dissimilar metals contact each other, galvanic corrosion is more likely to occur between the dissimilar metals, and accordingly, the contact resistance between the dissimilar metals may increase.
In the battery module 200 according to the present example embodiment, the first and the second terminals 130 and 140 of the adjacent rechargeable batteries 100 may be disposed next to one another. Thus, the connection member 160 may be welded to the first terminal 130 of one rechargeable battery 100 and the second terminal 140 of the other rechargeable battery 100 .
The connection member 160 may be generally plate-shaped. In an implementation, grooves 162 are formed at both ends of the connection member 160 in order to pass the top head portions 121 b and 122 b of the fixtures 121 and 122 . The connection member 160 may be fitted between the protrusions 131 and 141 of the terminals 130 and 140 . The protrusions 131 and 141 of the respective terminals 130 , 140 and the connection member 160 may be welded to each other such that welded portions 165 are formed at the contact regions between the connection member 160 and the terminals 130 and 140 . The connection member 160 may be formed with the same material as the terminals 130 and 140 . For example, the connection member 160 , the first terminal 130 of one battery and the second terminal 140 of the adjacent battery may each be, or may each include, copper. In an implementation, the terminals 130 and 140 may be copper, and the connection member 160 may also be copper. In another implementation, the terminals 130 and 140 may be aluminum, and the connection member 160 may also be aluminum.
In the present example embodiment, in case that the terminals 130 and 140 and the connection member 160 are formed with the same material, the connection member 160 may be easily attached to those terminals by way of laser welding or resistance welding. Furthermore, when the connection member 160 is formed with copper, having a high electrical conductivity and a low resistivity, the resistance may be reduced so that the total output of the battery module 200 is enhanced. When the connection member 160 and the terminals 130 and 140 are attached to each other by way of welding, the contact resistance between the terminals 130 and 140 and the connection member 160 may be prevented from increasing from impact or external vibration.
FIG. 6 illustrates a partial sectional view of a battery module according to a third example embodiment.
The battery module 400 according to the present example embodiment may include a plurality of rechargeable batteries 300 , and respective connection members 170 electrically interconnecting the rechargeable batteries 300 .
The battery module 400 according to the present example embodiment may have the same structure as the battery module 200 according to the first example embodiment except for the structure of a first terminal 180 and the connection member 170 . Descriptions of same elements as the battery module 200 will not be repeated.
The first terminal 180 may be electrically connected to an electrode assembly 110 by way of the first fixture 121 , e.g., a rivet, and fixed to the cap plate 120 . The first fixture 121 may be electrically connected to the electrode assembly 110 via a first lead member 115 .
As with the first example embodiment, the first terminal 180 of one rechargeable battery 300 and an adjacent second terminal 140 of the rechargeable battery 300 neighboring thereto may be electrically connected to each other by way of the connection member 170 . The first terminal 180 and the second terminal 140 may be formed with the same material. For example, the first and second terminals 180 , 140 may each be, or may each include, copper. The connection member 170 may be formed of the same material as the first and second terminals 180 , 140 . The connection member 170 may be fitted between protrusions 181 of the first terminal 180 and protrusions 141 of the terminals 180 and 140 , and welded to the protrusions 181 and 141 of the second terminal and 140 . Welded portions 175 may be formed at the contact regions between the terminals 180 and 140 and the connection member 170 . A groove 172 , e.g., a recess, may be formed at the bottom side of the connection member 170 in order to receive the top head 121 b of the first fixture 121 . The top surface of the groove 172 may cover the top head 121 b.
The first terminal 180 may be plate-shaped, and protrusions 181 may be formed at both lateral ends of the first terminal 180 . A corrosion resistance layer 185 may be formed, e.g., by a deposition process such as plating, at the contact area between the first terminal 180 and the first fixture 121 . The deposition process may be, e.g., vapor deposition, sputtering, electroplating, electroless plating, etc. The corrosion resistance layer 185 may be formed with a material having an ionization tendency between that of the material for the first terminal 180 and the material for the first fixture 121 .
With a difference in ionization tendency between the corrosion resistance layer 185 and the first terminal 180 , and the difference in ionization tendency between the corrosion resistance layer 185 and the first fixture 121 , each being smaller than the difference in ionization tendency between the first terminal 180 and the first fixture 121 , the galvanic corrosion made at the first terminal 180 and the corrosion resistance plating layer 185 may be reduced.
In an implementation, the corrosion resistance layer 185 may be formed on the first terminal 180 by way of plating. Thus, a gap may be avoided between the first terminal 180 and the corrosion resistance layer 185 , and, hence, galvanic corrosion made at the first terminal 180 may be further reduced. In an implementation, the corrosion resistance layer 185 may not be formed at the contact area between the connection member 170 and the first terminal 180 . Accordingly, the connection member 170 and the first terminal 180 may contact each other directly, such that the resistance between the connection member 170 and the first terminal 180 may not be increased due to the corrosion resistance layer 185 .
In a specific example according to the present embodiment, the first terminal 180 is formed with copper, the first fixture 121 is formed with aluminum, and the corrosion resistance layer 185 is formed with nickel, nickel having an ionization tendency between copper and aluminum. As nickel is greater in ionization tendency than copper but smaller than aluminum and has excellent corrosion resistance, it may reduce the occurrences of corrosion in a stable manner.
Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. For example, features have been described herein as being formed of a particular material relative to a material of an adjacent contacting feature. However, such particular materials may be a surface coating. For example, a connection member may have a coating of copper or a copper-containing alloy, rather than being formed of copper of the copper-containing alloy. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims. | A battery includes a battery case, an electrode assembly in the battery case, the electrode assembly including a first electrode, a first terminal exposed to an exterior of the battery case, the first terminal being electrically connected to the first electrode, a first fixing member mechanically coupling the first terminal to the battery, the first fixing member forming at least part of an electrical path from the first terminal to the first electrode, and a corrosion resistance member providing an electrical path from the first terminal to the first fixing member and being in direct contact with each of the first terminal and the first fixing member. | 7 |
CROSS REFERENCE TO RELATED APPLICATION:
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/084,001 filed on Jul. 28, 2008, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an electronic tag housing used to support an electronic tag. More particularly, the present invention relates to a housing, which supports an electronic tag and which may be secured to variously configured containers, such as containers having curved surfaces, using suction.
BACKGROUND OF THE INVENTION
[0003] It is widely known to use electronic tags for various purposes. Electronic article surveillance (EAS) tags as well as radio frequency identification (RFID) tags are used for purposes such as tracking sales and shipments of products to which they are attached. They also may be used to provide theft deterrence to articles to which they are attached.
[0004] It is desirable to provide a single electronic tag housing, which may be easily applied to a variety of products with different shaped surfaces, such as cylinders of various sizes and both flat and curved surfaces. The efficient use of such electronic tags requires the tag to be securely attached to the desired article to prevent inadvertent or unauthorized removal therefrom. However, to function effectively in the retail market, it is desirable to have the tag be quickly and efficiently removed from the article so that the purchaser can remove the article from the purchased location, especially when the tags are used in combination with article surveillance.
[0005] It is, therefore, desirable to provide an electronic tag housing of this type, which can easily be manufactured and applied, yet remain securely attached.
SUMMARY OF THE INVENTION
[0006] The present invention provides an electronic tag housing assembly for attaching to an article surface. The assembly includes a housing, having a base and a cover overlying the base for support of a tag therebetween. A suction cup is secured to the base having an upper surface and an opposed lower suction surface for suction attachment to the article surface, and an adhesive is applied to the lower suction surface.
[0007] The present invention further provides a combination of an article with an article surface, a housing, an electronic tag supported within the housing, and a suction cup. The housing includes a base and a cover. The cover overlies the base and supports the tag therebetween. The suction cup is secured to the base. The suction cup has an upper surface and an opposed lower surface for suction attachment to the article surface. The lower suction surface includes an adhesive thereon for adhesively securing the lower suction surface to the article surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1A , 1 B, and 1 C shows an exploded perspective view of the components of the electronic tag housing assembly of the present invention.
[0009] FIGS. 2A , 2 B, 2 C, and 2 D show isometric, side, top, and bottom views of the electronic tag housing assembly fully assembled.
[0010] FIGS. 3A , 3 B, and 3 C show a front, a side, and an enlarged view of the electronic tag housing assembly attached to a compressed gas cylinder.
[0011] FIG. 4 shows the electronic tag housing assembly attached to a box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] The present invention provides a tag housing assembly including a housing, which supports an electronic tag, for example, an electronic article surveillance (EAS) tag or radio frequency identification (RFID) tag. The housing is attachable to an article so as to maintain the tag with the article to track shipment, purchase and/or to provide theft deterrence.
[0013] The tag housing assembly of the present invention supports a flexible suction cup, which may be suction attached to an article. The suction cup enables the housing to be attached to a variety of containers including both curved and flat containers. While the housing may be used in combination with any desired article, the present invention is particularly useful with articles having curved surfaces, such as compressed gas cylinders.
[0014] FIGS. 1A and 1B show the components of a tag housing assembly 10 . With reference to FIG. 1A , the tag housing assembly 10 of the present invention includes a housing 12 , an electronic tag 14 , and a suction cup 16 . The housing 12 further includes a base 18 and a cover 20 overlying the base 18 to support the tag 14 . The suction cup 16 includes a lower suction surface 22 that attaches to an article and an upper surface 24 with a post 26 to receive the housing 12 .
[0015] In the present embodiment, the tag 14 is a generally planar member, which may function as an EAS tag or an RFID tag, as is well known in the art. Other configurations and types of electronic tags 14 are also contemplated within the scope of the present invention.
[0016] The tag housing 12 is generally a planar shaped two-piece member including the base 18 and the cover 20 . The base 18 may include a cavity 28 formed therein. The cavity 28 is configured to accommodate the tag 14 therein. The cover 20 is positionable over the base 18 and is attached thereto to cover and enclose the tag 14 within the cavity 28 of the base 18 . The cover 20 is attached to the base 18 by any well known attachment technique, such as friction fit, adhesive, sonic welding, and the like.
[0017] The base 18 includes a suction cup catch 30 that attaches the base 18 to the suction cup 16 using the post 26 located on the upper surface 24 of the suction cup 16 . The catch 30 is attached to the base 18 by any well known attachment technique, such as friction fit, adhesive, sonic welding, and the like. It is contemplated however, that the catch 30 may also be integrally formed with the base 18 . A suction cup lock 32 is configured for engagement with the catch 30 and used to secure the post 26 to the base 18 . Preferably, the lock 32 is attached to the catch 30 in a non-removable fashion. For example, the lock 32 may include one way spring fingers 32 a that engage with a mating structure (not shown) on the catch 30 to non-removably secure the lock 32 to the catch 30 .
[0018] FIG. 1B , shows a lower surface of the suction cup 16 . The lower surface 22 of the suction cup 16 contains an adhesive 34 to securely attach the housing assembly 10 to an article surface. In a preferred embodiment shown in FIGS. 1A and 1B a coating of the adhesive 34 is applied directly to the lower surface 22 of the suction cup 16 with a removable release strip 36 and a protective film 38 overlaying the adhesive 34 . When the release strip 36 and the protective film 38 are removed from the lower suction surface 22 , the suction cup 16 may be attached to the article surface by the suction cup 16 and secured by the adhesive 34 . The adhesive 34 may include any variety of well known adhesives 34 .
[0019] The invention also contemplates using a separately applied adhesive 34 , such as a two sided disc 35 , with the removable release strips 36 and the protective film 38 on both sides of the disc 35 , as shown in FIG. 1C . The two sided disc 35 may include a first side 37 of the disc 35 for adhesive attachment to the lower suction surface 22 and a second side 39 of the disc 35 for adhesive attachment to the article surface.
[0020] Referring to FIGS. 2A-2D , the electronic tag housing assembly 10 is more fully shown. FIG. 2A shows an isometric view 40 of the tag housing assembly 10 with the housing 12 assembled and attached to the suction cup 16 . FIG. 2B shows the side view 50 of the tag housing assembly 10 with the suction cup lock 32 visible. A top view 60 of the tag housing assembly 10 is shown in FIG. 2C . FIG. 2D shows a bottom view 70 of the tag housing assembly 10 with the adhesive 34 , the release strip 36 , and the protective film 38 on the lower surface 22 of the suction cup 16 .
[0021] FIGS. 3A-3C show the electronic tag housing assembly 10 attached to a compressed gas cylinder 80 , having a non-flat or curved article surface 82 . In one embodiment of the present invention, the tag housing assembly 10 is attached to the curved article surface 82 by removing the release strip 36 and the protective film 38 that covers the adhesive 34 on the lower suction surface 22 , attaching the suction cup 16 to the curved article surface 82 , and securing the tag housing assembly 10 to the curved article surface 82 by both suction and adhesion. This embodiment shows the flexible nature of the suction cup 16 which allows it to conform to the curved surface of the cylinder 80 . While a suction attachment is achieved between the suction cup 16 and the curved article surface 82 of the cylinder 80 , the primary attachment is by adhesive attachment of the suction cup 16 to the cylinder 80 .
[0022] FIG. 4 shows a further embodiment of the electronic tag housing assembly 10 attached to a box 90 , having a flat article surface 92 . In one embodiment, the tag housing assembly 10 is attached to the flat article surface 92 using a two sided disc 35 . First, the release strip 36 and the protective film 38 are removed from the first side 37 of the disc 35 and the first side 37 of the disc 35 is attached to the lower suction surface 22 . Then, the release strip 36 and the protective film 38 are removed from the second side 39 of the disc 35 and the second side 39 of the disc 35 is attached to the flat article surface 92 by both suction and adhesion.
[0023] The present invention further allows authorized personnel to remove the tag housing assembly 10 from the product by removing the lock 32 from the catch 30 and separating the suction cup 16 and the housing 12 .
[0024] Various changes to the foregoing described and shown structures would now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims. | An electronic tag housing which may be secured to variously configured containers, such as containers having curved surfaces. The housing could have a base and a cover overlying the base for support of a tag therebetween. A flexible suction cup is secured to the base, the suction cup has an upper surface and an opposed lower suction surface for suction attachment to the article surface. An adhesive is applied to the lower suction surface for additional attachment to the suction cup to the curved surface. | 4 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to an apparatus for measuring fluid levels in a container, and more particularly, to measuring fluid levels optically.
BACKGROUND OF THE INVENTION
[0002] There are numerous applications where it is necessary to measure an amount of fuel in a container.
[0003] U.S. patent application Ser. No. 10/955,485, “Method and system for encoding fluid level” filed by Holcomb et al. on Sep. 30, 2004 and issued as U.S. Pat. No. 6,992,757, describe a float riding on the surface of a fluid. The float is mechanically coupled to a rotating encoder disk which is segmented with optically transparent and opaque regions. A set of light emitting diodes (LEDs) are aligned with photo sensors on the other side of the disk So that the fluid level can be encoded as the disk rotates as the float moves up and down.
[0004] U.S. patent application Ser. No. 10/800,484, “Optical fluid level monitor” filed by David Corven et al. on Mar. 15, 2004, describes an optical sensor that includes a display, a light pipe optically connected to the display and extending to a level of interest in the reservoir, where the light pipe is formed from a material having a refractive index higher than air's refractive index and less than or equal to the liquid's refractive index; and a light optically connected to the light pipe. The light pipe can be a glass or plastic rod, or a bundle of optical fibers.
[0005] U.S. patent application Ser. No. 10/267,965, “Fluid container with level indicator, and fluid level indicator assembly for a fluid container,” filed by Lee et al. on Oct. 9, 2002, describes fluid level sensor that includes a visual display of a fluid level in a container using multiple capillary tubes terminating at different vertical levels from one another in the container.
[0006] U.S. patent application Ser. No. 10/265,954, “LCC-based fluid-level detection sensor” filed by Shi et al. on Oct. 7, 2002 and issued as U.S. Pat. No. 6,949,758, describes a fluid level sensor based on light communication channel (LCC) technology. One end of the LCC is connected to a signal source while another end is connected to a sensor. The LCC is dipped in a fluid container and a signal propagates and undergoes internal reflection through the LCC towards one of its ends which is connected to the sensor. The fluid level is detected by measuring an intensity of the signal reflected with the LCC that reaches a sensor.
[0007] U.S. Pat. No. 5,852,946, “Method and apparatus for detecting fluid level” issued Cowger on Dec. 29, 1998, describes a fluid level detector for providing a signal indicative of fluid level in a fluid container. The fluid level detector includes a first light conduit portion for providing light to fluid within the fluid container. A second light conduit portion is provided for receiving light provided by the first light conduit portion. Also included is a light path extending from the first light conduit portion to the second conduit portion. The light path has a light path length, which varies with an amount of fluid within the fluid container. The light path length variation produces light intensity variation at the second conduit portion which is indicative of fluid level in the fluid container.
[0008] U.S. Pat. No. 5,747,824, “Apparatus and method for sensing fluid level” issued to Jung et al. on May 5, 1998, describes an array of infrared LEDs and an array of photo sensors are positioned vertically in a cassette. A vertical line on which the LEDs are arranged is substantially parallel to a direction in which the fluid level is within the cassette. The LEDs are aimed upwardly at an angle of approximately 20 degrees from horizontal so the a beam of light does not penetrate the fluid/air interface.
[0009] The Jung system can be distinguished according to a number of characteristics. First, for each level to be measured that system requires a light source and sensor pair for each fluid level to be detected. Second, the system cannot detect how far below or above the fluid level is for a single source/sensor pair. Third, for accurate readings of multiple levels a baffle is required to block energy at various angles. For fluids that can scatter light, adjacent sensors need to be properly oriented.
SUMMARY OF THE INVENTION
[0010] The embodiments of the invention provide a fluid level sensor. Optical structures block transmission of light beam only when the fluid is within a certain level range. The structures can be serially stacked to construct encoder channels, which respond to fluid levels in multiple ranges. Multiple stacks can be combined to construct incremental, absolute, or any of a variety of standard encoder topologies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1-6 are block diagrams of light pipes for measuring fluid levels according to an embodiment of the invention;
[0012] FIG. 7 is a block diagrams of a light pipe for measuring fluid levels according to an embodiment of the invention with a seven segment display;
[0013] FIG. 8 is a perspective diagram of the light pipes of FIG. 6 ; and
[0014] FIG. 9 is a side view of a light pipe for an irregularly shaped container.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] The embodiments of our invention provide an optical fluid level encoder for measuring a level of fluid in a container.
[0016] FIG. 1 shows a structure of a basic “building block” component of our encoder. A container 100 is partially filled with a fluid 101 and air 102 . A fluid level is 105 .
[0017] A light pipe 150 is arranged at an angle in the container. The light pipe 150 includes a light source 110 , e.g., a LED, a light sensor 120 , e.g., a photo detector. It should be noted that the positions of the source and sensor can be reversed.
[0018] The light pipe also includes one or more optical conduits 130 . In this embodiment, the two optical conduits are separated by a gap 135 . A length of the optical conduits and gap(s) can be precisely controlled. In the preferred embodiment, the optical conduits are constructed of cylindrical transparent acrylic rods of different lengths. The diameter of the rods is about 5 mm.
[0019] In the preferred embodiment, the diameter of the rod is made the same as the diameter of the LED 110 and the phototransistor 120 to facilitate assembly of the encoder, see FIG. 9 .
[0020] As an advantage, any light beam entering the conduits at one end exits the conduits at the opposite end due to total internal reflection. Total internal reflection occurs when light beam is refracted at the medium boundary of the conduit to effectively reflect all of the light back into the conduit. Therefore, the conduits can be curved, see FIG. 9 .
[0021] Optional means 160 for indicating or measuring a light intensity is connected to the light sensor. The encoded output value can be “0” (off) or “1” (on), or some continuous value as described below. The artisan skilled in the art will recognize that the means 160 can be any measurement component, e.g., electrical, optical, and mechanical. It should also be noted that the sensor 120 , can be passive, a translucent rod that is visible. In this case, the light beam will be visible in the sensor as long as the light beam penetrates the sensor.
[0022] The optical conduits is arranged between the light source and the light sensor along a path of the light beam, such that at least one part of the light beam passes through the optical conduit, and at least an other part of the light beam passes through the fluid when the container holds the fluid. It should be noted that the light beam can be any optical signal including visible light, infrared, ultraviolet, or in the form of a laser beam.
[0023] As shown in FIG. 1 , the level of the fluid 101 is below the gap 135 . Therefore, light beam 111 emitted by the source 110 is sensed, and it can be deduced that the fluid level range 105 is either below the gap 135 or above the gap 135 , i.e., the container is almost empty or almost full.
[0024] As shown in FIG. 2 , the level of the fluid 101 is above the gap 135 . Therefore, the light beam 111 emitted by the source 110 will be sensed, and it can be deduced that the fluid level range 105 is above the gap 135 or below the gap 135 ; again, the container is almost empty or almost full.
[0025] As shown in FIG. 3 , the level of the fluid is in the gap. Therefore, the light is reflected at the fluid/air interface and no light is sensed, and it is possible that the fluid level range 105 is in the gap 135 . For an air/water interface, the critical angle for internal reflection is 48.75° or greater.
[0026] By precisely cutting the lengths of the optical conduits, it is possible to construct a fluid level encoder that can maintain the fluid level over a small range of values, e.g., only the values where the fluid level is in the gap.
[0027] During operation, as the fluid level rises, the level indicator can be incremented each time a gap is reached, and as the fluid level falls, the level indicator can be decremented. Thus, the configuration shown in FIG. 3 can indicate three different ranges of levels of fluid.
[0028] FIGS. 4A , 4 B, and 4 C show alternative arrangements with a single optical conduit. If the fluid level is in the range of the optical conduit, the output of the encoder is logical “1” or “on”, and logical “0” or “off otherwise.
[0029] The fluid level encoder will always be on when the container is almost empty in FIG. 4A , half full for Figure B, and almost full for FIG. 4C .
[0030] FIG. 5 shows an arrangement where the light pipe has multiple, e.g., six optical conduits, and five corresponding gaps to indicate eleven different fluid levels.
[0031] Stacked Light Pipes
[0032] In another embodiment of the invention as shown in FIG. 6 , multiple light pipes 601 are “stacked” adjacently in the container, with the optical conduits and gaps being of different lengths. Thus, it is possible to construct an optical fluid level encoder. There is no necessity of stacking in any particular direction, as long as the liquid-air interface 105 covers and uncovers the optical conduits ends in an order needed to generate the desired output sequence. In one preferred embodiment, this output sequence is a Gray code.
[0033] Gray Code
[0034] A Gray code provide an encoding of 2 n binary numbers such that only one bit changes from one value to the next. As an advantage, Gray codes are useful encoding fluid levels because a slight position change in the fluid level only affects one bit. In a conventional binary code, up to n bits can change as the fluid level rises or falls across a single dividing line, and a slight misalignments of the measuring device can cause extremely incorrect level readings.
[0035] For example, moving from level 7 to level 8 , i.e., that is, 0111 to 1000 in binary, can result in any of the 16 possible results from 0000 to 1111 as an intermediate state, depending on the slightest misalignment in the individual detectors for a 0 and a 1 in each of the four channels. Because a Gray code changes only one bit at a time, the worst case error is a single count in either direction, and that error only exists for the maximum permitted assembly misalignment of the assembly during manufacture.
[0036] A binary-reflected Gray code for n bits can be constructed by taking a Gray code for n-1 bits, and repeating it in reverse order, then prepending a zero to all values in the first half of the new code and a 1 to all values in the second half of the new code.
[0000]
For example, a 2-bit Gray code is:
00
01
11
10.
Repeating the code again, in reverse order, yields:
00
01
11
10
10
11
01
00.
Prepending a zero to each value in the first half yields:
000
001
011
010
10
11
01
00.
and prepending a 1 to each value in the second half yields:
000
001
011
010
110
111
101
100,
which is a valid three-bit Gray code. This process can be repeated
indefinitely to yield Gray codes of any desired length and resolution.
Note that the above Gray code is not the only possible one; for
example, rotations of a valid Gray code yield other valid Gray codes. In
the above example, we can rotate the 2-bit code
00
01
11
10
to
01
00
10
11,
which yields the 3-bit code:
001
000
010
011
111
110
100
101.
[0037] FIG. 6 shows an optical fluid level encoder with three light pipes for encoding according to the above described three-bit rotated Gray code. For the fluid level shown in FIG. 6 , the Gray code is code 011.
[0038] It should be understood that other types of codes can also be encoded; the codes need not be absolute codes such as binary or Gray codes. Quadrature codes can be used, as can virtual absolute codes, where a quadrature code provides high resolution, and a third code line provides a unique sequencing signature. As the fluid level changes slightly, the state of the unique sequencing code line yields a unique sequence that can only occur in one position, thus giving an absolute level with only three channels of data.
[0039] FIG. 8 shows how the light pipes can be stacked. A housing 810 is formed of, for example, plastic. The housing includes parallel channels 811 . A part 812 of the channels is slightly rounded so that the optical conduits 130 , light sources 110 and sensors 120 can be snapped into the channels.
[0040] Direct Digital Reading Fluid Level Device
[0041] Other embodiments are also possible as shown in FIG. 7 . In one embodiment, the light pipes readout is entirely optical. FIG. 7 shows a conventional seven segment numerical display device is often used to indicate numeric digits, e.g., 4. To generate a numeric display of the fluid level, we determine which segments should be lit for which fluid level range, and then stacks appropriately arranged light pipes to generate this pattern. The light emerging light from each stack can then be optically directed to the appropriate segment of the display. This arrangement gives a numeric reading of the fluid level using only light. No moving parts or electronics circuits are required, other than the power to the light sources.
[0042] Irregularly Shaped Containers
[0043] As an advantage, the fluid level encoder as described herein can also be used with irregular shaped containers as shown in FIG. 9 . With such containers, it is impossible to use conventional mechanical sensors such as floats, or optical sensors that require a direct line of sight from the light source to the sensor. Here, the conduits 140 “bend” the light from the source 110 , around corners, to the sensor 120 . Note, in portions of the light pipe where the fluid level does not change much, the number of conduits can be sparse.
[0044] Although the invention has been described by way of examples of preferred embodiments, it is to be understood that various other adaptations and modifications can be made within the spirit and scope of the invention. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention. | An apparatus measures a fluid level in a container. A light source emits a light beam. A light sensor can sense the light beam. An optical conduit is arranged in a container for holding fluid. The optical conduit is arranged between the light source and the light sensor along a path of the light beam, such that at least one part of the light beam passes through the optical conduit, and at least an other part of the light beam passes through the fluid when the container holds the fluid. The sensor senses the light beam when a level of the fluid coincides with the one part of the light beam passing through the optical conduit, and the sensor does not sense the light beam when the level of the fluid coincides with the other part of the light beam passing through the fluid due to internal reflection at the fluid level. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for detecting deterioration of a catalyst installed in an exhaust passage of an internal combustion engine for exhaust gas purification.
2. Description of the Related Art
Three-way catalysts for simultaneously promoting the oxidation of unburned constituents (HC and CO) and the reduction of nitrogen oxides (NO x ) in automotive exhaust have been used on automotive engines to control exhaust emissions. For a maximum oxidation/reduction efficiency of the three-way catalyst, the air-fuel ratio (A/F), a measure of engine combustion state, must be controlled within a very narrow range (called the window) and centered on stoichiometry. To achieve this, in fuel injection control in an engine, an O 2 sensor (oxygen concentration sensor--see FIG. 1) is mounted and detects whether the air-fuel ratio is on the lean side or rich side with respect to stoichiometry on the basis of the concentration of residual oxygen in the exhaust gas, and air-fuel ratio feedback control is performed to correct the quantity of fuel based on the sensor output.
In such air-fuel ratio feedback control, the O 2 sensor for detecting the oxygen concentration is mounted as close as possible to the combustion chamber, that is, on the upstream side of the catalytic converter. Furthermore, to compensate for variations in the output characteristic of the O 2 sensor, a double O 2 sensor system having a second O 2 sensor on the downstream side of the catalytic converter has also been introduced for commercial use. The principle of this system is based on the fact that, on the downstream side of the catalytic converter, the exhaust gas is thoroughly stirred, and its oxygen concentration is almost in equilibrium by the action of the three-way catalyst; consequently, the output of the downstream O 2 sensor changes only slightly compared with the upstream O 2 sensor, and thus indicates whether the air/fuel mixture as a whole is on the rich side or lean side. In the double O 2 sensor system, sub air-fuel ratio feedback control is performed using the O 2 sensor downstream of the catalyst in addition to the main air-fuel ratio feedback control by the O 2 sensor upstream of the catalyst, and the coefficient for air-fuel ratio correction by the main air-fuel ratio feedback control is corrected based on the output of the downstream O 2 sensor, to accommodate variations in the output characteristic of the upstream O 2 sensor and thereby improve the precision of air-fuel ratio control.
Even when such precise air-fuel ratio control is performed, if the catalyst deteriorates due to exposure to exhaust gas heat or is poisoning by lead and other contaminants, a sufficient exhaust gas purification performance cannot be obtained. To address this problem, a variety of catalyst deterioration detection devices have been proposed in the prior art. One such device diagnoses the deterioration of the catalyst by detecting a decrease in the O 2 storage effect (the function to store excessive oxygen and reuse it for the purification of unburned exhaust emissions) after warmup using an O 2 sensor mounted on the downstream side of the catalyst. That is, deterioration of the catalyst leads to a degradation in the purification performance, and the device deduces the degradation of the purification performance from a decrease in the O 2 storage effect; more specifically, by using an output signal from the downstream O 2 sensor, the device obtains response curve length, feedback frequency, etc. and detects the decrease of the O 2 storage effect and hence, the deterioration of the catalyst. In one specific example disclosed in Japanese Patent Unexamined Publication No. 5-98948 (corresponding U.S. Pat. No. 5,301,501), the length of the response curve of the output of the downstream O 2 sensor is obtained during feedback control toward stoichiometry, and by comparing its response curve length or the ratio of that length to the response curve length of the upstream O 2 sensor with a reference value, the deterioration of the catalyst is determined.
On the other hand, recent years have also seen the development of an internal combustion engine in which the air-fuel ratio is controlled so that the three-way catalyst can provide a constant and stable purification performance. That is, the O 2 storage capability is such that, when the exhaust gas is in a lean state, excessive oxygen is adsorbed, and when the exhaust gas is in a rich state, the necessary oxygen is released, thereby purifying the exhaust gas; however, such a capability is limited. To make effective use of the O 2 storage capability, therefore, it is important to maintain the amount of oxygen stored in the catalyst at a prescribed level (for example, one-half the maximum oxygen storage amount) so that the next change in the air-fuel ratio of the exhaust gas can be accommodated, whether it is a change to a rich state or a lean state. When the oxygen amount is maintained in this manner, a consistent O 2 adsorption/desorption function can be achieved, thus ensuring a consistent oxidation/reduction performance of the catalyst.
In the internal combustion engine in which the O 2 storage amount is controlled at a constant level to maintain the purification performance of the catalyst, an air-fuel ratio (A/F) sensor (see FIG. 2) capable of a linear detection of air-fuel ratio is used, and feedback control (F/B control) is performed based on proportional and integral operations (PI operations). That is, a feedback fuel correction amount is calculated by
Next fuel correction amount=K p *(Present fuel error)+K s *Σ(previous fuel errors)
where
Fuel error=(Fuel amount actually burned in cylinder)-(Target fuel amount in cylinder with intake air at stoichiometry)
Fuel amount actually burned in cylinder=Detected value of air amount/Detected value of air-fuel ratio
K p =Proportional gain
K s =Integral gain
As can be seen from the above equation for the fuel correction amount, the proportional term is the component that acts to maintain the air-fuel ratio at stoichiometry, as in the feedback control using an O 2 sensor, while the integral term is the component that acts to eliminate the steady-state error (offset). That is, by the action of the integral term, the O 2 storage amount in the catalyst is maintained at a constant value. For example, as shown in FIG. 3, when enleanment occurs as a result of abrupt acceleration or the like, the air-fuel ratio is enriched by the action of the integral term, offsetting the effect of the enleanment. Control performed to intentionally vary the air-fuel ratio in this manner in order to maintain the O 2 storage amount at a constant level is called counter control.
In such an internal combustion engine equipped with an O 2 storage amount constant control system with an A/F sensor mounted on the upstream side of the catalyst, an O 2 sensor also may be mounted on the downstream side of the catalyst to compensate for variations in the output characteristic of the A/F sensor. In that case also, it will be possible to detect the deterioration of the catalyst by detecting a decrease in the O 2 storage effect of the catalyst by using the O 2 sensor, as in the double O 2 sensor system. For example, Japanese Patent Unexamined Publication No. 6-101455 (corresponding U.S. Pat. No. 5,357,754) discloses an internal combustion engine in which feedback control of the air-fuel ratio is performed based on the output of an A/F sensor mounted upstream of a three-way catalyst, and the deterioration of the catalyst is determined based on the average value and the variation amplitude of the output of an O 2 sensor mounted downstream of the catalyst.
However, when the above catalyst deterioration detection process is applied to the O 2 storage amount constant control system, the following problem will arise. First, in the O 2 storage amount constant control system, counter control is performed as needed, as described above. When the control is performed, the A/F sensor output voltage VAF, and hence the air-fuel ratio, varies widely, as shown in FIG. 4A (No emission perturbations occur since the air-fuel ratio of the gas actually entering the catalyst stays within the window). Furthermore, since the sub feedback control by the O 2 sensor is performed so that the O 2 sensor output is at or very near stoichiometry (see FIG. 1), the output voltage VOS of the O 2 sensor varies greatly with the variation of the air-fuel ratio. In addition, an excessive response occurs due to a sudden change in the gas exposure condition of the O 2 sensor. This can cause erroneous determination if the deterioration of the catalyst is determined based on the length of the response curve of the output of the O 2 sensor, etc.
The following problem will also arise. The amplitude of the swing of the downstream O 2 sensor depends on the variation of the air-fuel ratio of the gas exiting the catalyst, which in turn depends on the variation of the air-fuel ratio of the gas entering the catalyst. Accordingly, even when there is no change in the catalyst performance, if there occurs a change in the amplitude of the variation of the air-fuel ratio of the catalyst entering gas, the amplitude of the swing of the downstream O 2 sensor also changes. When determining the deterioration of the catalyst based on the output of the downstream O 2 sensor, therefore, erroneous determination may result due to changes in the variation amplitude of the air-fuel ratio of the catalyst entering gas. The reason for the occurrence of such erroneous determination will be explained below with reference to drawings.
FIG. 5 is a diagram showing how the output voltage VOS of the downstream O 2 sensor varies for normal catalyst and abnormal (deteriorated) catalyst conditions when the air-fuel ratio variation of the catalyst entering gas is "minimum", "small", "medium", "large", and "maximum", respectively, for convenience's sake (the variation is approximately equal to the output voltage VAF of the A/F sensor, mounted upstream of the catalyst, that linearly detects the air-fuel ratio). When the VAF variation, and hence the VAF curve length LVAF, is "minimum", the VOS variation amplitude, and hence the VOS curve length LVOS, is "minimum" regardless of whether the catalyst condition is normal or abnormal, and the response curve length ratio of LVOS to LVAF is 1.0.
Next, when LVAF is "small", if the catalyst is normal, LVOS remains "minimum" because of the O 2 storage effect, and the response curve length ratio is 0.5; on the other hand, if the catalyst is deteriorated, the O 2 storage effect does not work, and LVOS is "medium", resulting in a response curve length ratio of 2.0. When LVAF is "medium", if the catalyst is normal, LVOS is "small", and the response curve length ratio is 0.2; if the catalyst is deteriorated, LVOS reaches a limit value "large" (the limit of the so-called Z characteristic of the O 2 sensor--see FIG. 1), while the response curve length ratio decreases to 1.5. Next, when LVAF is "large", if the catalyst is normal, LVOS is "medium", and the response curve length ratio is 0.4; if the catalyst is deteriorated, LVOS remains "large", and the response curve length ratio further decreases to 1.0. Finally, when LVAF is "maximum", if the catalyst is normal, LVOS reaches the limit value "large", and the response curve length ratio is 0.6; if the catalyst is deteriorated, LVOS remains "large", and the response curve length ratio further decreases to 0.6.
The distributions of data for the response curve length LVOS and response curve length ratio LVOS/LVAF are respectively shown in FIGS. 6A and 6B. In these figures, numbers (1), (2), . . . , (5) for normal catalyst and 1!, 2!, . . . , 5! for deteriorated catalyst are plotted correspondingly to the numbers in FIG. 5. As can be seen from these figures, if the deterioration of the catalyst is to be determined by simply comparing the response curve length LVOS or the response curve length ratio LVOS/LVAF using the prior art technique, there is a region where the values overlap between the normal and deteriorated catalysts, and in that region, determination of the deterioration of the catalyst is impossible. In this way, even when there is no change in the catalyst performance, if the variation amplitude of the air-fuel ratio of the catalyst entering gas changes, the variation amplitude of the air-fuel ratio of the catalyst exiting gas, and hence the amplitude of the swing of the downstream O 2 sensor, changes; therefore, determining the deterioration of the catalyst based on the output of the downstream O 2 sensor involves a possibility of erroneous determination.
SUMMARY OF THE INVENTION
In view of the above situation, it is an object of the present invention to provide a catalyst deterioration detection device that can determine catalyst deterioration accurately on the basis of the output of an O 2 sensor mounted downstream of the catalyst while preventing erroneous determination due to counter control, for an internal combustion engine in which air-fuel ratio feedback control is performed based on the output of an A/F sensor mounted upstream of the catalyst.
It is another object of the present invention to provide a catalyst deterioration detection device that can determine catalyst deterioration accurately on the basis of the output of an O 2 sensor mounted downstream of the catalyst regardless of the variation amplitude of the air-fuel ratio of a mixture entering the catalyst, for an internal combustion engine in which air-fuel ratio feedback control is performed based on the output of an A/F sensor mounted upstream of the catalyst.
It is a further object of the present invention to improve exhaust gas purification performance and contribute to the prevention of air pollution by establishing a technique that can determine catalyst deterioration accurately by means of an O 2 sensor mounted downstream of the catalyst, for an internal combustion engine in which an O 2 storage amount constant control system using an A/F sensor is employed.
According to a first aspect of the invention, there is provided a catalyst deterioration detection device for an internal combustion engine, comprising: a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability; an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting an air-fuel ratio; air-fuel ratio feedback control means for, based on the output of the air-fuel ratio sensor, calculating a feedback correction amount consisting of a proportional term for bringing the air-fuel ratio to stoichiometry and an integral term for bringing an integrated value of an error between the air-fuel ratio and stoichiometry to zero; an O 2 sensor, mounted downstream of the three-way catalyst, for detecting whether the air-fuel ratio is rich or lean; catalyst deterioration determining means for determining deterioration of the three-way catalyst on the basis of the length of a response curve that the output of the O 2 sensor describes during the time that air-fuel ratio feedback control is being performed by the air-fuel ratio feedback control means; and a response curve length calculation interrupting means for interrupting the calculation of the response curve length being performed by the catalyst deterioration determining means for a predetermined length of time when the output of the air-fuel ratio sensor or the amount of change of the output has exceeded a preset value.
According to a second aspect of the invention, there is provided a catalyst deterioration detection device for an internal combustion engine, comprising: a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability; an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting an air-fuel ratio; air-fuel ratio feedback control means for, based on the output of the air-fuel ratio sensor, calculating a feedback correction amount consisting of a proportional term for bringing the air-fuel ratio to stoichiometry and an integral term for bringing an integrated value of an error between the air-fuel ratio and stoichiometry to zero; an O 2 sensor, mounted downstream of the three-way catalyst, for detecting whether the air-fuel ratio is rich or lean; catalyst deterioration determining means for determining deterioration of the three-way catalyst on the basis of the length of a response curve that the output of the O 2 sensor describes during the time that air-fuel ratio feedback control is being performed by the air-fuel ratio feedback control means; and integral term limiting means for imposing an upper limit on an absolute value of the integral term or on a gain of the integral term when processing for determination is being performed by the catalyst deterioration determining means.
According to a third aspect of the invention, there is provided a catalyst deterioration detection device for an internal combustion engine, comprising: a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability; an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting an air-fuel ratio; first air-fuel ratio feedback control means for, based on the output of the air-fuel ratio sensor, calculating a feedback correction amount consisting of a proportional term for bringing the air-fuel ratio to stoichiometry and an integral term for bringing an integrated value of an error between the air-fuel ratio and stoichiometry to zero; an O 2 sensor, mounted downstream of the three-way catalyst, for detecting whether the air-fuel ratio is rich or lean; second air-fuel ratio feedback control means for correcting the output of the air-fuel ratio sensor on the basis of the output of the O 2 sensor; catalyst deterioration determining means for determining deterioration of the three-way catalyst on the basis of the length of a response curve that the output of the O 2 sensor describes during the time that air-fuel ratio feedback control is being performed by the first air-fuel ratio feedback control means; and air-fuel ratio sensor output correction inhibiting means for inhibiting the correction of the output of the air-fuel ratio sensor by the second air-fuel ratio feedback control means when processing for determination is being performed by the catalyst deterioration determining means.
According to a fourth aspect of the invention, there is provided a catalyst deterioration detection device for an internal combustion engine, comprising: a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability; an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting air-fuel ratio; air-fuel ratio feedback control means for feedback controlling the air-fuel ratio toward stoichiometry on the basis of the output of the air-fuel ratio sensor; an O 2 sensor, mounted downstream of the three-way catalyst, for detecting whether the air-fuel ratio is rich or lean; catalyst deterioration determining means for determining deterioration of the three-way catalyst by comparing the length of a response curve that the output of the O 2 sensor describes or the ratio of the response curve length of the output of the O 2 sensor to that of the output of the air-fuel ratio sensor with a deterioration determination reference value during the time that air-fuel ratio feedback control is being performed by the air-fuel ratio feedback control means; and catalyst deterioration determination limiting means for imposing a limit so that the determination by the catalyst deterioration determining means is carried out only when the response curve length or variation amplitude of the output of the air-fuel ratio sensor is within a prescribed range.
According to a fifth aspect of the invention, there is provided a catalyst deterioration detection device for an internal combustion engine, comprising: a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability; an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting an air-fuel ratio; air-fuel ratio feedback control means for feedback controlling the air-fuel ratio toward stoichiometry on the basis of the output of the air-fuel ratio sensor; an O 2 sensor, mounted downstream of the three-way catalyst, for detecting whether the air-fuel ratio is rich or lean; catalyst deterioration determining means for determining deterioration of the three-way catalyst by comparing the length of a response curve that the output of the O 2 sensor describes or the ratio of the response curve length of the output of the O 2 sensor to that of the output of the air-fuel ratio sensor with a deterioration determination reference value during the time that air-fuel ratio feedback control is being performed by the air-fuel ratio feedback control means; and reference value changing means for changing the deterioration determination reference value according to the response curve length or variation amplitude of the output of the air-fuel ratio sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the present invention will be apparent from the following description with reference to the accompanying drawings, in which:
FIG. 1 is a characteristic diagram showing O 2 sensor output voltage as a function of air-fuel ratio;
FIG. 2 is a characteristic diagram showing A/F sensor output voltage as a function of air-fuel ratio;
FIG. 3 is a diagram for explaining counter control;
FIG. 4A is a time chart illustrating A/F sensor output voltage VAF, and FIG. 4B is a time chart showing O 2 sensor output voltage VOS responding to the VAF;
FIG. 5 is a diagram showing how the output voltage VOS of the O 2 sensor mounted downstream of a catalyst varies for normal catalyst and abnormal catalyst conditions when the air-fuel ratio variation of catalyst entering gas (the output voltage VAF of the A/F sensor mounted upstream of the catalyst) is minimum, small, medium, large, and maximum, respectively;
FIG. 6A is a diagram showing the distribution of data of the output response curve length LVOS of the O 2 sensor in FIG. 5, and FIG. 6B a diagram showing the distribution of data of the ratio of the output response curve length of the O 2 sensor to that of the A/F sensor, LVOS/LVAF, in FIG. 5;
FIG. 7 is a schematic diagram showing the general construction of an electronically controlled internal combustion engine equipped with a catalyst deterioration detection device according to one embodiment of the present invention;
FIG. 8 is a block diagram showing the hardware configuration of an engine ECU according to one embodiment of the present invention;
FIG. 9 is a diagram for explaining the principle of a first embodiment;
FIG. 10 is a flowchart illustrating a processing sequence for a cylinder air amount estimation and target cylinder fuel amount calculation routine according to the first embodiment;
FIG. 11 is a diagram for explaining how the estimated cylinder air amount and calculated target cylinder fuel amount are stored;
FIG. 12 is a flowchart illustrating a processing sequence for a main air-fuel ratio feedback control routine according to the first embodiment;
FIG. 13 is a flowchart illustrating a processing sequence for a sub air-fuel ratio feedback control routine according to the first embodiment;
FIG. 14 is a flowchart illustrating a processing sequence for a fuel injection control routine according to the first embodiment;
FIGS. 15A and 15B show a flowchart illustrating a processing sequence for a catalyst deterioration detection routine according to the first embodiment;
FIG. 16 is a diagram for explaining the principle of a second embodiment;
FIGS. 17A and 17B show a flowchart illustrating a processing sequence for a catalyst deterioration detection routine according to the second embodiment;
FIG. 18 is a flowchart illustrating a processing sequence for a main air-fuel ratio feedback control routine according to the second embodiment;
FIG. 19 is a flowchart illustrating a processing sequence for a sub air-fuel ratio feedback control routine according to a third embodiment;
FIGS. 20A and 20B are diagrams for explaining the principles of fourth and fifth embodiments, respectively;
FIG. 21 is a diagram showing a map for obtaining from the response curve length LVAF of the A/F sensor output a reference value L ref for determining catalyst deterioration based on the response curve length LVOS of the O 2 sensor output;
FIGS. 22A and 22B show a flowchart illustrating a processing sequence for a catalyst deterioration detection routine according to the fourth embodiment;
FIG. 23 is a diagram showing a map for obtaining from the response curve length LVAF of the A/F sensor output a reference value R ref for determining catalyst deterioration based on the response curve length ratio LVOS/LVAF between the O 2 sensor and A/F sensor outputs; and
FIGS. 24A and 24B show a flowchart illustrating a processing sequence for a catalyst deterioration detection routine according to the fifth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 7 is a schematic diagram showing the general construction of an electronically controlled internal combustion engine equipped with a catalyst deterioration detection device according to one embodiment of the present invention. Air necessary for combustion in the engine 20 is filtered through an air cleaner 2, and introduced through a throttle body 4 into a surge tank (intake manifold) 6 for distribution to an intake pipe 7 of each cylinder. Intake air flow rate is measured by an air flow meter 40, and is regulated by a throttle valve 5 provided in the throttle body 4. Intake air temperature is detected by an intake air temperature sensor 43. Further, intake manifold pressure is detected by a vacuum sensor 41.
The opening angle of the throttle valve 5 is detected by a throttle angle sensor 42. When the throttle valve 5 is in its fully closed position, an idle switch 52 is turned on, and its output as a throttle full-close signal is set active. An idle speed control valve (ISCV) 66 for adjusting the air flow rate during idling is installed in an idle adjust passage 8 that bypasses the throttle valve 5.
On the other hand, the fuel stored in a fuel tank 10 is drawn by a fuel pump 11, passes through a fuel pipe 12, and is injected into the intake pipe 7 through a fuel injector valve 60.
The air and fuel are mixed together in the intake pipe 7, and the mixture is drawn through an intake valve 24 into a combustion chamber 21 of a cylinder 20, that is, into the engine body. In the combustion chamber 21, the air/fuel mixture is first compressed by the piston 23, and then ignited and burned causing a rapid pressure rise and thus producing power. To accomplish the ignition, an ignition signal is applied to an igniter 62, which controls the supply and cutoff of a primary current to an ignition coil 63, and the resulting secondary current is supplied to a spark plug 65 by an ignition distributor 64.
The ignition distributor 64 is provided with a reference position detection sensor 50 which generates a reference position detection pulse for every 720° CA rotation of its shaft measured in degrees of crankshaft angle (CA), and a crankshaft angle sensor 51 which generates a position detection pulse for every 30° CA. Actual vehicle speed is detected by a vehicle speed sensor 53 that produces output pulses representing the vehicle speed. The engine 20 is cooled by a coolant introduced into a coolant passage 22, and the coolant temperature is detected by a coolant temperature sensor 44.
The burned air/fuel mixture is discharged as exhaust gas into an exhaust manifold 30 through an exhaust valve 26, and then introduced into an exhaust pipe 34. The exhaust pipe 34 is mounted with an A/F sensor 45 for linearly detecting an air-fuel ratio based on the oxygen concentration of the exhaust gas. In the exhaust system further downstream is mounted a catalytic converter 38 which contains a three-way catalyst for simultaneously promoting the oxidation of unburned constituents (HC and CO) and the reduction of nitrogen oxides (NO x ) contained in the exhaust gas. The exhaust gas thus purified in the catalytic converter 38 is discharged into the atmosphere.
This engine is of the type that performs sub air-fuel ratio feedback control in order to compensate for variations in the output characteristic of the A/F sensor 45, and an O 2 sensor 46 is mounted in the exhaust system downstream of the catalytic converter 38.
An engine electronic control unit (engine ECU) 70 is also shown which is a microcomputer system that performs control for the detection of catalyst deterioration contemplated by the invention, as well as fuel injection control, ignition timing control, idle speed control, etc. The hardware configuration is shown in the block diagram of FIG. 8. Signals from the various sensors and switches are input via an A/D conversion circuit 75 or via an input interface circuit 76 to a central processing unit (CPU) 71 which, in accordance with programs and various maps stored in a read-only memory (ROM) 73, performs operations using the input signals, and based on the results of the operations, outputs control signals for the various actuators via respective drive control circuits 77a-77d. A random-access memory (RAM) 74 is used to temporarily store data during the operation and control processes. A backup RAM 79 is supplied with power from a battery (not shown) directly connected to it, and is used to store data (such as various learning values) that should be retained when the ignition switch is off. These constituent parts of the ECU are interconnected by a system bus 72 consisting of an address bus, a data bus, and a control bus.
A description will now be given of the engine control process performed by the ECU 70 for the internal combustion engine having the above-described hardware configuration.
Ignition timing control is performed by sending an ignition signal to the igniter 62 via the drive control circuit 77b after determining optimum ignition timing by comprehensively judging the engine condition based on engine rpm obtained from the crankshaft angle sensor 51 and on signals from other sensors.
In idle speed control, an idle state is detected based on the throttle full-close signal from the idle switch 52 and the vehicle speed signal from the vehicle speed sensor 53, and actual engine rpm is compared with the target rpm calculated according to the engine coolant temperature measured by the coolant temperature sensor 44, etc. Based on the resulting error, the control amount to achieve the target rpm is determined, and the amount of air is adjusted by controlling the ISCV 66 via the drive control circuit 77c, thereby maintaining optimum idle speed.
The detection of catalyst deterioration according to the present invention will be described in detail below, along with the fuel injection control. In the first to third embodiments hereinafter described, determination of the catalyst deterioration is made based on the O 2 sensor downstream of the catalyst while erroneous determination due to counter control is prevented. Each embodiment is concerned with an O 2 storage amount constant control system using an A/F sensor.
First, a description will be given of the first embodiment. The principle of the first embodiment is shown in FIG. 9. As shown, in the first embodiment, when the absolute value of the output of the A/F sensor 45 exceeds a limit value (upper limit "a" or lower limit "b") that can cause an excessive response of the O 2 sensor 46, the summation of data (the output VOS of the O 2 sensor 46) for determination of the catalyst deterioration is interrupted for a prescribed duration of time considering the distance between the two sensors (the time required until the gas detected by the A/F sensor reaches the O 2 sensor).
FIG. 10 is a flowchart illustrating a processing sequence for a cylinder air amount estimation and target cylinder fuel amount calculation routine according to the first embodiment. This routine is executed for every predetermined crankshaft angle. First, cylinder air amount MC i and target cylinder fuel amount FCR i , obtained from the engine operation up to the previous execution of the routine, are updated. More specifically, MC i and FCR i "i" times back (i=0, 1, . . . , n-1) are updated to MC i+1 and FCR i+1 "i+1" times back (step 102). This is done to store data of the cylinder air amount MC i and target cylinder fuel amount FCR i for the previous n times into the RAM 74 and calculate new MC 0 and FCR 0 .
Then, based on the outputs from the vacuum sensor 41, crankshaft angle sensor 51, and throttle angle sensor 42, the present intake manifold pressure PM, engine rpm NE, and throttle angle TA are obtained (step 104). Then, using the data of PM, NE, and TA, the air amount MC 0 supplied into the cylinder is estimated (step 106). Usually, the cylinder air amount can be estimated from the intake manifold pressure PM and engine rpm NE, but in this embodiment, provisions are made to detect a transient state based on a change in the value of the throttle angle TA so that an accurate air amount can be calculated in a transient state.
Next, using the cylinder air amount MC 0 and stoichiometric air-fuel ratio AFT, the calculation
FCR.sub.0 ←MC.sub.0 /AFT
is performed to calculate the target fuel amount FCR 0 that should be supplied into the cylinder to maintain the air/fuel mixture at stoichiometry (step 108). The thus calculated cylinder air amount MC 0 and target cylinder fuel amount FCR 0 are stored in the RAM 74, as shown in FIG. 11, as the latest data obtained from the present execution of the routine.
FIG. 12 is a flowchart illustrating a processing sequence for a main air-fuel ratio feedback control routine according to the first embodiment. This routine is executed for every predetermined crankshaft angle. First, it is determined whether conditions for feedback are satisfied (step 202). The feedback conditions are not satisfied, for example, when the coolant temperature is below a predetermined value, the engine is being cranked, the quantity of fuel is being increased after engine start or during engine warmup, there is no change in the output signal of the A/F sensor 45, or the fuel is being cut off. In other cases, the conditions are satisfied. When the conditions are not satisfied, the fuel correction amount DF in the feedback control is set to 0 (step 220), and the routine is terminated.
When the feedback conditions are satisfied, the fuel amount error FD i obtained from engine operation up to the previous execution of the routine (representing the difference between the actually burned fuel amount and the target cylinder fuel amount) is updated. More specifically, FD i "i" times back (i=0, 1, . . . , m-1) is updated to FD i+1 "i+1" times back (step 204). This is done to store data of the fuel amount error FD i for the previous m times into the RAM 74 and calculate new fuel amount error FD 0 .
Next, the output voltage value VAF of the A/F sensor 45 is detected (step 206). Then, using the A/F sensor output voltage correction amount DV calculated by the sub air-fuel ratio feedback control described later, the calculation
VAF←VAF+DV
is performed to correct the A/F sensor output voltage VAF (step 208). Next, by referencing the characteristic diagram of FIG. 2 based on the corrected VAF, the present air-fuel ratio ABF is determined (step 210). The characteristic diagram of FIG. 2 is converted into a map and stored in advance in the ROM 73.
Next, using the cylinder air amount MC n and target cylinder fuel amount FCR n (see FIG. 11) already calculated by the cylinder air amount estimation and target cylinder fuel amount calculation routine, the calculation
FD.sub.0 ←MC.sub.n /ABF-FCR.sub.n
is performed to obtain the difference between the actually burned fuel amount and the target cylinder fuel amount (step 212). The cylinder air amount MC n and target cylinder fuel amount FCR n n times back are used considering the time difference between the air-fuel ratio currently being detected by the A/F sensor and the actual combustion. In other words, such a time difference necessitates storing the cylinder air amount MC i and target cylinder fuel amount FCR i for the previous n times.
Next, the calculation
DFP←K.sub.fp *FD.sub.0
is performed to calculate the proportional term of proportional-integral control (PI control) (step 214). Here, K fp is the proportional gain. Next, the calculation
DFS←K.sub.fs *ΣFD.sub.i
is performed to calculate the integral term of PI control (step 216). Here, K fs is the integral gain. Finally, the calculation
DF←DFP+DFS
is performed to determine the fuel correction amount DF applied by the main air-fuel ratio feedback control (step 218).
FIG. 13 is a flowchart illustrating a processing sequence for the sub air-fuel ratio feedback control routine according to the first embodiment. This routine is executed at prescribed intervals of time longer than the intervals at which the main air-fuel ratio feedback control routine is executed. First, similarly to the main air-fuel ratio feedback control, it is determined whether conditions for sub air-fuel ratio feedback control are satisfied (step 302). If the conditions are not satisfied, the A/F sensor output voltage correction amount DV is set to 0 (step 312), and the routine is terminated.
When the feedback conditions are satisfied, the voltage error VD i obtained from engine operation up to the previous execution of the routine (representing the difference between the target O 2 sensor output voltage and the actually detected O 2 sensor output voltage) is updated. More specifically, VD i "i" times back (i=0, 1, . . . , p-1) is updated to VD i+1 "i+1" times back (step 304). This is done to store data of the voltage error VD i for the previous p times into the RAM 74 and calculate a new voltage error VD 0 .
Next, the output voltage VOS of the O 2 sensor 46 is detected (step 306). Then, using the VOS and the target O 2 sensor output voltage VT (for example, 0.5 V), the calculation
VD.sub.0 ←VT-VOS
is performed to obtain the latest voltage error VD 0 (step 308).
Finally, the calculation
DV←K.sub.vp *VD.sub.0 +K.sub.vs *ΣVD.sub.i
is performed to determine the A/F sensor output voltage correction amount DV applied by PI control (step 310). Here, K vp and K vs are the proportional and integral gains, respectively. The thus determined correction amount DV is used to compensate for variations in the output characteristic of the A/F sensor in the main air-fuel ratio feedback control routine, as previously described.
FIG. 14 is a flowchart illustrating a processing sequence for a fuel injection control routine according to the first embodiment. This routine is executed for every predetermined crankshaft angle. First, using the target cylinder fuel amount FCR 0 calculated in the cylinder air amount and target cylinder fuel amount calculation routine, and the feedback correction amount DF calculated in the main air-fuel ratio feedback control routine, the calculation
FI←FCR.sub.0 *α+DF+β
is performed to determine the fuel injection amount FI (step 402). Here, α and β are a multiplication coefficient and an addition correction amount, respectively, which are determined by other engine operating parameters. For example, α includes basic corrections based on signals from various sensors such as the intake air temperature sensor 43, coolant temperature sensor 44, etc., while β includes corrections based on changes in the amount of fuel adhering to wall surfaces (this amount changes with changing intake manifold pressure in a transient driving condition). Finally, the determined fuel injection amount FI is set in the drive control circuit 77a for the fuel injection valve 60 (step 404).
FIGS. 15A and 15B show a flowchart illustrating a processing sequence for a catalyst deterioration detection routine according to the first embodiment. This routine is executed at prescribed intervals of time. First, it is detected whether or not the output voltage VAF of the A/F sensor 45 is equal to or larger in magnitude than the upper limit value "a" or lower limit value "b" (step 502). If VAF≧a or VAF≦b, then a designated monitor disable counter CMDIS is set to a prescribed value A (step 504), and the routine is terminated.
If a<VAF<b, it is determined whether the value of the monitor disable counter CMDIS is positive or not (step 506). If CMDIS>0, the process proceeds to step 508; if CMDIS≦0, the process proceeds to step 512. In step 508, CMDIS is decremented, and in the next step 510, it is determined if CMDIS is 0 or not. If it is not 0, the routine is terminated; if it is 0, the process proceeds to step 512. In step 512, it is determined whether or not monitor conditions for the determination of deterioration are satisfied. If the monitor conditions are not satisfied, the routine is terminated; if the monitor conditions are satisfied, the process proceeds to step 514 and on to subsequent steps.
In step 514, the response curve length LVAF of the output VAF of the A/F sensor 45 is calculated by
LVAF←LVAF+|VAF-VAFO|
In the next step 516,
VAFO←VAF
to prepare for the next execution of the routine.
In step 518, the response curve length LVOS of the output VOS of the O 2 sensor 46 is calculated by
LVOS←LVOS+|VOS-VOSO|
In the next step 520,
VOSO←VOS
to prepare for the next execution of the routine.
Next, a designated counter CTIME is incremented (step 522), and it is determined whether a predetermined value C 0 is exceeded or not (step 524). If CTIME>C 0 , the process proceeds to step 526; if CTIME≧C 0 , the routine is terminated. At step 526, a deterioration determination reference value L ref is determined from LVAF. The reason the deterioration determination reference value L ref is determined based on LVAF is that, when determining the deterioration of the catalyst based on the response curve length LVOS of the output VOS of the O 2 sensor 46, the determination reference value used to discriminate between normal and deteriorated catalyst conditions varies depending on the response curve length LVAF of the output VAF of the A/F sensor 45. The reference value L ref is converted into a map and stored in advance in the ROM 73. Next, in step 528, it is determined whether or not the response curve length LVOS of the output VOS of the O 2 sensor 46 is equal to or larger than the deterioration determination reference value L ref . If LVOS≧L ref , it is determined that the catalyst is deteriorated, and a designated alarm flag ALM is set to 1 (step 530), while at the same time, an alarm lamp 68 (see FIGS. 7 and 8) is turned on (step 532). If LVOS<L ref , it is determined that the catalyst is not deteriorated, and the alarm flag ALM is set to 0 (step 534). The alarm flag ALM is stored in the backup RAM 79 (step 536) so that it can be recovered at the time of repair or inspection. Finally, CTIME, LVAF, and LVOS are cleared to prepare for the next execution of the catalyst deterioration determination process (step 538).
According to the first embodiment described above, since the interval during which the amount of change of the O 2 sensor output increases greatly is masked, the accuracy of the catalyst deterioration diagnosis improves. In the first embodiment, such an interval is masked when the output voltage VAF of the A/F sensor 45 goes outside the range defined by the upper limit value "a" and lower limit value "b"; alternatively, provisions may be made to mask the interval when the absolute value of the amount of change of VAF, |ΔVAF|, exceeds a prescribed value.
The second embodiment will now be described. In the first embodiment, the calculation of the response curve length was masked during a specific interval in the catalyst deterioration determination process. In contrast, in the second embodiment, the counter control is limited during the execution of the catalyst deterioration determination process, that is, an upper limit is imposed on the absolute value of the integral term of the fuel correction amount, thereby making the output of the O 2 sensor return slowly to stoichiometry, as shown in FIG. 16, and thus preventing an excessive response.
In the second embodiment, the cylinder air amount estimation and target cylinder fuel amount calculation routine, the sub feedback air-fuel ratio control routine, and the fuel injection amount control routine are the same as those used in the first embodiment, but the catalyst deterioration detection routine and the main air-fuel ratio feedback control routine are modified from the corresponding routines used in the first embodiment.
FIGS. 17A and 17B show a flowchart illustrating a processing sequence for the catalyst deterioration detection routine according to the second embodiment. Only the differences between the flowchart of FIGS. 15A and 15B in the first embodiment and FIGS. 17A and 17B will be described. First, steps 502 to 510 for judging the conditions for the A/F sensor output voltage are eliminated. Instead, steps 604 and 606 are added next to the step 602 for judging the monitor conditions. That is, if the monitor conditions are not satisfied, a monitor execution progress flag MONEX is set to 0, and if the monitor conditions are satisfied, MONEX is set to 1. Steps 608 to 630 are the same as the steps 514 to 536 in the first embodiment. In step 632, processing for clearing MONEX is added to the processing in step 538. In this way, in the second embodiment, the catalyst deterioration determination is carried out without regard to the value of VAF, and during execution, the monitor execution progress flag MONEX is set to 1.
FIG. 18 is a flowchart illustrating the main air-fuel ratio feedback control routine according to the second embodiment. The only difference from the flowchart of FIG. 12 in the first embodiment is the addition of steps 718 and 720. That is, after the integral term DFS of the fuel correction amount DF is calculated in step 716, if the catalyst deterioration determination process is in progress (MONEX=1), the absolute value of the integral term, |DFS|, is limited to below a predetermined value B.
In this way, the variation of the air-fuel ratio is suppressed, which makes the output of the O 2 sensor return slowly to stoichiometry, eliminates an excessive response, and improves the accuracy of the diagnosis. As a modified example of the second embodiment, control may be performed so that the gain K fs of the integral term DFS is reduced during the execution of the catalyst deterioration determination process.
Next, the third embodiment will be described. In the third embodiment, the output correction of the A/F sensor applied based on the output of the O 2 sensor is inhibited during the execution of the catalyst deterioration determination process, thereby making the output of the O 2 sensor return slowly to stoichiometry, and thus preventing an excessive response, as in the second embodiment. In the third embodiment, the cylinder air amount estimation and target cylinder fuel amount calculation routine is the same as that used in the first and second embodiments, the main air-fuel ratio feedback control routine is the same as that used in the first embodiment, the fuel injection control routine is the same as that used in the first and second embodiments, and the catalyst deterioration detection routine is the same as that used in the second embodiment; only the sub air-fuel ratio feedback control routine is modified.
FIG. 19 is a flowchart illustrating a processing sequence for the sub air-fuel ratio feedback control routine according to the third embodiment. The only difference from the flowchart of FIG. 13 in the first embodiment is the addition of step 804. That is, when the catalyst deterioration determination process is in progress (MONEX=1), the A/F sensor output voltage correction amount DV is set to 0, so that no correction is applied to the output voltage VAF of the A/F sensor 45. In this way, the output of the O 2 sensor is made to return slowly to stoichiometry, an excessive response is eliminated, and the accuracy of the diagnosis improves.
The fourth and fifth embodiments hereinafter described are both intended to achieve an accurate determination of catalyst deterioration based on the output of the O 2 sensor downstream of the catalyst, regardless of the variation amplitude of the air-fuel ratio of the mixture entering the catalyst. FIGS. 6A and 6B, previously given, simply plotted the data of FIG. 5 in one dimension by taking the response curve length LVOS or the response curve length ratio LVOS/LVAF along the ordinate. When the same data are plotted in two dimensions by taking the response curve length LVAF of the A/F sensor output along the abscissa, the results will be as shown in FIGS. 20A and 20B. It is shown that within a specific range of LVAF, a threshold value for discriminating between normal and deteriorated catalyst conditions can be set. Instead of LVAF, the amplitude of the output variation may be employed, since the amplitude of the output variation is substantially proportional to the response curve length LVAF of the A/F sensor output. In the fourth and fifth embodiment, the catalyst deterioration determining operation based on the output of the O 2 sensor downstream of the catalyst is performed when the length of the response curve of the A/F sensor output is within a predetermined range.
The processing routine for the catalyst deterioration determination according to the fourth and fifth embodiments will be described below. In the fourth and fifth embodiments, the cylinder air amount estimation and target cylinder fuel amount calculation routine, the main air-fuel ratio feedback control routine, the sub feedback air-fuel ratio control routine, and the fuel injection control routine are respectively the same as those shown in FIGS. 10, 12, 13, and 14, and only the catalyst deterioration detection routine is newly produced.
In the fourth embodiment, determination of the deterioration of the catalyst is made based on the response curve length LVOS of the output of the O 2 sensor 46, and the catalyst deterioration determination reference value L ref used for that purpose is determined according to the response curve length LVAF of the output of the A/F sensor 45, as shown in FIG. 21. The reference value L ref is converted into a map and stored in advance in the ROM 73. FIGS. 22A and 22B show a flowchart illustrating the catalyst deterioration detection routine according to the fourth embodiment. This routine is executed at prescribed intervals of time.
First, in step 902, it is determined whether or not monitor conditions for the deterioration determination are satisfied; if the monitor conditions are not satisfied, the routine is terminated, and if the monitor conditions are satisfied, the process proceeds to step 904 and on to subsequent steps. The monitor conditions are: the main air-fuel ratio feedback control based on the output of the A/F sensor 45 is in progress; the sub air-fuel ratio feedback control based on the output of the O 2 sensor 46 is in progress; and the engine load is above a predetermined value.
In step 904, the output voltage VAF of the A/F sensor 45 and the output voltage VOS of the O 2 sensor 46 are detected. Next, in step 906, the response curve length LVAF of VAF is updated by the calculation
LVAF←LVAF+|VAF-VAFO|
Next, in step 908, the response curve length LVOS of VOS is updated by the calculation
LVOS←LVOS+|VOS-VOSO|
Next, in step 910,
VAFO←VAF
VOSO←VOS
to prepare for the next execution of the routine. In calculating the response curve length LVAF of the A/F sensor, provisions may be made to stop the summation of the response curve lengths LVAF and LVOS (holding the result of the summation) when the difference between the maximum and minimum values of the A/F sensor output (the amplitude of the output) momentarily exceeds a threshold value, and to resume the summation when it drops below the threshold value.
Next, in step 912, the counter CTIME for measuring monitor time is incremented, and in step 914, it is determined whether or not the counter value has exceeded the predetermined value C 0 . If CTIME>C 0 , the process proceeds to step 916, and if CTIME≦C 0 , the routine is terminated. In step 916, it is determined whether or not V 0 ≦LVAF≦V 1 is satisfied, that is, whether or not the present value of LVAF is within the catalyst deterioration determinable region shown in FIG. 21. If it is not within that region, the present catalyst deterioration determining operation is abandoned, and the process proceeds to step 930. On the other hand, if the value is within that region, the process proceeds to step 918.
In step 918, by referencing the map shown in FIG. 21, the deterioration determination reference value L ref is determined based on the value of LVAF. Next, in step 920, it is determined whether or not the response curve length LVOS of the O 2 sensor output is equal to or larger than the deterioration determination reference value L ref . If LVOS≧L ref , it is determined that the catalyst is deteriorated, and the designated alarm flag ALM is set to 1 (step 922), while at the same time, the alarm lamp 68 (see FIGS. 7 and 8) is turned on (step 924). If LVOS<L ref , it is determined that the catalyst is not deteriorated, and the alarm flag ALM is set to 0 (step 926). The alarm flag ALM is stored in the backup RAM 79 (step 928) so that it can be recovered at the time of repair or inspection. Finally, in step 930, CTIME, LVAF, and LVOS are cleared to prepare for the next execution of the catalyst deterioration determination process.
The fifth embodiment will be described next. In the fifth embodiment, determination of the deterioration of the catalyst is made based on the ratio of the response curve length LVOS of the output VOS of the O 2 sensor 46 to the response curve length LVAF of the output VAF of the A/F sensor 45, that is, the response curve length ratio LVOS/LVAF, and the catalyst deterioration determination reference value R ref used for that purpose is determined according to the response curve length LVAF of the output of the A/F sensor 45, as shown in FIG. 23. The reference value R ref is converted into a map and stored in advance in the ROM 73. FIGS. 24A and 24B show a flowchart illustrating the catalyst deterioration detection routine according to the fifth embodiment.
The only difference from the flowchart of FIGS. 22A and 22B in the fourth embodiment is that the contents of steps 1018 and 1020 are different from those of the corresponding steps 918 and 920 in the fourth embodiment. More specifically, in step 1018, by referencing the map shown in FIG. 23, the deterioration determination reference value R ref is determined based on the value of LVAF. Then, in step 1020, it is determined whether or not the response curve length ratio LVOS/LVAF is equal to or larger than the deterioration determination reference value R ref . If LVOS/LVAF≧R ref , it is determined that the catalyst is deteriorated, and if LVOS/LVAF<R ref , it is determined that the catalyst is not deteriorated. The remainder of the processing is the same as that in the fourth embodiment.
According to the catalyst deterioration determination process of the fourth or fifth embodiment described above, the determination process is carried out based on the response curve length LVOS of the O 2 sensor output or on the response curve length ratio LVOS/LVAF between the O 2 sensor and A/F sensor outputs when the response curve length LVAF of the A/F sensor output is within a predetermined range; since the region where the response curve length or the response curve length ratio overlaps the normal and the deteriorated catalyst conditions (see FIGS. 6A and 6B) is excluded in this way, erroneous determination is prevented. Furthermore, since the deterioration determination reference value is changed according to the response curve length LVAF of the A/F sensor output, it becomes possible to compensate for the effects of the limit of the Z characteristic of the O 2 sensor (detection becomes impossible in the case of a catalyst exit gas variation larger than a prescribed value). Instead of LVAF, the amplitude of the output variation may be employed, since the amplitude of the output variation is substantially proportional to the response curve length LVAF of the A/F sensor output.
The present invention has been described with reference to the preferred embodiments, but it will be appreciated that the invention is not limited to the illustrated embodiments; rather, it will be easy for those skilled in the art to devise various other embodiments.
In any of the embodiments, since the deterioration of the catalyst is determined accurately on the basis of the output of the O 2 sensor mounted downstream of the catalyst, the exhaust gas purification performance improves, and as a result, air pollution is prevented. | A catalyst deterioration detection device for an internal combustion engine, according to the present invention, includes a three-way catalyst mounted in an exhaust passage of the internal combustion engine and having an O 2 storage capability and an air-fuel ratio sensor, mounted upstream of the three-way catalyst, for linearly detecting an air-fuel ratio. An air-fuel ratio feedback control unit, based on the output of the air-fuel ratio sensor, calculates a feedback correction amount consisting of a proportional term for bringing the air-fuel ratio to stoichiometry and an integral term for bringing an integrated value of an error between the air-fuel ratio and stoichiometry to zero. An O 2 sensor, mounted downstream of the three-way catalyst, detects whether the air-fuel ratio is rich or lean. A catalyst deterioration determining unit determines deterioration of the three-way catalyst on the basis of the length of a response curve that the output of the O 2 sensor describes during the time that air-fuel ratio feedback control is being performed by the air-fuel ratio feedback control unit. A response curve length calculation interrupting unit interrupts the calculation of the response curve length being performed by the catalyst deterioration determining unit for a predetermined length of time when the output of the air-fuel ratio sensor or the amount of change of the output has exceeded a preset value. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not applicable)
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to optical methods and apparatus for use in ion implantation dosage, measurement of energy and depth.
[0004] 2. Description of Related Art
[0005] Precise measurement of ion implantation characteristics is of profound importance in the art of integrated circuit (IC) fabrication. The requirements of high density, large scale integration have placed tremendous burdens on inspection and measurement techniques. For example, the ability to accurately measure dopant concentration for control of implantation parameters is paramount to efficient, cost-effective semiconductor device manufacture. Precisely controlled dopant concentrations are important for instance because smaller circuit features impose tighter dose distribution parameters with regard to energy and concentration. Accurate measurement of these parameters plays a critical role in the continuing trend towards further miniaturization and scalability, and towards accurate control of device characteristics as required for high yield and specific types of applications.
[0006] Various approaches have been taken for measuring implantation characteristics. One prior art optical approach to determining implantation conditions utilizes the effect known as modulated optical reflectivity (MOR), wherein two monochromatic light beams, from separate laser souces for instance, are directed confocally onto the substrate under test. The first light beam induces excitations in the material, which excitations are a function of a measured parameter, such as implantation density. The second light beam is a reading beam, whose reflection by the surface is measured to provide an indication of the measured parameter. Two prior art references, U.S. Pat. No. 5,034,611 (Alpern, et al.) and U.S. Pat. No. 5,769,540 (Schietinger, et al.) are directed to this MOR approach.
[0007] The MOR approach suffers from several disadvantages, including low sensitivity, inadequate spacial resolution, and limited repeatability. Specifically, while this approach is purportedly non-destructive, there is evidence that the excitation beam in the MOR technique in actuality alters the substrate material at the atomic level, and this alteration is cumulative in effect, such that repeated tests of a specific site result in changes to the material and yield inaccurate measurement results. It is believed that the alterations at least in part contribute to changes in the implantation measurement, wherein the implantation site is locally “damaged” by the high thermal state of the substrate caused by the excitation laser. The claims of non-destructiveness are further complicated by the fact that the MOR effect itself, and its underlying causes, are not entirely understood. Further, the MOR approach is high in cost because of its need for high energy, monochromatic coherent light from multiple light sources. In addition, the excitation and subsequent reading processes consume an unacceptable amount of time for each test incident, which, in the aggregate, severely limits the number of tests per wafer which can be performed in a production environment, especially for larger-sized substrates. In particular, it takes several milliseconds of exposure to the excitation laser light in order to reach the level of excitation required to derive a meaningful reading by the reading light. Over multiple readings, the measurement duration per wafer becomes impractical.
BRIEF SUMMARY OF THE INVENTION
[0008] In accordance with the invention, there is provided a method for measuring one or more characteristics of implantation in a substrate. The method includes, before implantation, directing non-destructive light onto a quiescent substrate at a first set of one or more measurement points to thereby cause light reflection by the substrate, and detecting the light reflection. After implantation, non-destructive light is directed onto the substrate at the first set of one or more measurement points to thereby cause light reflection by the substrate, and light reflection is detected. The method further includes correlating the detected light reflection before implantation to the detected light reflection after implantation to obtain one or more differential measurement values each associated with a corresponding measurement point and indicative of an implantation characteristic of the substrate at the corresponding measurement point.
[0009] Further in accordance with the invention, there is provided a method for generating an implantation characteristic profile of a quiescent substrate, wherein the substrate is non-destructively illuminated at a plurality of measurement points prior to implantation. For each illuminated measurement point prior to implantation, a spectral distribution and intensity of reflected light is detected. The substrate is also non-destructively illuminated at a plurality of measurement points after implantation, and for each illuminated measurement point after implantation, a spectral distribution and intensity of reflected light is detected. A map is generated of differential measurement values each associated with a corresponding measurement point and indicative of an implantation characteristic of the substrate at the corresponding measurement point.
[0010] Further in accordance with the invention, there is provided a device for non-destructively measuring dopant concentration in a substrate, including a light source, a light detector generating a detection signal in response to light impinging on the light detector, an optical system directing light from the light source to an illumination area on the substrate and directing light reflected by the substrate from the illumination area onto the light detector, a stage for relatively moving the substrate in first and second scanning patterns, and a processor which, during the first scanning pattern, obtains from the light detector a first set of detection signals each corresponding to a measurement point on the substrate, and during the second scanning pattern, obtains from the light detector a second set of detection signals each corresponding to each of said measurement points, such that for each measurement point, a pair of detection signals are obtained. The processor further generates a set of differential measurement values each derived from one of the pair of detection signals, the set of differential measurement values being indicative of implantation characteristic levels in the substrate, including any of dopant concentration, dose, energy and depth.
[0011] Further in accordance with the invention, a method for characterizing a substrate is taught, the method including directing non-destructive light onto a surface of a substrate in a quiescent state at a plurality of measurement points on the substrate to thereby cause light reflection by the substrate, detecting light reflected from the substrate at the plurality of measurement points, and using the detected reflected light to generate a map indicative of relative reflectivity across the surface of the substrate.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0012] Many advantages of the present invention will be apparent to those skilled in the art with a reading of this specification in conjunction with the attached drawings, wherein like reference numerals are applied to like elements.
[0013] FIG. 1 is a diagrammatical view of a system and method in accordance with the invention;
[0014] FIG. 1A is a diagrammatical view of further embodiment system and method in accordance with the invention;
[0015] FIG. 2 is a view of a scanning pattern in accordance with the invention;
[0016] FIGS. 3A and 3B are two dimensional and three dimensional views of displayed mappings of detected implantation characteristics pertaining to a defective implantation process;
[0017] FIGS. 4A and 4B are two dimensional and three dimensional views of displayed mappings of detected implantation characteristics pertaining to a non-defective implantation process;
[0018] FIG. 5 is a diagrammatical view illustrating a scanning process for scanning a portion of a substrate in accordance with the invention; and
[0019] FIG. 6 is a diagrammatical view of a further system and method illustrating the scanning of a substrate in an ion implanter for real-time dose monitoring and control in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 shows an arrangement 100 in accordance with the invention. A light source, for example an LED 110 , directs light through an objective 120 and beamsplitter 130 onto a substrate 140 . The light impinges substrate 140 at an incidence location 150 , and is reflected by the substrate and beamsplitter through focusing lens 160 onto a detector, such as photodiode 170 . Substrate 140 is disposed on a stage 180 such that relative motion between the impinging light from source 110 and the substrate can be effected, in order to implement a substrate surface scan as described below. Either the impinging light, or the substrate, or both, can be moved in order to achieve the relative motion. A detector 182 detects light from source 110 and provides an input signal to a processor 190 for controlling desired characteristics of the illumination, for example the duration of each sampling incident or pulse, and for determining a base point against which measured illumination from photodiode 170 is compared.
[0021] The light source in the arrangement of FIG. 1 can provide either monochromatic or polychromatic light and is preferably non-coherent light. It can be one or more LEDs, or other single or multiple sources of light whose wavelength range is selected primarily based on the type of substrate under consideration. These substrates include, but are not limited to, a bare silicon (Si) substrate, a gallium arsenide (GaAs) substrate, a silicon carbide (SiC), a silicon oxide (SiO 2 ), and an indium phosphide (InP) substrate, with each substrate having a preferred light wavelength range that can readily determined by one of ordinary skill in the art. The substrate can be a coated substrate, for example with a thin film, or ultra-thin film (USF). Further, the substrate can be implanted over a range of energies, including low energy implantation into bare silicon wafers, or wafers with a thin oxide on the silicon. Known processes for low energy implantation, to which the present invention is applicable, include ULE (ultra-low energy) utilizing isotype separation and beam line processes and PLAD (plasma doping) implant processes.
[0022] Other factors may also be considered in selecting the wavelength range of light from light source 110 , such as the implantation species in the substrate, and whether the substrate material is of the low dose, high dose or super high dose implant type. Low dose implants, whose dosage levels are in the range of about 6×10 11 to 3×10 12 ions/cm 2 , are used in threshold adjust (Vt) implant applications. High dose materials, with dosage levels that are in the range of the high 10 15 to low 10 16 ions/cm 2 , are used in CMOS source/drain and bipolar emitter implant applications. Super high dose materials, with dosage levels that are in the range of the mid 10 16 to low 10 17 ions/cm 2 , have uses in applications such as wafer splitting, for example according to Smartcut™ techniques.
[0023] The energy of light is selected such that the impinging beam on the substrate is substantially non-destructive, particularly with respect to any implanted material in the substrate. That is, the implantation characteristics of the material should not be significantly altered by the impinging light, in order to accurately measure the nature of the implantation, for instance, and in order to ensure that consistent results are obtained over multiple readings. Based on these conditions, the substrate is considered to be in a quiescent state before and during the reading, meaning that it is not in an excited state when reading is initiated upon impingement of light from source 110 , and is not, to any appreciable degree, excited by impingement of light from source 110 . The latter condition—that impingement from source 110 does not appreciably excite the substrate—does not preclude some alterations in the material, which may be persistent or non-persistent. However, these alterations are not cumulative to any extent that would affect the accuracy or repeatability of the measurements performed in accordance with the invention.
[0024] Given these constraints, the intensity of light used will vary depending on the material. As a relative measure, CorMap™ units (CMU™) are used to measure the intensity of light used with different materials, and are defined as a relative measure of light intensity in the range of 0 to about 65,000. Accordingly, for a bare silicon (Si) substrate, an intensity value of about 50,000 CMU™ is preferred. For a gallium aresnide (GaAs) substrate, a value of about 50,000 CMU™ is preferred. For silicon carbide (SiC), a value of about 64,000 CMU™ is preferred. For indium phosphide (InP), a value of about 60,000 CMU™ is preferred.
[0025] Objective 120 and focusing lens 160 can each be one or more optical elements, and are merely represented in FIG. 1 as single devices for simplicity. They are part of optical system 156 , which may include beam shaping, filtering and focusing optics. Objective 120 is designed to focus light onto substrate 140 to define on the surface thereof, at incidence point 150 , an illumination area 164 approximately 0.8 mm 2 in size.
[0026] Light reflected by substrate 140 is directed to detector 170 via beamsplitter 130 and focusing lens 160 . Detector 170 is any type of photodetector having one or multiple sensing elements which are sensitive to the particular light wavelengths as reflected from substrate 140 . Electrical signals corresponding to the reflected light are provided by detector 170 to a processor 190 , which serves to analyze the reflected light in order to determine implantation or other characteristics of the substrate 140 . Implantation characteristics include one or more of implantation energy, dosage, species, depth, or other characteristics, all of which have been found to be functions of the spectral distribution and intensity of the reflected light. Thus for the case of an implanted substrate, an analysis of the reflected light is used to provide qualitative and/or quantitative indications of one or more implantation characteristics, particularly when the other characteristics are known. For example, if the energy and species are known, the dosage can be determined from the reflected light. Further, when performed over the entire substrate surface, in a prescribed scanning pattern, implant mapping can be conducted and implantation uniformity determined, as described in greater detail below. This information is in turn useful for assessing many factors during the implantation and fabrication processes. For instance, implanter performance can be assessed and the implant process can be controlled in a feedback type process performed either in real time or during subsequent implantation runs. For real time, in process operation, the information from processor 190 can be used to provide direct input and control to the implanter device, via implant controller 192 , as illustrated in FIGS. 1 and 6 .
[0027] It will be appreciated that the invention can be used with any implantable species, including but not limited to the commonly used electrically non-active dopants which, for a silicon substrate, include hydrogen (H+), silicon, germanium, oxygen and argon, and for a gallium arsenide (GaAr) substrate, include argon, gallium, arsenic, and hydrogen (H+).
[0028] FIG. 2 shows a scanning pattern 200 representing the preferred path that illumination area 164 ( FIG. 1 ) traverses across the surface of substrate 140 during a substrate analysis process. This scanning pattern is generally a series of concentric circles, each representing a sequence of discrete measurements taken along measurement points P i disposed in a circular path around substrate center 210 . In this particular example the substrate is a 300 mm wafer, although other types of substrate, circular or otherwise, can be used, and the scanning pattern adjusted accordingly. For example, a linear pattern (not shown) can be used when the substrate is a flat panel display having a rectangular shape. Such a linear pattern would comprise a series of parallel lines representing the sequence of discrete measurements taken along the straight lines.
[0029] To achieve scanning pattern 200 of FIG. 2 , relative motion between illumination area 164 ( FIG. 1 ) and substrate 140 is effected. Preferably, the pattern begins with the innermost circle 220 1 , whose circumference is traversed by for example incrementally rotating stage 180 ( FIG. 1 ) and wafer 140 around the center of the wafer at a first distance r 1 , sampling at each measurement point P i to conduct the spectral distribution and reflected light intensity measurement described above, and then moving on to the next measurement P i , and so on. At the completion of the circle 220 1 , the position of the illumination area 164 is indexed radially outward, a distance of r δ which may be about 1 mm, to begin the next concentric circle 220 2 , and so on.
[0030] The separation between consecutive measurement points P i on a circle can be approximated as a linear distance d i . This separation, along with the radial distance r δ between circles 220 i , is selected depending on the total number of measurements desired for each substrate. Preferably, this total number of measurements for a 300 mm a silicon wafer is about 86,700, and is about 37,700 for a 200 mm silicon wafer. The linear d i and radial distances r δ corresponding to these total measurements are about 0.8 mm and 1.0 mm, respectively.
[0031] Due to the relatively short duration of each measurement, it is contemplated that using the aforementioned scanning pattern, a 300 mm silicon wafer can be scanned in about 5 minutes or less, while a 200 mm silicon wafer can be scanned in about 3 minutes or less.
[0032] The scan measurements are compiled by processor 190 , which generates a map of values corresponding to the measurement points on the surface of the substrate 140 . This map, based on the above measurement distances and densities, can have a spacial resolution of about 0.8 mm 2 for either the 200 mm or the 300 mm silicon wafer.
[0033] It is also contemplated that other scanning processes can be used. In FIG. 1A , for instance, scanning can be effected by way of optical fibers 130 , and suitably configured optical components. A combination of rotational and linear motions, represented by arrows R and L in FIG. 1A , which may be more compatible with some existing scanning platforms, are utilized to implement the desired scanning pattern. It will appreciated that other types of imaging, relative motion and light detection expedients may also be used in accordance with the invention, including those using two dimensional arrays of photodiodes (not show), for example.
[0034] In accordance with one method of the invention, the substrate under measurement is scanned prior to implantation, and then again after implantation. The same pattern is used in the pre-implant and post-implant scans, and mapped values corresponding to measurement points before implantation and after implantation are correlated to one another in order to obtain, for each measurement point on the surface of the substrate, a differential measurement value indicative of the implantation characteristic change attributable to the implantation process. From these values, an implantation characteristics map is generated by processor 190 , which map can be used for real time or subsequent control of the implantation process. Real time control can be effected by routing processor control signals to implant controller 192 .
[0035] In addition, the implantation characteristics map can be displayed graphically, on a display device 194 ( FIG. 1 ) in order to enable visualization of the implant process. The display can be a two dimensional or three dimensional view, as shown respectively in FIGS. 3A and 3B , which depict mappings 310 A and 310 B indicating implanter malfunction—namely, a mechanical malfunction on a batch-type implanter—resulting in an uneven implant gradient, most dramatically seen in the high gradient regions 320 A and 320 B. By comparison, FIGS. 4A and 4B illustrate implantation mappings 410 A and 410 B of acceptable uniformity, indicating a properly functioning implantor.
[0036] It will be appreciated that since in this embodiment differential measurement values are used, rather than the absolute measurements themselves, the method and process of the invention can be applied to many kinds of substrates and materials, during almost all phases of processing. In particular, it can be used to measure implantation of bare wafers without any features, or it can be used to measure implantation of wafers or other materials at various stages of fabrication, for example implantation o wafers after photomask. Since only the differences between measurements before and after implantation are needed to generate the necessary diagnosis information—that is, the differential measurement values—the effects of the particular fabrication stage at which the substrate is at are canceled out, and only the implantation characteristics are measured. Of course, other substrate characteristics, and not merely those relating to implantation, can also be measured in this manner.
[0037] Moreover, it will be appreciated that while the implantation or other characteristics of a whole substrate are usually of interest, mandating scans of the whole substrate, in some cases only partial scans are necessary, and the scanning motion and/or software can be adjusted accordingly. In accordance with a preferred embodiment, however, if only a portion of a substrate such as a semiconductor wafer is of interest, the whole substrate is still scanned, and the portions that are not of interest are simply subtracted out. FIG. 5 is illustrative of this approach, which is generally more practical than modifying the scanning pattern and associated mechanical motions involved to focus only on the area of interest. In FIG. 5 , the region of interest in wafer 500 is rectangular region 510 . A scan of the whole wafer 500 is conducted, with the measurements corresponding to the shaded region 520 being simply discarded in favor of those in region 510 .
[0038] The invention can also be applied for providing background map information of a substrate, without regard to subsequent measurements. For instance, an unimplanted wafer, whether bare or coated with a special sensitive coating, for example ultra sensitive film (USF) or other resist type coating, can be measured prior to implant. From this background scan measurement, data and a contour map (or other maps such as a three-dimensional map, diameter map, and so forth) can be generated to show possible imperfections in the material or in the coating, or both. A mean (average) value and standard deviation of all the data points (37,700 for a 200 mm wafer or 87,700 for a 300 mm wafer) is displayed along the map. In some instances, no implant is desired, but the substrate quality or special thin film—Si 3 N 4 , for instance—is to be measured and evaluated. This can be displayed directly after completion of the background scan.
[0039] It may also be desired to simply generate an implant map without resort to a differential measurement. An implant scan is performed after a substrate is implanted. The substrate is typically previously measured for a background scan, although that may not be necessary when the substrate material has shown, with statistically high confidence, to be the same day to day, week to week. According to this method, a mean value and standard deviation of all the data points is displayed along the map. The implant map can be displayed directly, without the need for the subtraction of implant from the background. This approach can be used to highlight differences in areas of the substrate or in certain details in the implant map and in the difference map. The background scan can be derived from a standard substrate or from a computer generated artificial map.
[0040] The above are exemplary modes of carrying out the invention and are not intended to be limiting. It will be apparent to those of ordinary skill in the art that modifications thereto can be made without departure from the spirit and scope of the invention as set forth in the following claims. | Light from a light source is directed towards a plurality of measurement points on a substrate to characterize the substrate based on light reflectivity. In a differential approach, light is directed onto the substrate before and after dopant implantation. Reflected light is detected and analyzed for spectral distribution and intensity. A differential measurement is derived, from which implantation uniformity is determined. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 13/885,627, filed Aug. 5, 2013, which is a U.S. National Stage Application of International Application No. PCT/MX2011/000138, filed Nov. 15, 2011, which claims priority to Mexican Patent Application MX/A/2010/012479, filed Nov. 16, 2010, all of which are incorporated herein by reference in their entireties for all purposes.
SCOPE OF THE INVENTION
[0002] This invention involves a pharmaceutical composition and its preparation in the form of a tablet, coated tablet, or capsule to be used in the treatment of irritable bowel syndrome, also known as irritable colon syndrome, based on: an intestinal motility modifier, an agent that prevents gas retention, a digestive enzyme, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant.
BACKGROUND
[0003] Enzymes as medications have two important features that distinguish them from other types of drugs. First, enzymes normally bind and act upon their substrates with high affinity and specificity; second, enzymes are catalytic molecules, meaning they decrease the activation energy of a determined reaction, through which they convert multiple white molecules (substrates) into the desired products. The two aforementioned features make pharmaceutical enzymes potent and specific so they can carry out a therapeutic biochemical activity in the body that small molecules cannot; as a result, scientists have worked on the development of various enzymes for use as therapeutic agents. This concept of therapeutic enzymology already existed as substitution therapy for use in cases of genetic deficiencies in the 1960s. In 1987 the Food and DrugAdministration approved the first drug containing a recombinant enzyme, Activase® (alteplase, a recombinant human tissue plasminogen activator) for treatment of heart attacks caused by a clot blocking a coronary artery. In 1990, Adagen®, a form of bovine adenosine deaminase (BAD) treated with polyethylene glycol was approved for use in patients with a type of severe combined immunodeficiency (SCID), which is caused by chronic BAD deficiency. In 1994 Ceredase® was approved, the first enzyme replacement therapy with a recombinant enzyme, for the treatment of Gaucher's disease, related to lysosomal storage disease caused by glucocerebrosidase deficiency. Sacarosidase, a fructohydrolase β-fructofuranoside obtained from Saccharomyces cerevisiae yeast, is used in the treatment of congenital sucrase-isomaltase enzyme deficiency (CSID) in which patients are incapable of metabolizing sucrose. In the case of phenylketonuria, a genetic disease caused by reduced or non-existent activity of the phenylalanine hydroxylase enzyme, which converts phenylalanine into tyrosine, an oral treatment is being used in oral treatment based on the phenylalanine ammonialyase enzyme that is derived from a yeast, which degrades phenylalanine in the gastrointestinal tract. Another enzyme, a peptidase, is used in an oral formulation as a supplemental therapy in cases of Celiac's disease, a disorder of the small intestine caused by an autoimmune system reaction to the protein gliadin, which is found in products derived from wheat (Vellard, Michael. The enzyme as a drug: application of enzymes as pharmaceuticals. Current Opinion in Biotechnology. 2003. Vol. 14: 444-450). The hydrolytic enzyme α-D-galactosidase, used in the treatment of gastrointestinal disorders, transforms non-absorbable oligosaccharides in the intestinal tract to prevent them from being fermented by intestinal bacterial flora (a gas-producing process); in reducing intestinal gas production, visceral distention is decreased and therefore, symptoms like distention, abdominal pain and flatulence decrease as well (http://www.beanogas.com accessed on Apr. 28, 2009). α-D-galactosidase hydrolyzes three complex carbohydrates: raffinose, stachyose and verbascose to transform them into monosaccharides: Glucose, galactose and fructose and into the disaccharide: sucrose (whose hydrolysis is instantaneous during normal digestion). The α-D-galactosidase enzyme is not normally produced by human beings, for which reason raffinose, stachyose and verbascose arrive intact at the colon, where they are fermented by bacterial flora in a chemical reaction that produces hydrogen and methane (gas). Administration of the enzyme with food breaks up these three oligosaccharides before they arrive at the colon, preventing fermentation and gas production. The α-D-galactosidase that is used as a medication comes from the non-toxic food-grade fungus Aspergillus niger (http://www.beanogas.com accessed on Apr. 28, 2009). Various other enzymes exist that are used medicinally for digestive disorders, among them amylase, β-D-galactosidase, cellulase, hemicellulase, lipase, papain, pepsin, rutin, chymotrypsin and trypsin.
[0004] Irritable bowel syndrome (IBS), previously known as irritable colon syndrome, is a functional disorder of the intestine, characterized by symptoms of abdominal discomfort or pain that are associated with changes in bowel habits. IBS is currently understood to be a result of interactions between many factors that contribute to the onset of symptoms, rather than as a singular disease. There is no single physiopathological mechanism that can explain it but there are at least 3 interrelated factors that act in ways that vary from person to person.
[0005] The factors are:
i) Changed intestinal reactivity, ii) motility or secretion in response to provocative luminal stimuli (food, distention, inflammation, bacterial factors) or environmental stimuli (psycho-social stress) that result in symptoms of diarrhea or constipation and iii) bowel hypersensitivity with increased visceral perception and pain.
[0007] Changes in regulation of the “brain-intestine” axis.
[0008] Diagnosis of IBS is based on identifying positive symptoms, called the Rome III Diagnostic Criteria (Longstreth, G. F. 2006. Functional bowel disorders. Gastroenterology. Vol. 130, No. 5:1480-91), and on ruling out other intestinal tract diseases with similar manifestations. These criteria are:
[0009] Recurring abdominal discomfort or pain for at least three days per month for the last three months, associated with two or more of the following conditions: a) improvement with defecation, b) onset associated with a change in the frequency of bowel movements and c) onset associated with a change in the appearance of stool.
[0010] In which discomfort refers to a disagreeable sensation not described as pain.
[0011] The criteria must have been fulfilled in the last three months, with onset of symptoms at least six months before diagnosis.
[0012] IBS is one of the most common medical disorders in the world, occurring more frequently in women aged 30 to 50, with prevalence in Latin America between 9 and 18% (Schmulson, Max J. 2008. Limited diagnostic screening can decrease the direct economic impact of irritable bowel syndrome (IBS). Rev Med Chile. Vol. 136: 1398-1405).
[0013] The symptom pattern in Mexico is IBS with constipation; abdominal distention is a common symptom in this pattern of the disease. In the Mexican population, abdominal distention and gas are reported as symptoms with high frequency. Irritable bowel syndrome is a real pathological condition that has significant impact on those who suffer from it (symptom severity, functional impairment, diminished quality of life), in addition to constituting a significant economic burden for society and the state, in terms of the costs of medical care and absences from work (American Gastroenterological Association; 2002; American Gastroenterological Association position statement; “irritable bowel syndrome. Gastroenterology”. Vol. 123, No. 6:2105-7).
[0014] There is no ideal or standard treatment for this disease. Trimebutine maleate, commonly known as trimebutine, has been used since 1969 as treatment for functional bowel disorders, including irritable bowel syndrome. Its principal effects are regularization of intestinal motility and an elevated threshold for pain caused by visceral distention (Roman F. J., et al. 1999. Pharmacological properties of trimebutine and N-monodesmethyltrimebutine. J Pharmacol Exp Ther. Vol. 289, No. 3:1391-1397).
[0015] Abdominal pain, distention and flatulence represent very common symptoms in functional bowel disorders, including irritable bowel syndrome, but their physiopathology and treatment have not been completely explained. Patients frequently associate these symptoms with excessive gas production in the bowel and reduction of the latter could represent an effective strategy for symptomatic improvement in irritable bowel syndrome, for which simethicone has been used. Simethicone is an inert silicon that acts directly on the surface tension of gastrointestinal mucous, thus affecting the formation of bubbles in the digestive tract, destroying them and encouraging the confluence of small bubbles into bigger bubbles, which translates into the prevention of gas retention and the associated discomforts. It is important to note that these symptoms may be produced or worsened in a patient with irritable bowel syndrome, not only by an increase in gas production, but also by the “normal” presence of gas in the digestive tube coupled with increased visceral sensitivity. Strategies do currently exist for the treatment of this problem, such as the use ofactivated carbon,dietary restriction and probiotic consumption; however, none of these are ideal and the results obtained are contradictory in each case. In this context, the breakdown of non-absorbable oligosaccharides, found in legumes, fruits and vegetables, before they reach the colon (where they will be fermented by bacterial flora and will produce gas) may represent an attractive alternative. Administration of α-D-galactosidase may achieve this effect (Di Stefano M., et al. 2007; “The effect of oral alpha-galactosidase on intestinal gas production and gas-related symptoms”. Dig Dis Sci. January. Vol. 52, No. 1:78-83).
[0016] There are pharmaceutical products that modify intestinal motility for use with intestinal disorders, such as:
Trimebutine and its salts. Fenoverine. Mebeverine. Dicycloverine. Pinaverium bromide. Alosetron. Tegaserod. Loperamide. Floroglucinol. Trimetilfloroglucinol. Butylscopolamine. Pargeverine.
[0029] All of these can be used in combination with simethicone to obtain a pharmaceutical formulation for oral administration to be used in intestinal disorders, as is the specific case with irritable bowel syndrome.
[0030] There are also various enzymes with physiological activity that are useful in the treatment of intestinal disorders, such as: α-D-galactosidase, amylase, cellulase, hemicellulase, lipase, papain, rutin, chymotrypsin and trypsin.
[0031] All of the aforementioned enzymes can be used in combination with simethicone and with intestinal motility modifiers to obtain a pharmaceutical formulation for oral administration to be used in intestinal disorders, as is the specific case with irritable bowel syndrome.
[0032] The combination of trimebutine and its salts, a regulating agent of intestinal motility with analgesic properties, simethicone, an agent that prevents gas retention, and an enzyme or enzyme combination, results in an effective treatment for symptomatology reduction in patients with irritable bowel syndrome.
[0033] Considering that trimebutine acts upon Auerbach's (muscular) and Meissner's (submucosal) plexus specifically, it acts upon the enkephalinergic receptors responsible for regulating peristaltic movements. Trimebutine acts as much on hypermotility as on hypomotility, depressing or elevating peristalsis and leading to normalization of intestinal transit. Trimebutine also has analgesic(modulation of visceral sensitivity), antispasmodic and antiemetic properties (Delvaux M. & Wingate D. 1997. Trimebutine: “Mechanism of action, effects on gastrointestinal function and clinical results”. J Int Med Res. Vol. 25, No. 5:225-46).
[0034] Among the solutions that have been proposed to treat IBS symptomatology, the paper WO2001/047515 reports the use of trimebutine alone, to develop a useful medication to treat somatic pain and abdominal inflammation; however, it only focuses on symptom relief for this ailment.
[0035] Similarly, numerous papers exist concerning the treatment of inflammation, abdominal pain and ailments associated with IBS; however, treatment of IBS at its source has not been resolved in any of said papers as shown by the following citations:
[0036] The paper MXPA02006376 refers to the use of trimebutine alone to prevent or treat somatic pain and inflammation associated with gastric ailments; however, when looking to alleviate symptoms, pain is not eradicated as a function of its causal agent.
[0037] The paper US 2003/0119903 reports the use of trimebutine alone to prepare a medication to treat somatic inflammatory pain as well as chronic pain associated with gastric ailments.
[0038] The paper US 2004/0009234 reports a pharmaceutical composition and associated treatment to prevent gastrointestinal disorders, making use of trimebutine alone without achieving the desired end result of combatting the origin of these ailments.
[0039] The paper MX00PA05010821A reports the use of trimebutine to treat constipation, without achieving the desired end result of combating the origin of these ailments.
[0040] The paper WO1995001803 reports the use of trimebutine to treat gastrointestinal pain and disorders such as indigestion caused by excessive food intake, gastro-esophageal reflux, dyspepsia and constipation without achieving the desired end result of combating the source of these ailments.
[0041] The paper WO95001784 reports the use of a pharmaceutical composition for treating and alleviating indigestion, heartburn and other gastrointestinal disorders using famotidine, sucralfate, simethicone and α-D-galactosidase; however, the composition of the specified publication lacks an agent that effectively promotes rapid gastric emptying, which makes it inefficient in the treatment of IBS, as the patient who is unable to defecate quickly will not have a sensation of relief.
[0042] The paper US 2008/0038240 reports the use of enzymes to improve absorption of carbohydrates in humans, avoiding the formation of intestinal gases.
[0043] The paper U.S. Pat. No. 4,447,412 reports an enzymatic composition for the treatment of digestive dysfunction, composed of pancreatic and proteolytic enzymes.
[0044] The paper U.S. Pat. No. 4,079,125 reports an extended-release enzymatic composition able to withstand several hours of exposure to gastric fluids, protecting the biological activity of the enzymes and releasing them after 5-30 minutes of exposure to intestinal fluids.
[0045] The papers U.S. Pat. No. 5,460,812 and U.S. Pat. No. 324,514 report the use of enzymes in the treatment of digestive disorders.
[0046] One objective of this invention is to provide a pharmaceutical composition for oral administration with application in intestinal disorders based on an intestinal motility modifier, an agent that prevents gas retention, digestive enzymes, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant.
[0047] Another objective of this invention is to provide a pharmaceutical formulation for oral administration with application in intestinal disorders based on an intestinal motility modifier, an agent that prevents gas retention, digestive enzymes, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant that is effective in normalizing intestinal transit.
[0048] Another objective of this invention is to provide a pharmaceutical formulation for oral administration with application in intestinal disorders based on an intestinal motility modifier, an agent that prevents gas retention, digestive enzymes, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant that is effective in achieving analgesic activity in the treatment of gastrointestinal ailments.
[0049] Another objective of this invention is to provide a pharmaceutical formulation for oral administration with application in intestinal disorders based on an intestinal motility modifier, an agent that prevents gas retention, digestive enzymes, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant that is effective in achieving antispasmodic activity.
[0050] A final objective of this invention is to provide a pharmaceutical composition or formulation for oral administration with application in intestinal disorders based on an intestinal motility modifier, an agent that prevents gas retention, digestive enzymes, a binding agent, a diluting agent, an adsorbent, a disintegrant, a lubricant, and a glidant that is effective in reducing symptoms related to intestinal gas such as distention, pain and flatulence.
DETAILED DESCRIPTION OF THE INVENTION
[0051] The pharmaceutical formulation is prepared in the form of a tablet, coated tablet, or capsule, for use in irritable bowel syndrome, also known as irritable colon syndrome, based on an intestinal motility modifier, an agent that prevents gas retention and digestive enzymes.
[0052] The intestinal motility modifier, the agent that prevents gas retention, the digestive enzyme, the binding agent, the diluting agent, the disintegrant, the lubricant, and the glidant, are mixed.
[0053] A binder solution is prepared.
[0054] The intestinal motility modifier, the enzyme α-D-galactosidase, the binding agent, the diluting agent, the disintegrant, the lubricant, and the glidant are sifted in order to break up any clumps.
[0055] All of the substances mentioned in the previous step are mixed and then moistened with the binder solution.
[0056] The product resulting from the previous step is ground, dried and sifted.
[0057] If the final composition is solid, the mixture is compressed to form a tablet or a coated tablet; otherwise capsules are prepared.
[0058] The tablets or capsules are packaged in packing material.
[0059] To carry out the specified manufacturing process, one will use the equipment that is conventionally used in the production of a pharmaceutical formulation with the indicated characteristics. All of the raw materials used are of pharmaceutical grade. Below, some practical examples of how the formulations were prepared are detailed for illustrative, but not restrictive, purposes.
EXAMPLES
[0060] An example of tablet formulation of Trimebutine Maleate/α-D-galactosidase/Simethicone obtained by wet granulation.
[0000]
Component
Amount
Trimebutine maleate
200.000
mg
Simethicone
75.000
mg
α-D-galactosidase
90.000
mg*
Pregelatinized starch
75.000
mg
Lactose hydrous
105.000
mg
Croscarmellose sodium
30.000
mg
Microcrystalline cellulose
115.000
mg
Dibasic calcium phosphate
300.000
mg
Magnesium stearate
10.000
mg
*90 mg is equivalent to 450 U/gal. U/Gal considering a raw material of α-D-galactosidase with enzymatic activity of 5,,000 U/gal per gram.
Procedure for Manufacturing Tablets of Trimebutine Maleate/α-D-Galactosidase/Simethicone by Wet Granulation.
[0061] 1. Prepare a binder solution by dispersing 20% of the pregelatinized starch in a sufficient amount of water.
[0062] 2. Pass the following raw materials through a sieve with mesh size of 420 to 2,000 microns:
The rest of the pregelatinized starch (80%) The α-D-galactosidase Trimebutine maleate Lactose hydrous Croscarmellose sodium Dibasic calcium phosphate
[0069] 3. Add the dibasic calcium Phosphate and the pregelatinized starch (80%) into the mixer/granulator and mix for 5 to 20 minutes at 50 to 200 rpm.
[0070] 4. At the end of this mixing and without stopping the stirring, manually add the simethicone in “string” form over a time period not to exceed 15 minutes.
[0071] 5. Add the Trimebutine Maleate, α-D-galactosidase, Lactose hydrous and Croscarmellose sodium to the mixer and mix for 5 to 20 minutes at 50 to 200 rpm.
[0072] 6. Moisten with the binder solution from step 1.
[0073] 7. Pass the product obtained from the grinder in step 6 through a sieve with openings from 3,000 to 5,000 microns.
[0074] 8. Dry the product at a temperature of 30 to 60° C. until it reaches a residual humidity of 1.0-3.0%.
[0075] 9. Grind the product obtained in step 8 through a grinder with a sieve from 0.033 to 0.094 inches and at a speed of 500 to 1,500 rpm.
[0076] 10. Pass the microcrystalline Cellulose and the magnesium stearate through a sieve with a mesh size from 420 to 2,000 microns.
[0077] 11. Add the following products to the mixer:
[0078] The granules obtained in step 9;
[0079] the microcrystalline Cellulose obtained in step 10 and mix for 10 to 30 minutes at 15 to 30 rpm.
[0080] 12. Add the magnesium stearate obtained in step 9 to the mixer and mix for 5 to 10 minutes at 15 to 30 rpm.
[0081] 13. Compress the product obtained in step 12.
[0082] An example of the formulation of Trimebutine Maleate/α-D-galactosidase/Simethicone tablets obtained by direct compression.
[0000]
Component
Amount
Trimebutine maleate
200,000
mg
Simethicone
75,000
mg
α-D-galactosidase
90,000
mg*
Croscarmellose sodium
30,000
mg
Microcrystalline cellulose
210,000
mg
Magnesium
310,000
mg
Magnesium stearate
10,000
mg
*90 mg are equivalent to 450 U/gal. U/Gal considering a raw material of α-D-galactosidase with enzymatic activity of 5.000 U/gal per gram.
Example Procedure for the Manufacture of Trimebutine Maleate/α-D-Galactosidase/Simethicone Tablets by Direct Compression.
[0083] 1. Pass the following raw materials through a sieve with mesh size of 420 to 2,000 microns:
The α-D-galactosidase Trimebutine maleate Microcrystalline cellulose Croscarmellose sodium Dibasic calcium phosphate
[0089] 2. Add the magnesium Aluminometasilicate to a mixer and begin stirring at a speed between 40 and 100 rpm. Without stopping the stirring, manually add the Simethicone in “string” form very gradually over a time not to exceed 30 minutes (Mixture A).
[0090] 3. Add the following products to a mixer:
Half of mixture A from step 2 Half of the microcrystalline Cellulose Half of the Trimebutine maleate The α-D-galactosidase The Croscarmellose sodium The rest of the Trimebutine maleate The rest of the microcrystalline Cellulose The rest of mixture A And mix for 10 to 30 minutes at 15 to 30 rpm (mixture B)
[0100] 4. Pass the magnesium stearate through a sieve with mesh size of 420 to 2,000 microns.
[0101] 5. Add the magnesium stearate obtained in step 4 to mixture B and mix for 5 to 10 minutes at 15 to 30 rpm.
[0102] 6. Compress the product obtained in step 5.
[0103] An example of manufacturing Trimebutine Maleate/α-D-galactosidase/Simethicone tablets obtained through dry granulation.
[0000]
Component
Amount
Trimebutine maleate
200.000
mg
Simethicone
75.000
mg
α-D-galactosidase
90.000
mg*
Hydroxypropyl cellulose
50.000
mg
Lactose hydrous
110.000
mg
Crospovidone
30.000
mg
Microcrystalline cellulose
125.000
mg
Dibasic calcium phosphate
310.000
mg
Magnesium stearate
10.000
mg
*90 mg are equivalent to 450 U/gal. U/Gal considering a raw material of α-D-galactosidase with enzymatic activity of 5000 U/gal per gram.
[0104] Example Procedure for the Manufacture of Trimebutine Maleate/α-D-Galactosidase/Simethicone Tablets by Dry Granulation.
[0105] 1. Pass the following raw materials through a sieve with mesh size of 420 to 2,000 microns:
The hydroxypropyl cellulose The α-D-galactosidase Trimebutine maleate Lactose hydrous 50% of the Crospovidone Dibasic Calcium Phosphate.
[0112] 2. Incorporate the Dibasic Calcium Phosphate and the hydroxpropyl cellulose to the granulating mixing equipment and mix for 5 and 20 minutes at 50 to 200 rpm.
[0113] 3. After mixing and without stopping stirring, manually add the simethicone in “string” form for no longer than 30 minutes.
[0114] 4. Add Trimbutine Maleate, α-D-galactosidase, Microcrystalline Cellulose, 50% of the Crospovidone to the mixer and mix between 5 and 20 minutes at 50 to 200 rpm.
[0115] 5. Compress the product obtained in step 4.
[0116] 6. Grind the product obtained in step 5 with the granulating equipment with a mesh size of 1,180 to 2,000 microns.
[0117] 7. Compress the granules that were obtained in step 6 again.
[0118] 8. Grind the product obtained in step 7 with the granulating equipment with a mesh size of 1,400 to 1,700 microns.
[0119] 9. Pass the 50% of the Crospovidone, the microcrystalline cellulose, and the magnesium Stearate through a sieve with a mesh size of 420 to 2,000 microns,
[0120] 10. Add the following products to the mixer:
The granules obtained in step 8. 50% of the Croscarmellose Sodium from step 9. The Microcrystalline cellulose obtained in step 9 And mix for 10 to 30 minutes at 15 to 30 rpm.
[0125] 11. Add the magnesium stearate obtained in step 9 to the mixer and mix for 5 to 10 minutes at 15 to 30 rpm.
[0126] 12. Compress the product obtained in step 11. Below are the excipients which can adequately perform the indicated functions:
[0000]
Function
Excipient
Binding Agent
Hydroxypropyl cellulose, corn starch, propyl
cellulose, methyl cellulose.
Diluting Agent
Lactose, Microcrystalline cellulose, mannitol,
sucrose
Absorbing Agent
Dibasic calcium phosphate, aluminum and
magnesium silicate, colloidal silicon dioxide,
microcrystalline cellulose
Disintegrating Agent
Croscarmellose sodium, corn starch,
crospovidone
Lubricating Agent
Magnesium stearate, talc, stearic acid
Gliding Agent
Colloidal Silicon Dioxide
The diluting agent is selected from the excipients that have the function of increasing the apparent volume of the powder, and as such, increase the weight of the pill or capsule.
The absorbing agent is selected from the excipients that are able to absorb certain amounts of liquid in an apparently dry condition.
The disintegrating agent is selected from the excipients that are able to break (disintegrate) the pill and the granules when they come into contact with a liquid.
The lubricating agent is selected from the excipients that are able to reduce the friction between the granules and the wall of the matrix during the process of compression or filling of the capsules.
The gliding agent is selected from the excipients that are able to provide a flow to the granules of the hopper to the cavity of the matrix through the reduction of inter-particle friction.
The binding agent is selected from the excipients that provide cohesiveness to the materials in powder form, forming granules. | A pharmaceutical composition or formulation adapted for oral administration in tablet, coated tablet, capsule or reconstitutable powder form for the prevention or treatment of intestinal disorders such irritable bowel syndrome, also known as irritable colon syndrome, based on an intestinal motility modifier, an agent that prevents gas retention, of digestive enzymes, a binding agent, a diluting agent, an absorbent agent, a lubricant, aglidant, and an disintegrating agent or suspending agent, effective in the normalization of intestinal disorders, to achieve an analgesic activity, to achieve an anti-spasmic activity and to reduce the symptoms associated with intestinal gas such as distention, abdominal pain and flatulence. | 0 |
This application is a continuation of application Ser. No. 310,317 filed Oct. 9, 1981, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a digital to analog converting apparatus having an analog to digital converter (hereinafter called "A/D converter") which converts an analog output signal into a digital signal so that the digital signal may be compared with a digital input signal.
There has long been used a digital to analog (D/A) converting apparatus having a plurality of switches, a resistor ladder circuit, an A/D converter, a comparator and a switching control circuit. The switches are opened and closed under the control of the switching control circuit, whereby the resistor ladder circuit divides a power source voltage and generates an analog voltage of a desired value. The analog voltage is applied to the comparator through the A/D converter and is then compared with a digital input signal supplied to the comparator. The output of the comparator is supplied to the switching control circuit. The switching control circuit controls the switches in accordance with the output of the comparator. This sequence of operation is repeated until the two input signals to the comparator have the same value. When the input signals of the comparator are the same, that is, when the output voltage of the resistor ladder circuit is changed to equal that of the digital input signal, the D/A conversion is completed. While the above-described D/A converting apparatus responds very quickly, it requires a large amount of circuitry due to the resistor ladder circuit, and is therefore expensive.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a digital to analog converting apparatus which has little circuitry and which is thus inexpensive.
This object is achieved by a digital to analog converting apparatus which comprises comparison means having first and second input terminals and generating a comparison signal representing a difference between two signals supplied to the first and second input terminals, the first input terminal being connected to receive a digital signal; a current generating circuit connected to the comparison means for generating current according to the value of the comparison signal; a capacitor connected to the current generating circuit; and an analog to digital converter connected to the capacitor and the second input terminal of the operation circuit for supplying to the second input terminal a digital signal whose value corresponds to an output voltage of the capacitor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block circuit diagram of a first embodiment of a digital to analog converting apparatus according to the invention;
FIG. 2 is a flow chart illustrating operation of the apparatus of FIG. 1;
FIG. 3 shows an output voltage waveform;
FIG. 4 is a block circuit diagram of a second embodiment of a digital to analog converting apparatus according to the invention; and
FIG. 5 is a flow chart illustrating operation of the apparatus of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to the accompanying drawings, the embodiments of the invention will be described.
FIG. 1 shows a first embodiment of this invention. An input terminal 10 is connected to an input register 12. An output signal of the input register 12 is supplied to a central processing unit 14 (hereinafter called "CPU 14"). An output signal of the CPU 14 is coupled to two output registers 16 and 18. An output signal of the output register 16 is coupled to the gate of an N channel MOS FET 20, and an output signal of the output register 18 to the gate of an N channel MOS FET 22. Both MOS FETs 20 and 22 function as analog switches. A power source terminal 24 of positive polarity is grounded via a current source 26, MOS FETs 20 and 22 and another current source 28. The current sources 26 and 28 are each constituted by, for example, a resistor. The current source 26 supplies current to the MOS FET 20, and the current source 28 receives current from the MOS FET 22. The node at which the MOS FETs 20 and 22 are connected is grounded via a capacitor 30 and is connected to a voltage follower amplifier 32 having a high input impedance. The output terminal of the amplifier 32 is connected to an output terminal 34 and also to an A/D converter 36. An output signal of the A/D converter 36 is supplied to an output register 38, an output signal of which is supplied to the CPU 14.
Now referring to the flow chart of FIG. 2, operation of the embodiment of FIG. 1 will be described.
Assume that a digital value D1 has been stored into the input register 12 through the input terminal 10 and that the capacitor 30 is charged to a certain voltage. Then, the A/D converter 36 supplies the input register 38 with a digital voltage D2 which corresponds to the output of the amplifier 32, i.e. the output voltage of the capacitor 30 amplified.
In step 100, the CPU 14 commences a sampling cycle. In step 102 it reads the data D1 and D2 from the input registers 12 and 38, respectively. In step 104 it determines if D1 and D2 are equal. If D1 and D2, i.e. the digital input value and analog output value, are found equal, the CPU 14 proceeds to step 106, wherein an L signal is stored in both the output registers 16 and 18. If D1 and D2 are not found equal, the CPU 14 determines in step 108 whether D1 is greater than D2 or not. As long as the L signal is stored in both the output registers 16 and 18, the MOS FETs 20 and 22 remain non-conductive and the output voltage of capacitor 30 remains unchanged.
If D1 is greater than D2 in step 108, that is, if the digital input value supplied to the input register 12 is greater than the analog output value supplied to the output terminal 34, the CPU 14 proceeds to step 110. In step 110 an H signal is stored in the output register 16, and an L signal in the output register 18. In this case, the MOS FET 20 becomes conductive, and the MOS FET 22 becomes non-conductive. As a result, an output current flows from the current source 26 via the MOS FET 20 and the capacitor 30 is therefore charged. The output voltage of the capacitor 30 then rises and is supplied to the A/D converter 36. Consequently, D2 increases, and the analog output value approaches the digital input value.
If D1 is less than D2 in the step 108, H and L signals are stored in step 112 respectively in the output registers 18 and 16. In this case, the MOS FET 20 becomes non-conductive, and the MOS FET 22 becomes conductive. As a result, the capacitor 30 is discharged and current flows via the MOS FET 22 to the current source 28. Consequently, the output voltage of the capacitor 30 decreases and D2 becomes smaller and thus approaches D1.
After steps 106, 110 and 112 are executed, the CPU 14 proceeds again to the step 102 and reads data D1 and D2 from the input registers 12 and 38, respectively. Thereafter, steps 104, 106, 108, 110 and 112 are repeated once or more times until the analog value supplied to the output terminal 34 becomes equal to the digital input value supplied to the input terminal 10.
The A/D converter 36 converts the analog output value to a digital value during every sampling period. The output voltage of the A/D converter 36 may therefore fluctuate from the true value as illustrated in FIG. 3, wherein the broken line is the true value and T1, T2 and T3 are sampling times. This does not matter since the fluctuation would be 10 mA at most in the case when the current sources 26 and 28 supply 0.1 mA, the capacitor 30 has a capacitance of 50 μF and the sampling cycle is 5 ms.
As mentioned above, the apparatus of FIG. 1 uses a capacitor instead of a resistor ladder circuit. The invention therefore provides a digital to analog converting apparatus which is small, simple and inexpensive. The CPU 14 may be used not only to achieve analog to digital conversion but also to perform other operations. If the CPU 14 is used in this way, interruption will only be effected when it is desired to carry out an analog to digital conversion, at which time the operations shown in FIG. 2 will be carried out. Once the CPU 14 has stored signals in the output registers 16 and 18, it next interruption. Other devices than the CPU 14 may be used to compare the digital input with the analog output. For example, a discrete comparator or a logic circuit may be used for that purpose. Further, the CPU 14, A/D converter 36 and registers 12 and 38 may be replaced by a microcomputer. Still further, instead of the MOS FETs, bipolar transistors, relay switches, etc. may be used for the analog switches.
FIG. 4 shows a second embodiment of this invention. In FIG. 4, same numerals are used to denote the same elements as shown in FIG. 1. This embodiment is identical with the embodiment of FIG. 1, except that it is not provided with the output register 16 and the analog switch 20. As shown in FIG. 4, the output terminal of the output register 18 is connected to the base of an NPN transistor 22. The transistor 22 functions as an analog switch, with its emitter grounded and its collector connected to the anode of a diode 40. A power source terminal 24 is connected to an input terminal of a current source 42 which supplies current to the transistor 22. The cathode of the diode 40 is grounded via a capacitor 30 and connected to the connecting apparatus output terminal 34 via a Darlington pair of transistors 44. The output terminal of the Darlington pair of transistors 44 is also connected to the A/D converter 36.
Now, referring to the flow chart of FIG. 5, operation of the embodiment of FIG. 4 will be described, the input registers 12 and 38 having received data D1 and D2, respectively.
In step 202 the CPU 14 reads D1 and D2 respectively from the input registers 12 and 38. In step 204 it is determined if D1 is greater than D2. If D1 is greater than D2, that is, if the digital input value is greater than the analog output value, the CPU 14 proceeds to step 206, wherein an L signal is stored in the output register 18. In this case, the transistor 22 is non-conductive. As a result, the output current of the current source 42 flows into the capacitor 30 via the diode 40, thus raising the output voltage of the capacitor 30. Consequently, the analog output value approaches the digital input value.
If D1 is less than D2, that is, if the digital input value is smaller than the analog output value, an H signal is stored in the output register 18 in step 208. In this case, the transistor 22 become conductive. The output current of the current source 42 flows to ground via the transistor 22. The capacitor 30 is therefore not charged. As a result, a discharge current path is formed, which extends from the capacitor 30 to the output terminal 34 via the Darlington pair of transistors 44 as indicated by a broken line in FIG. 4. The capacitor 30 is thus discharged, whereby the output voltage of the capacitor 30 gradually decreases. Consequently, the analog output value approaches the digital input value.
Steps 202, 204 and 206 are repeated in sequence, one or more times, until the analog output value increases to be equal to the digital input value. Similarly, steps 202, 204 and 208 are repeated in sequence, one or more times, until the analog output value decreases to be equal to the digital input value. Thus, an analog voltage corresponding to the digital input value will be obtained at the output terminal 34.
The embodiment of FIG. 4 uses a Darlington pair of transistors in place of the current source of the embodiment of FIG. 1 to discharge the capacitor 30. The leakage current of the Darlington pair of transistors is used to discharge the capacitor 30. This technique renders the apparatus of FIG. 4 simpler than that of FIG. 1. | A digital to analog converting apparatus is disclosed, which converts an analog output voltage into a digital value and compares the digital value with a digital input value, and corrects the analog output voltage according to the result of the comparison. The apparatus includes a current source for supplying current according to the result of the comparison and a capacitor which is charged and discharged by the current from the current source. The output voltage of the capacitor is provided as the analog output voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is the National Stage of international Application No. PCT/CN2014/093492, filed Dec. 10, 2014, which claims the benefit of priority to Chinese Patent Application No. 201410012557.7 titled “BEARING LIMITING SYSTEM AND LIMITING METHOD”, filed with the Chinese State Intellectual Property Office on Jan. 10, 2014, the entire disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This application relates to a hearing position-limiting system and a position-limiting method.
BACKGROUND
[0003] In the conventional technology, limitation to a bearing inner race at one side is typically implemented by providing a shaft shoulder on a shaft, and the technique of limitation to the bearing inner race at the other side mainly includes the following kinds. One kind is to provide a groove or screw threads on the shaft, and secure a position-limiting component via this groove or the screw threads, and then limit the bearing by the position-limiting component; another kind is to limit the bearing by an interference fit; the third kind is to limit the bearing by adhesion; and the fourth kind is to mount a shaft cap on a shaft end.
[0004] The position limiting implemented by the interference fit and the adhesion have low reliability. Providing the groove or the screw threads on the shaft to limit the bearing inner race may reduce the strength of the shaft, thereby affecting the performance and the operation safety of the entire mechanical equipment. The method of mounting a shaft cap on a shaft end is not applicable to a bearing mounted on a long shaft. For the bearing mounted on the long shaft, the long shaft is generally designed to be a tapered shape, and an end of the shaft far away from the load end generally has a small shaft diameter.
SUMMARY
[0005] In order to eliminate the defects in the conventional technology such as low reliability, affecting the strength of the shaft and further affecting the performance and operation safety of the mechanical equipment, and inapplicable to a bearing mounted on a long shaft, a bearing position-limiting system and a position-limiting method are provided according to the present application.
[0006] According to an aspect of the present application, a bearing position-limiting system is provided according to the present application, which includes a position-limiting projection, a bearing inner race and a force transferring part arranged between the position-limiting projection and the bearing inner race. An inner diameter of the bearing inner race is larger than an outer diameter of the position-limiting projection.
[0007] According to another aspect of the application, a bearing position-limiting method is provided, which includes: applying a radial action force to a bearing inner race along a shaft at a mounting position of a bearing to a proximal end from a distal end by taking an position-limiting projection integrally formed with the shaft as a force application point, wherein an outer diameter of the position-limiting projection is smaller than an inner diameter of the bearing inner race.
[0008] At least the following beneficial effects are achieved by the embodiments of the present application.
[0009] The bearing position-limiting system according to the embodiments of the present application is convenient for installation, and is capable of achieving effective position-limiting to the bearing inner race without affecting the strength of the shaft and interfering the assembly and disassembly of the bearing, and is particularly applicable to the hearing mounted on a long shaft. The bearing position-limiting method according to the embodiments of the present application is easy to operate, and has low requirement to the operating environment and capability of the operators.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other objects and features of the present application will be further described clearly by means of the following description in conjunction with the drawings, in which:
[0011] FIG. 1 is a first schematic view showing the structure of a bearing position-limiting system according to an embodiment of the present application;
[0012] FIG. 2 is a second schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
[0013] FIG. 3 is a third schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
[0014] FIG. 4 is a fourth schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
[0015] FIG. 5 is a first cross-sectional schematic view showing the structure of a rigid ring of the bearing position-limiting system according to the embodiment of the present application; and
[0016] FIG. 6 is a second cross-sectional schematic view showing the structure of the rigid ring of the bearing position-limiting system according to the embodiment of the present application.
REFERENCE NUMERALS IN THE DRAWINGS
[0017] 1 —position-limiting projection, 2 —bearing inner race,
[0018] 3 —force transferring part, 4 —first rigid component,
[0019] 5 —second rigid component, 6 —connecting component,
[0020] 7 —stuck part, 8 —bolt,
[0021] a—bolt hole, b—through slot,
[0022] c—half through slot.
DETAILED DESCRIPTION
[0023] The bearing position-limiting system according to the embodiments of the present application is applicable to a bearing mounted on a long shaft, and the long shaft is in a tapered shape, and an end of the shaft far away from a load end has a smaller shaft diameter. In the present application, an end which is far away from the load end and has a small shaft diameter is defined as a distal end, and an end which is close to the load end and has a large shaft diameter is defined as a proximal end. A set of bearing position-limiting system is designed according to the present application just by utilizing the feature that the long shaft is in the tapered shape.
[0024] A first embodiment is described hereinafter.
[0025] As shown in FIG. 1 , which is a first schematic view showing the structure of the bearing position-limiting system according to an embodiment of the present application, the bearing position-limiting system according to the embodiment includes a position-limiting projection 1 , a bearing inner race 2 and a force transferring part 3 . The force transferring part 3 is arranged between the position-limiting projection 1 and the bearing inner race 2 , and an inner diameter of the bearing inner race 2 is larger than an outer diameter of the position-limiting projection 1 . Preferably, the position-limiting projection 1 is integrally formed with a shaft.
[0026] Specifically, the position-limiting projection 1 is located at a certain distance from a bearing mounting position, and the force transferring part 3 abuts against the position-limiting projection 1 and the bearing inner race 2 , thus transferring the position-limiting action of the position-limiting projection 1 to the bearing inner race 2 . Preferably, the force transferring part 3 is a ring-shaped structure, and an inner diameter of the force transferring part 3 at a side close to the position-limiting projection 1 is smaller than the outer diameter of the position-limiting projection 1 , thus, the force transferring part 3 can abut against the position-limiting projection 1 . The position-limiting projection 1 may be in a shape of a projected baffle ring integrally formed with the shaft.
[0027] Further, in order to ensure the assembly and disassembly of a bearing outer race and a roller are not affected, the inner diameter of the bearing inner race 2 may be smaller than a maximum outer diameter of the force transferring part 3 , and an outer diameter of the bearing inner race 2 may be larger than the maximum outer diameter of the force transferring part 3 .
[0028] The force transferring part 3 may be at least one integrally formed circular ring and/or at least one multi-piece split circular ring. The force transferring part 3 may be an elastic component and/or a rigid component. If the force transferring part 3 is an elastic component, the elastic component may be mounted between the position-limiting projection 1 and the bearing inner race 2 from an end, having a small diameter, of the long shaft with the aid of the elasticity. If the force transferring part 3 is a rigid component, the force transferring part 3 may also be mounted between the position-limiting projection 1 and the bearing inner race 2 from the end, having a small shaft diameter, of the long shaft after being heated, and then the force transferring part 3 can abut against the position-limiting projection 1 and the bearing inner race 2 after being cooled. In practical applications, however, the force transferring part 3 is preferably a structure spliced by multiple pieces in a circumferential direction, i.e., a multi-piece snapping circular ring. Thus, there is no need to mount the spliced structure along an axial direction. As shown in FIG. 1 , the force transferring part 3 is a split fixed ring formed by two opposite pieces. After the bearing inner race is mounted, the split fixed ring formed by two opposite pieces is mounted between the projection 1 and the bearing inner race 2 , and threaded holes are provided at the joints of the fixed ring, and the two pieces are connected by a hexagon socket-head bolt.
[0029] In the bearing position-limiting system according to the embodiment, the position-limiting projection is designed on the long shaft to have an outer diameter not larger than the inner diameter of the bearing inner race, and the force transferring part transfers the position-limiting action to the bearing inner race, effectively and mechanically securing the bearing inner race without affecting the assembly of the bearing inner race and the strength of the long shaft.
[0030] A second embodiment is described hereinafter.
[0031] As shown in FIG. 2 , which is a second schematic view showing the structure of the bearing position-limiting system according to a second embodiment of the present application, the difference between the second embodiment and the first embodiment lies in that the force transferring part 3 includes a first rigid component 4 and a second rigid component 5 . Specifically, the first rigid component 4 is located close to the bearing inner race 2 , and the second rigid component 5 is located close to the position-limiting projection 1 . Preferably, the first rigid component 4 is a rigid ring mounted on the shaft by an interference fit (i.e., the first rigid component is an interfering ring) and abuts against the bearing inner race 2 . The second rigid component 5 may also be the same as that in the first embodiment, which is in a form of a two-piece or multi-piece split fixed ring. As shown in FIG. 4 , the first rigid component 4 and the second rigid component 5 may be connected together by a bolt 8 . Specifically, threaded holes may be provided in the first rigid component 4 in the axial direction, in addition, the threaded holes may also be provided correspondingly on the second rigid component 5 in the axial direction. The first rigid component 4 and the second rigid component 5 are connected together by the bolt 8 so as to form a single piece, and finally the second rigid component 5 abuts against the position-limiting projection 1 .
[0032] The interfering ring prevents an axial movement of the bearing inner race by means of the interference fit, however, this method still has a risk of failure. Thus, a two-piece split fixed ring is further provided to cooperate with the interfering ring, which effectively prevents the failure of the interfering ring, and further effectively prevents the axial movement of the bearing inner race.
[0033] A third embodiment is described hereinafter.
[0034] As shown in FIG. 3 , which is a third schematic view showing the structure of the hearing position-limiting system according to a third embodiment of the present application, the difference between the third embodiment and the second embodiment lies in that the first rigid component (i.e. the interfering ring) 4 is located at a certain distance from the second rigid component 5 , and the first rigid component 4 and the second rigid component 5 are connected together by a connecting component 6 , and specifically, the connecting component 6 may be a bolt. In an using process, the second rigid component 5 is mounted after the bearing and the first rigid component 4 are mounted, and the first rigid component 4 and the second rigid component 5 are connected by the bolt passing through both of them, and are secured by a nut finally. In this way, a certain gap exists between the first rigid component 4 and the second rigid component 5 , which ensures that the second rigid component 5 can be mounted on the shaft smoothly, and also saves the material of the bearing position-limiting component. As with the above embodiments, the second rigid component 5 may also be in a form of a two-piece or multi-piece split fixed ring same with that in the first embodiment. As a further improvement to this embodiment, the first rigid component (i.e., interfering ring) 4 may be dispensed, and only the second rigid component 5 is left, thus, the second rigid component 5 directly abuts against the bearing inner race by the bolt connecting with the second rigid component 5 .
[0035] A fourth embodiment is described hereinafter.
[0036] This embodiment mainly refers to a further improvement to the position-limiting projection 1 , as shown in FIG. 3 . The position-limiting projection 1 may be in a form of one or more projected blockers arranged in a circumferential direction, and the outer diameter of the position-limiting projection 1 is generally smaller than (at least not larger than) the inner diameter of the bearing inner race 2 , which ensures that the assembly and disassembly of the bearing inner race 2 are not affected. Each of the projected blockers may be in a square shape (a square shape as shown in the drawings) or in a circular-arc shape.
[0037] If the blockers are provided on the shaft, the entire force transferring part 3 or the second rigid component 5 may be designed as a rigid ring with a particular structure, and the rigid ring is a tapered ring-shaped structure (as shown in FIG. 6 ) which conforms to the profile of the shaft. The rigid ring is provided with one or more through slots and one or more half through slots (i.e., a stuck part 7 , as shown in FIG. 3 ) which match the blockers on the shaft in size and number, and the rigid ring is also provided with the threaded holes in the axial direction. The outer diameter of the rigid ring should not be larger than the outer diameter of the bearing inner race, which ensures that the rigid ring does not affect the assembly and disassembly of the bearing outer race and the roller. FIG. 5 is a first cross-sectional schematic view showing the structure of a rigid ring according to the fourth embodiment of the present application (taken along the plane where the circumference is located), and FIG. 6 is a second cross-sectional schematic view showing the structure of the rigid ring according to the fourth embodiment of the present application (taken along the plane where the axis is located). As shown in FIGS. 5 and 6 , the rigid ring shown in the drawings is provided with a through slot b, a half through slot c and a bolt hole a.
[0038] Taking the structure shown in FIG. 3 as an example, the second rigid component 5 is designed to be a rigid ring having a particular structure, and is in cooperation with the interfering ring as the first rigid component 4 , so as to achieve position limitation. The mounting process is as follows. The second rigid component 5 is mounted after the interfering ring is mounted, and firstly, the through slot b is aligned with one of the projected blockers on the shaft, and after the second rigid component 5 is completely pushed to a right side of the projected blocker on the shaft, the second rigid component 5 is rotated by a certain angle so as to allow the half through slot c on the second rigid component 5 to be aligned with the projected blocker on the shaft, and then the baffle ring is moved leftward, which allows the projected blocker to abut against the half through slot c. In addition, as a further improvement, the half through slot c may also be designed to be an L shape to prevent the rigid ring from moving towards the shaft end continually.
[0039] After the second rigid component 5 is mounted, the bolt 8 as a connecting component 6 is screwed into the threaded hole a. The bolt 8 may be a hexagon socket flat-ended bolt, and multiple bolts 8 may be provided and the number of the bolts 8 screwed-in can be selected based on the outer diameter of the shaft. After the bolt 8 is screwed, the flat end of the bolt abuts against the first rigid component 4 , and then the bolt 8 is rotated continually. Since the second rigid component 5 also has screw threads, rotating the bolt 8 continually would push the second rigid component 5 to move leftward until the projected blocker on the shaft abuts against the half through slot c in the second rigid component 5 , thus the entire system is pressed tightly, and when the bolt 8 is rotated in place, a washer and a nut may be mounted for the final securing.
[0040] The technical solutions of the present application are introduced by the above four embodiments, and improvements adopted in various embodiments may also be combined mutually. Therefore, in general, the various variants for the above embodiments are summarized as follows. The rigid ring may not only solely act as the force transferring part 3 , specifically, one end of the rigid ring is engaged with the blockers, and the other end of the rigid ring is connected to the bearing inner race, but also form the force transferring part 3 together with at least another rigid component, and the rigid ring (i.e., the second rigid component 5 ) as one end of the force transferring part is engaged with the blockers, the other rigid ring (i.e., the first rigid component 4 ) as the other end of the force transferring part abuts against the bearing inner race. The second rigid component 5 and the first rigid component 4 may not abut directly, but by a connecting component 6 . As long as a structure may achieve applying an axial acting force along the shaft to the bearing inner race 2 to a proximal end from a distal end and take the position-limiting projection 1 as a force application point, the intended object of the present application can be achieved by the structure.
[0041] As an implementation, an elastic component (e.g., a spring) may also be provided between the projected blockers or the projected baffle ring (i.e., the position-limiting projection 1 ) and the bearing inner race 2 as an implementation of the three transferring part 3 . The elastic component has two ends respectively in connection with the position-limiting projection 1 and the bearing inner race 2 . Alternatively, the elastic component is only a portion of the force transferring part 3 , and forms the force transferring part 3 together with other rigid components. For example, one end of the elastic component is in connection with the position-limiting projection 1 , and the other end of the elastic component is in connection with the rigid ring mounted with the interference fit on the shaft, and the interfering rigid ring is in connection with the bearing inner race. Thus, the limitation to the bearing inner race 2 is achieved by taking the position-limiting projection 1 as a force application point.
[0042] As an implementation, the split rigid ring formed by the two opposite pieces may be mounted between the position-limiting projection 1 and the bearing inner race 2 , and one or more threaded holes are designed in the two opposite pieces so as to connect the two split opposite pieces to form an entire circle, further, one or more threaded holes are designed in the rigid ring in the axial direction. An inner diameter of the rigid ring is in an clearance fit with the shaft such that the rigid ring is movable along the shaft, meanwhile an outer diameter of the rigid ring is not larger than the outer diameter of the bearing inner race 2 , which ensures that the rigid ring does not interfere the assembly and disassembly of the bearing outer ring and the roller.
[0043] After the bearing inner race 2 is assembled, the split rigid ring formed by the two opposite pieces may then be mounted. After the split two pieces are connected into the entire circle by the bolt, the hexagon socket set screw with flat point is screwed into the threaded hole of the rigid ring. The set screw is screwed until the set screw abuts against the hearing inner race 2 , at this time, the set screw is screwed continually such that the rigid ring moves towards the shaft end until the rigid ring abuts against the position-limiting projection 1 . For example, the half through slot on the rigid ring completely abuts against the blocker on the shaft, thus completely securing the bearing inner race 2 . In such a case, a washer and a nut are mounted on the set screw, thereby achieving the limitation and securing to the bearing inner race 2 .
[0044] In the above embodiments, an interfering ring may also be additionally mounted between the bearing inner race 2 and the rigid ring. After the bearing is, the interfering ring is mounted to abut against the bearing, in such a case, the set screw is allowed to abut against the interfering ring to achieve redundancy mechanical securing to the bearing inner race 2 . Apparently, those skilled in the art may appreciate that adding the interfering ring based on other embodiments is advantageous to the object of the present application. For example, after the interfering ring (i.e., the first rigid component 4 ) is provided to abut against the bearing inner race 2 , the second rigid component 5 is provided between the interfering ring and the position-limiting projection on the shaft, and the second rigid component 5 is secured to the interfering ring by the bolt. In such a case, the second rigid component 5 may be an arc-shaped steel block adapted to the long shaft of an axle. In the case that the position-limiting projection 1 on the shaft is in a form of multiple projected blockers, corresponding number of arc-shaped steel blockers may be provided, and an independent arc-shaped steel blocker is provided between each position-limiting projected blocker and the interfering ring. The arc-shaped steel blockers may also be less than the position-limiting projected blockers. That is to say, some adjacent arc-shaped steel blockers arranged between multiple position-limiting projected blockers and the interfering ring are integrally formed. In the case that the position-limiting projection 1 is a projected ring, the number of the arc-shaped steel blocks may be selected according to practical requirements.
[0045] There may be a variety of solutions for the design of the projected blocker, in addition to the square blocker, the projected blocker may also be in a circular arc shape, or may not be the scattered blockers but may be designed as a baffle ring in an entire circle shape. The shape of the through slot and the shape of the half through slot on the rigid ring may also be changed correspondingly.
[0046] Although the present application has been represented and described with reference to the preferred embodiments, it should be understood that, for the person skilled in the art, various modification and variations may be made to these embodiments without departing from the spirit and the scope of the present application defined by appended claims. | Disclosed is a bearing limiting system. The limiting system comprises a limiting bulge formed integrally with a shaft, a bearing inner race, and an acting force conduction part, wherein the acting force conduction part is arranged between the limiting bulge and the bearing inner race, and the inner diameter of the bearing inner race is larger than the outer diameter of the limiting bulge. The bearing limiting system is convenient in installation, can realize the effective limiting of a bearing inner race while not affecting either the strength of the shaft or the assembly and disassembly of the bearing, and is especially suitable for a bearing with a long shaft. | 5 |
FIELD OF THE INVENTION
[0001] The present invention discloses magnetic resonance (MR)-compatible contrast agents for detection of water-poor structures, such as bone and tissue calcification.
BACKGROUND
[0002] Magnetic resonance imaging (MRI) has become one of the most widely used imaging modalities in clinical practice that provides soft tissue images depicting both anatomy and pathologies. Since MRI signal arises from protons, water-poor structures, such as bone and tissue calcification, are essentially invisible.
[0003] Tissue calcification is an important biomarker for human disease, with microcalcifications being of paramount importance for the detection of breast cancer. However, MRI, now the standard of care for screening high-risk women for breast cancer, is unable to detect such calcifications.
[0004] About 80% of MRI protocols in North America employ injected contrast agents that improve tissue contrast and may give additional information {Caravan, 2006; Caravan, 1999}. The most commonly used MRI contrast agents are thermodynamic and kinetically stable low molecular weight gadolinium chelates that alter the relaxivity properties of the surrounding water {Bottrill, 2006}. While a wide range of nonspecific contrast agents are being used in clinical applications for evaluation of physiological parameters, the development of efficient targeted MRI contrast agents directed at specific molecular entities has dramatically expanded the range of possible applications for MRI by combining the noninvasiveness and high spatial resolution of MRI with the specific localization of molecular targets {Weinmann, 2003}. However, previous studies aimed at the development of bone-seeking agents, have shown that the Gd 3+ complex of DOTP 5− [1,4,7,10-Tetraazacyclododecane-1,4,7,10-tetra(methylene phosphonate)] failed to enhance the surrounding water signal when complexed to the bone {Alves, 2003}.
SUMMARY
[0005] Bisphosphonates (BPs) bind avidly to hydroxyapatite (HA) bone mineral surfaces {van Beek, 1998} and have both diagnostic {Ogawa, 2005; Lam, 2007} and therapeutic uses {Lipton, 2000}. BPs are analogues of endogenous pyrophosphates in which the hydrolysable oxygen atom that separates the two phosphate groups is replaced with a more stable carbon atom. The P-C-P structure is responsible for giving BPs their high affinity for bone, which can be further enhanced by addition of a hydroxyl group at the central carbon atom {van Beek, 1998}.
[0006] Osteoblastic bone lesions are typically diagnosed using BP-based radiotracers {Lam, 2007}. MRI of bone lesions could provide superior anatomical localization, would eliminate ionizing radiation, and could be used to guide magnetic resonance spectroscopic evaluation.
[0007] The reason for the inapplicability of MRI to bone and/or solid and semi-solid like structures is two-fold: (i) lack of free water in these structures, (ii) water that is present is partially bound, resulting in the short transverse relaxation times (T 2 ). Thus, it is prohibitively difficult to visualize bone surfaces using conventional magnetic resonance (MR) methodology. Recently, MR techniques employing various ultra short echo (UTE) signal acquisition schemes have become available {Irarrazabal, 1995; Song, 1998}. Rationale for exploiting UTE pulse sequence for MRI in present invention arises from previous work showing that TE on the order of 100 μsec is capable of providing excellent MRI of bone {Bydder, 2006}. In such “solid-like” environments, transverse relaxation times (T 2 ) are very short, averaging≈1 msec for bone and several msec for periosteum. Because of these short T 2 s, these structures are poorly seen using conventional gradient echo (GRE) or spin-echo sequences. However, UTE sequence alone is necessary but not sufficient for detecting calcification. Gd-based contrast agents specific for the calcium salt of interest, needed to be employed in conjunction with the UTE pulse sequence.
[0008] The present invention describes a preparation and application of BP-based MRI contrast agent for UTE MRI detection of HA microcalcification, a hallmark of malignant breast cancer.
[0009] Complicating the development of BP-based MRI contrast agents, however, is the proclivity of BP's to bind lanthanides, the water-poor environment of the bone surface, and the difficulty of chemical synthesis. Unlike most contrast agents and radiotracers, which are relatively immune to their aqueous environment, Gd-based MR contrast agents are highly sensitive to water (i.e., proton) access.
[0010] One aspect of the present invention seeks to provide BP-based MRI contrast agents with different spacer length between derivatives of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid (DOTA) and the BP. Because of propensity of BPs to chelate metals themselves {Alves, 2003}, the BP can be added in a pre-loading strategy after metal chelation by DOTA ( FIG. 1 and FIG. 2 ). Pre-loading of metals on DOTA eliminates the possibility of competition from in-vivo calcium for the phosphonate which could result in the release of toxic metals, such as, gadolinium. In such an aspect, linker, H 2 N-A-COOH is an amino acid or A is independently selected from an alkane, polyethylene glycol and polypropylene glycol. M is Y, In, Gd, Eu, or a lanthanide. In one embodiment, amino acid is natural amino acid. In some embodiment, amino acid is unnatural amino acid. In some embodiment an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit. In some embodiments Eu is loaded for PARACEST contrast agent. In some embodiments, Y is loaded for hyperpolarized MRI contrast agent.
[0011] In an another aspect, methyl ester protected BP can be generated before metal chelation on an organic chelating ligand ( FIG. 3 and FIG. 4 ). Methyl ester protected BP deprotection, after metal loading on an organic chelating ligand, results in contrast agent. In such an aspect, linker, H 2 N-A-COOH is amino acid or A is independently selected from an alkane, polyethylene glycol and polypropylene glycol. M is Y, In, Gd, Eu, or a lanthanide. In one embodiment, amino acid is natural amino acid. In some embodiment, amino acid is unnatural amino acid. In some embodiment an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit.
[0012] In an another aspect, BPs are conjugated to an organic chelating ligand ( FIG. 5 and FIG. 6 ) followed by metal chelation on an organic chelating ligand, results in contrast agent. In such an aspect, linker, H 2 N-A-COOH is an amino acid or A is independently selected from an alkane, polyethylene glycol and polypropylene glycol. M is Y, In, Gd, Eu, or a lanthanide. In one embodiment, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit.
[0013] In an another aspect, the present invention provides a contrast agent represented in general formula [I], and pharmaceutically acceptable salts, hydrates and solvents thereof:
[0000]
[0000] In such an aspect, BP is a bisphosphonate,
[0000]
[0000] is a linker, and
[0000]
[0000] is a metal chelate selected independently from:
[0000]
[0000] In one embodiment, bisphosphonate is independently selected from alendronate, etidronate, ibandronate, incadronate, neridronate, olpadronate, phosphonate, pamidronate, risedronate, tiludronate and zoledronate. In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, M is Y, In, Gd, Eu, or a lanthanide. In some embodiments Eu is loaded for PARACEST contrast agent. In some embodiments, Y is loaded for hyperpolarized MRI contrast agent. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit.
[0014] The major medical application of present invention is in the high sensitivity MRI detection of tissue calcification, especially microcalcification in breast cancer, without the need for ionizing radiation.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 represent metal hepta coordinated BP-based MRI contrast agents in which BPs can be added in a pre-loaded strategy after metal chelation by DOTA.
[0016] FIG. 2 represent metal octa coordinated BP-based MRI contrast agents in which BPs can be added in a pre-loaded strategy after metal chelation by DOTA.
[0017] FIG. 3 represent metal hepta coordinated BP-based MRI contrast agents in which methylester protected BPs can be generated before metal chelation on an organic chelating ligand.
[0018] FIG. 4 represent metal octa coordinated BP-based MRI contrast agents in which methylester protected BPs can be generated before metal chelation on an organic chelating ligand.
[0019] FIG. 5 represent metal hepta coordinated BP-based MRI contrast agents in which BPs are conjugated to an organic chelating ligand followed by metal loading on an organic chelating ligand.
[0020] FIG. 6 represent metal octa coordinated BP-based MRI contrast agents in which BPs are conjugated to an organic chelating ligand followed by metal loading on an organic chelating ligand.
[0021] FIG. 7 is a synthetic scheme for preparation of [Gd 3+ -DOTA]-Thr-Pam-Na (Scheme 1).
[0022] FIG. 8 is a synthetic scheme for preparation of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na (Scheme 2).
[0023] FIG. 9 is an alternative synthetic scheme for preparation of [Gd 3+ -DOTA]-Thr-Pam-Me (Scheme 3).
[0024] FIG. 10 is an alternative synthetic scheme for preparation of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Me (Scheme 4).
[0025] FIG. 11 is an alternative synthetic scheme for preparation of [Gd 3+ -DOTA]-Thr-Pam-Na (Scheme 5).
[0026] FIG. 12 is an alternative synthetic scheme for preparation of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na (Scheme 6).
DETAILED DESCRIPTION
[0027] In a present invention, a synthetic strategy is developed for BP-based MRI contrast agents particularly for water-poor structure such as bone lesions and tissue calcification, and more particularly for breast cancer microcalcification. BP-based MRI contrast agents are designed in which the small molecule BPs, a targeting ligand is engineered to contain a primary amine for conjugation, and is optimized for binding affinity and physicochemical properties independent of the desired functional molecules. Functional molecules are conjugated covalently to the targeting ligands with linkers that provide adequate isolation of the two functions.
[0028] The BP-based MRI contrast agents of present invention are prepared according to the methods known in the art, as illustrated in general in FIGS. 1-6 and described for specific compounds in examples 1-6. Products are characterized by analytical HPLC, NMR and LCMS, and are obtained in typical yields of 50-60%.
[0029] FIG. 1 of present invention describe a synthetic scheme for metal hepta coordinated BP-based MRI contrast agents in which BPs can be added in a pre-loaded strategy after metal chelation by DOTA. Linker with terminal primary amine and carboxylic acid functionality is conjugated with DOTA(tBu) 3 -NHS and subsequent removal of protecting groups on carboxylic moiety results in inermediate for metal chelation. Metal chelation is performed by reaction with metal chloride. Carboxylic acid functional group on DOTA pre-loaded with metal is activated and conjugated with primary amine functional group of BP to results in BP-based MRI contrast agents.
[0030] In one aspect of present invention, a method for synthesizing a BP-based MRI contrast agent is provided. The method involves steps of:
(a) Starting synthesis with an organic chelating ligand selected from the group of:
[0000]
[0000] where in one embodiment R is t-butyl ester, ester or hydrogen, and
R 1 is
[0000]
(b) reacting an organic chelating ligand with a linker having a primary amine and a carboxylic moiety at opposing ends, (c) treating the carboxylic moiety with oxalyl chloride to form an acid chloride at the carboxylic moiety, (d) reacting said acid chloride in one pot with trialkyl phosphite and dialkyl phosphite to form a alkylester protected BP, (e) deprotecting one or more carboxylic acid ester of an organic chelating ligand to yield one or more carboxylic acid functionality, (f) chelating a metal ion to result in a metal chelate, where the linker separate the metal chelate and the alkylester protected BP, and (g) deprotecting one or more BP ester of the alkylester protected BP to results in the BP-based MRI contrast agent.
[0034] In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit. In some embodiments, alkyl is methyl, ethyl or propyl. In some embodiments, metal ion is Y, In, Gd, Eu, or a lanthanide.
[0035] In an another aspect of present invention, a method for synthesizing a BP-based MRI contrast agent is provided. The method involves steps of:
(a) Starting synthesis with an organic chelating ligand selected from the group of:
[0000]
[0000] where in one embodiment R is t-butyl ester, ester or hydrogen, and
R 1 is
[0000]
(b) reacting an organic chelating ligand with a linker having a primary amine and a carboxylic moiety at opposing ends, (c) deprotecting one or more carboxylic acid ester of the organic chelating ligand to yield one or more carboxylic acid functionality, (d) chelating a metal ion to result in a metal chelate, where a metal chelate having a carboxylic moiety, and (e) reacting an amino BP with carboxylic moiety of a metal chelate to form an amide bond to results in BP-based MRI contrast agent.
[0039] In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit. In some embodiments, BP is independently selected from alendronate, neridronate, pamidronate, risedronate, tiludronate and zoledronate. In some embodiments, metal ion is Y, In, Gd, Eu, or a lanthanide.
[0040] In an another aspect of present invention, a method for synthesizing a BP-based MRI contrast agent is provided. The method involves steps of:
(a) Starting synthesis with an organic chelating ligand selected from the group of:
[0000]
[0000] where in one embodiment R is t-butyl ester, ester or hydrogen, and
R 1 is
[0000]
(b) reacting an amino BP with an organic chelating ligand to form an amide bond between a BP and an organic chelating ligand, (c) deprotecting one or more carboxylic acid ester of an organic chelating ligand to yield one or more carboxylic acid functionality, and (d) chelating a metal ion to one or more carboxylic acid ester of the organic chelating ligand to result in BP-based MRI contrast agent.
[0044] In some embodiments, linker separates an organic chelating ligand and the BP. In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit. In some embodiments, BP is independently selected from alendronate, neridronate, pamidronate, risedronate, tiludronate and zoledronate. In some embodiments, metal ion is Y, In, Gd, Eu, or a lanthanide.
[0045] In an another aspect, the present invention provides a contrast agent represented in general formula [II], and pharmaceutically acceptable salts, hydrates and solvents thereof:
[0000]
[0000] In such an aspect, BP is a bisphosphonate,
[0000]
[0000] is a linker, and
[0046] M is Y, In, Gd, Eu, or a lanthanide.
[0047] In one embodiment, bisphosphonate is independently selected from alendronate, etidronate, ibandronate, incadronate, neridronate, olpadronate, phosphonate, pamidronate, risedronate, tiludronate and zoledronate. In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1 -C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit.
[0048] In an another aspect, the present invention provides a contrast agent for MRI having a formula selected from the group of:
[0000]
[0000] In such an aspect, BP is a bisphosphonate,
[0000]
[0000] is a linker, and
[0049] M is Y, In, Gd, Eu, or a lanthanide.
[0050] In one embodiment, bisphosphonate is independently selected from alendronate, etidronate, ibandronate, incadronate, neridronate, olpadronate, phosphonate, pamidronate, risedronate, tiludronate and zoledronate. In some embodiments Eu is loaded for PARACEST contrast agent. In some embodiments, Y is loaded for hyperpolarized MRI contrast agent. In some embodiments, linker is independently selected from amino acid, alkane, polyethylene glycol and polypropylene glycol. In some embodiments, amino acid is natural amino acid. In some embodiments, amino acid is unnatural amino acid. In some embodiments, an alkane is C1-C20 straight chain carbon unit. In some embodiments, polyethylene glycol is 6 to 20 ethylene glycol unit. In some embodiments, polypropylene glycol is 6 to 20 propylene glycol unit.
[0051] The BP-based MRI contrast agents generated by methods of present invention can be used for many medical and non medical application that would benefit from MRI of water-poor structure such as bone lesions and tissue calcification, but none is of immediate need than breast cancer detection. In the general population, breast cancer screening employs x-ray mammography {Van Ongeval, 2006}. In 30% to 50% of cases, microcalcification is the hallmark for the presence of cancer {Morgan, 2005}, although x-ray mammography cannot distinguish the chemical form of the calcium salts present, and therefore relies on the pattern of crystal deposition {Stomper, 2003}. However, breast cancer calcifications are of two major types. Type I crystals, found more frequently in benign ductal cysts, are birefringent and colorless, and are composed of calcium oxalate {Morgan, 2005}. Type II crystals, most often seen in proliferative lesions and associated with breast cancer cells, are composed of calcium hydroxyapatite (HA), and are non-birefringent and basophilic {Haka, 2002}. Because of the relatively low sensitivity and specificity of x-ray mammography, MRI has become the standard of care for screening women at high genetic risk of the disease {Saslow, 2007}. Yet, the sensitivity and specificity of MR in this setting, estimated to be 80% and 90%, respectively {Lehman, 2007}, are still not high enough for maximal positive- and negative-predictive value.
[0052] HA microcalcifications are a hallmark of malignant breast cancer but cannot be detected by current clinical MRI. The major medical application of present invention is in the high sensitivity MRI detection of tissue calcification, especially microcalcification in breast cancer, without the need for ionizing radiation.
[0053] Present invention demonstrates an application of UTE sequences for MRI of contrast agents bound to calcifications in-vivo and in-vitro. Relaxivity properties and adsorption affinities of the complexes are tested using HA as a model of the calcification and bone surface, over other calcium salts, such as, Ca-oxalate (CO), Ca-pyrophosphate (CPP), Ca-phosphate (CP) and Ca-carbonate (CC) salts.
[0054] For in-vitro detection of HA by MRI, after a short incubation time with [Gd 3+ -DOTA]-Thr-Pam-Na (Scheme 1), UTE MRI, but not conventional gradient echo (GRE) sequence MRI is able to detect HA crystals with high sensitivity. Signal enhancement is dependent on the concentration of [Gd 3+ -DOTA]-Thr-Pam-Na incubated with the HA crystals, with incubation concentrations as low as 1 μM resulting in detectable signal enhancement. Signal enhancement is also dependent on relaxation time (TR), with TR≈200 msec providing the lowest background from bulk water and the highest signal enhancement of the HA crystals.
[0055] To determine the selectivity and specificity of [Gd 3+ -DOTA]-Thr-Pam-Na for HA, a major mineral component of calcifications and normal bone, over other calcium salts, in the present invention an incubation of equal quantity each of Ca-hydroxyapatite (HA), Ca-pyrophosphate (CPP), Ca-phosphate (CP), Ca-oxalate (CO) and Ca-carbonate (CC) salts with [Gd 3+ -DOTA]-Thr-Pam-Na in phosphate buffered saline (PBS) is performed. UTE MRI is taken before and after washing crystals, [Gd 3+ -DOTA]-Thr-Pam-Na has more than three fold higher specificity for HA over other calcium salts found in the body, and permits MRI detection of HA with good sensitivity.
[0056] For in-vivo detection of subcutaneously implanted HA crystals as a model of breast cancer microcalcification, in present invention, mice with subcutaneously implanted HA slurries (in PBS) are imaged by both UTE MRI and microCT after intravenous (IV) injection of [Gd 3+ -DOTA]-Thr-Pam-Na. After a minimum of 4 h of clearance, and consistent with the in-vitro results, UTE MRI provides a sensitive detection of HA crystals in-vivo, with the signal enhancement corresponding to the location of the x-ray dense crystals by microCT. Of note, the crystals are invisible by UTE MRI pre-injection of the contrast agent.
EXAMPLES
1. Preparation of [Gd 3+ -DOTA]-Thr-Pam-Na (Scheme 1; FIG. 7)
DOTA(tBu) 3 -Thr (Intermediate):
[0057] To a solution of threonine (0.19 mmol) in 0.1 mL water and dimethylformamide (DMF; 0.4 mL) at 0° C., is added triethylamine (TEA; 0.38 mmol) followed by dropwise addition of DOTA(tBu) 3 -NHS ester (0.12 mmol) in dimethylformamide (DMF; 0.5 mL) for 10 min with stirring. After 10 min, the ice bath is removed and stirring continued at room temperature (RT) for 16 h. The reaction mixture is poured over 2 mL ice-cold water and purified by preparative HPLC.
DOTA(COOH) 3 -Thr (Intermediate):
[0058] DOTA(tBu) 3 -Thr (0.10 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid is removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 3 -Thr is obtained without further purification as a white powder.
[Gd 3+ -DOTA]-Thr (Intermediate):
[0059] The chelation of Gd is performed by adding 0.10 mL of 1 M GdCl 3 (0.10 mmol) in water to a solution of 0.10 mmol of DOTA(COOH) 3 -Thr in 0.9 mL of 0.5 M acetic acid buffer (HAc/Ac − ), pH 5.5. The reaction mixture is stirred at RT for 12 h and purification by preparative HPLC results in an intermediate [Gd 3+ -DOTA]-Thr.
[0060] [Gd 3+ -DOTA]-Thr-Pam-Me (Intermediate):
[0061] Me-Pam {Bhushan, 2007} (0.01 mmol), O-(6-Chlorobenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HCTU; 0.01 mmol), and N-methylmorpholine (NMM; 0.01 mmol) are added at RT under N 2 atmosphere to 0.01 mmol [Gd 3+ -DOTA]-Thr in anhydrous dimethylsulfoxide (DMSO; 0.5 mL). After stirring for 1 h at RT, the reaction mixture is poured over 3 mL ice-cold water and purification by preparative HPLC results in an intermediate [Gd 3+ -DOTA]-Thr-Pam-Me.
[Gd 3+ -DOTA]-Thr-Pam-Na:
[0062] Trimethylsilyl bromide (Me 3 SiBr; 0.04 mmol) is added slowly to a solution of [Gd 3+ -DOTA]-Thr-Pam-Me (0.01 mmol) in dry dimethylformamide (DMF; 0.1 mL) at 0° C. under nitrogen atmosphere. The reaction mixture is vortexed at RT for 12 h. Methanolic NaOH is added to adjust pH between 4 and 4.2, vortexing for 30 min at RT followed by preparative HPLC purification results in the product [Gd 3+ -DOTA]-Thr-Pam-Na.
2. Preparation of [Gd 4′ -DOTA]-(PEG) 8 -Pam-Na (Scheme 2; FIG. 8)
DOTA(tBu) 4 -(PEG) 8 (Intermediate):
[0063] To a solution of Amino-(PEG) 8 -COOH (0.19 mmol) in 0.1 mL water and dimethylformamide (DMF; 0.4 mL) at 0° C., is added triethylamine (TEA; 0.38 mmol) followed by dropwise addition of DOTA(tBu) 4 -NHS ester (0.12 mmol) in dimethylformamide (DMF; 0.5 mL) for 10 min with stirring. After 10 min, the ice bath is removed and stirring is continued at RT for 16 h. The reaction mixture is poured over 2 mL ice-cold water and an intermediate DOTA(tBu) 4 -(PEG) 8 is purified by preparative HPLC.
DOTA(COOH) 4 -(PEG) 8 (Intermediate):
[0064] DOTA(tBu) 4 -(PEG) 8 (0.10 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid is removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 4 -(PEG) 8 is obtained without further purification as a white powder.
[Gd 4+ -DOTA]-(PEG) 8 (Intermediate):
[0065] The chelation of Gd is performed by adding 0.15 mL of 1 M GdCl 3 (0.10 mmol) in water to a solution of 0.10 mmol of DOTA(COOH) 4 -(PEG) 8 in 0.85 mL of 0.5 M acetic acid buffer (HAc/Ac − ), pH 5.5. The reaction mixture is stirred at RT for 12 h and an intermediate [Gd 4+ -DOTA]-(PEG) 8 is purified by preparative HPLC.
[Gd 4+ -DOTA]-(PEG) 8 -Pam-Me (Intermediate):
[0066] Me-Pam (0.01 mmol), O-(6-Chlorobenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HCTU; 0.01 mmol), and N-methylmorpholine (NMM; 0.01 mmol) are added at RT under N 2 atmosphere to 0.01 mmol [Gd 4+ -DOTA]-(PEG) 8 in 1 mL anhydrous dimethylsulfoxide (DMSO; 0.5 mL). After stirring for 1 h at RT, the reaction mixture is poured over 3 mL ice-cold water and is purified by preparative HPLC to obtain an intermadiate [Gd 4+ -DOTA]-(PEG) 8 -Pam-Me.
[0067] [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na:
[0068] Trimethylsilyl bromide (Me 3 SiBr; 0.04 mmol) is added slowly to a solution of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Me (0.01 mmol) in dry dimethylformamide (DMF; 0.1 mL) at 0° C. under nitrogen atmosphere. The reaction mixture is vortexed at RT for 12 h. Methanolic NaOH is added to adjust pH between 4 and 4.2, being vortexed for 30 min at RT and the product [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na is purified by preparative HPLC.
3. Preparation of [Gd 3+ -DOTA]-Thr-Pam-Me (Scheme 3; FIG. 9)
DOTA(tBu) 3 -Thr-Cl (Intermediate):
[0069] DOTA(tBu) 3 -Thr (0.02 mmol) is taken in tetrahydrofuran (THF; 1 mL) at 0° C. under nitrogen atmosphere, is added dimethylformamide (DMF; 5 μL) and 0.04 mmol of 2 M solution of oxalyl chloride in tetrahydrofuran (THF). The solution is stirred at RT for 1 h and after that solvent is removed to get solid DOTA(tBu) 3 -Thr-Cl which is used for next step reaction.
DOTA(tBu) 3 -Thr-Pam-Me (Intermediate):
[0070] To DOTA(tBu) 3 -Thr-Cl (0.02 mmol), is added dropwise trimethyl phosphite (0.025 mmol) at 0° C. under nitrogen atmosphere for 5 minutes and is stirred at RT for about 30 minutes. To the above reaction mixture, is added dropwise dimethyl phosphite (0.025 mmol) at 0° C. under nitrogen atmosphere for 5 minutes and is stirred at RT for about 30 minutes then is added 2 mL cold water and an intermediate DOTA(tBu) 3 -Thr-Pam-Me is purified by preparative HPLC.
DOTA(COOH) 3 -Thr-Pam-Me (Intermediate):
[0071] DOTA(tBu) 3 -Thr-Pam-Me (0.01 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid is removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 3 -Thr-Pam-Me is obtained without further purification as a white powder.
[Gd 3+ -DOTA]-Thr-Pam-Me:
[0072] The chelation of Gd is performed by adding 0.10 mL of 1 M GdCl 3 (0.01 mmol) in water to a solution of 0.01 mmol of DOTA(COOH) 3 -Thr-Pam-Me in 0.9 mL of 0.05 M acetic acid buffer (HAc/Ac − ), pH 5.5. The reaction mixture is stirred at RT for 12 h and product [Gd 3+ -DOTA]-Thr-Pam-Me is purified by preparative HPLC.
4. Preparation of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Me (Scheme 4; FIG. 10)
DOTA(tBu) 4 -(PEG) 8 -Cl (Intermediate):
[0073] DOTA(tBu) 4 -(PEG) 8 (0.02 mmol) is taken in tetrahydrofuran (THF; 1 mL) at 0° C. under nitrogen atmosphere, is added dimethylformamide (DMF; 5 μL) and 0.04 mmol of 2 M solution of oxalyl chloride in tetrahydrofuran (THF). The solution is stirred at RT for 1 h and after that solvent is removed to get solid DOTA(tBu) 4 -(PEG) 8 -Cl which is used for next step reaction.
DOTA(tBu) 4 -(PEG) 8 -Pam-Me (Intermediate):
[0074] To DOTA(tBu) 4 -(PEG) 8 -Cl (0.02 mmol), is added dropwise trimethyl phosphite (0.025 mmol) at 0° C. under nitrogen atmosphere for 5 minutes and is stirred at RT for about 30 minutes. To the above reaction mixture is added dropwise dimethyl phosphite (0.025 mmol) at 0° C. under nitrogen atmosphere for 5 minutes and is stirred at RT for about 30 minutes then is added 2 mL cold water and an intermediate DOTA(tBu) 4 -(PEG) 8 -Pam-Me is purified by preparative HPLC.
DOTA(COOH) 4 -(PEG) 8 -Pam-Me (Intermediate):
[0075] DOTA(tBu) 4 -(PEG) 8 -Pam-Me (0.01 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid is removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 4 -(PEG) 8 -Pam-Me is obtained without further purification as a white powder.
[Gd 4+ -DOTA]-(PEG) 8 -Pam-Me:
[0076] The chelation of Gd is performed by adding 0.15 mL of 1 M GdCl 3 (0.01 mmol) in water to a solution of 0.01 mmol of DOTA(COOH) 4 -(PEG) 8 -Pam-Me in 0.85 mL of 0.05 M acetic acid buffer (HAc/Ac − ), pH 5.5. The reaction mixture is stirred at RT for 12 h and product [Gd 4+ -DOTA]-(PEG) 8 -Pam-Me is purified by preparative HPLC.
5. Preparation of [Gd 3+ -DOTA]-Thr-Pam-Na (Scheme 5; FIG. 11)
DOTA(tBu) 3 -Thr-Pam/DOTA(tBu) 3 -Thr-Pam-Me (Intermediate):
[0077] Pamidronic acid/Me-Pam (0.01 mmol), O-(6-Chlorobenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HCTU; 0.01 mmol), and N-methylmorpholine (NMM; 0.01 mmol) are added at RT under N 2 atmosphere to 0.01 mmol DOTA(tBu) 3 -Thr in anhydrous dimethylsulfoxide (DMSO; 0.5 mL). After stirring for 1 h at RT, the reaction mixture is poured over 3 mL ice-cold water and an intermediate DOTA(tBu) 3 -Thr-Pam/DOTA(tBu) 3 -Thr-Pam-Me is purified by preparative HPLC.
[0000] DOTA (tBu) 3 -Thr-Pam (Intermediate):
[0078] Trimethylsilyl bromide (Me 3 SiBr; 0.04 mmol) is added slowly to a solution of DOTA(tBu) 3 -Thr-Pam-Me (0.01 mmol) in dry dimethylformamide (DMF; 0.1 mL) at 0° C. under nitrogen atmosphere. The reaction mixture is vortexed at RT for 12 h. Methanol/water (4/1) are added, being vortexed for 30 min at RT and an intermediate DOTA(tBu) 3 -Thr-Pam is purified by preparative HPLC.
DOTA(COOH) 3 -Thr-Pam (Intermediate):
[0079] DOTA(tBu) 3 -Thr-Pam (0.01 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid is removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 3 -Thr-Pam is obtained without further purification as a white powder.
[Gd 3+ -DOTA]-Thr-Pam-Na:
[0080] The chelation of Gd is performed by adding 0.10 mL of 1 M GdCl 3 (0.01 mmol) in water to a solution of 0.01 mmol of DOTA(COOH) 3 -Thr-Pam in 0.9 mL of 0.05 M acetic acid buffer (HAc/Ac), pH 5.5. The reaction mixture is stirred at RT for 12 h and product [Gd 3+ -DOTA]-Thr-Pam-Na is purified by preparative HPLC.
6. Preparation of [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na (Scheme 6; FIG. 12)
DOTA(tBu) 4 -(PEG) 8 -Pam/DOTA(tBu) 4 -(PEG) 8 -Pam-Me (Intermediate):
[0081] Pamidronic acid/Me-Pam (0.01 mmol), O-(6-Chlorobenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HCTU; 0.01 mmol), and N-methylmorpholine (NMM; 0.01 mmol) are added at RT under N 2 atmosphere to 0.01 mmol DOTA(tBu) 4 -(PEG) 8 in anhydrous dimethylsulfoxide (DMSO; 0.5 mL). After stirring for 1 h at RT, the reaction mixture is poured over 3 mL ice-cold water and an intermediate DOTA(tBu) 4 -(PEG) 8 -Pam/DOTA(tBu) 4 -(PEG) 8 -Pam-Me is purified by preparative HPLC.
DOTA(tBu) 4 -(PEG) 8 -Pam (Intermediate):
[0082] Trimethylsilyl bromide (Me 3 SiBr; 0.04 mmol) is added slowly to a solution of DOTA(tBu) 4 -(PEG) 8 -Pam-Me (0.01 mmol) in dry dimethylformamide (DMF; 0.1 mL) at 0° C. under nitrogen atmosphere. The reaction mixture is vortexed at RT for 12 h. Methanol/water (4/1) are added, being vortexed for 30 min at RT and an intermediate DOTA(tBu) 4 -(PEG) 8 -Pam is purified by preparative HPLC.
DOTA(COOH) 4 -(PEG) 8 -Pam (Intermediate):
[0083] DOTA(tBu) 4 -(PEG) 8 -Pam (0.01 mmol) is taken in trifluoroacetic acid (TFA; 1 mL). The solution is stirred at RT for 2.5 h then the acid removed by a N 2 stream. After lyophilization, an intermediate DOTA(COOH) 4 -(PEG) 8 -Pam is obtained without further purification as a white powder.
[Gd 4+ -DOTA]-(PEG) 8 -Pam-Na:
[0084] The chelation of Gd is performed by adding 0.15 mL of 1 M GdCl 3 (0.01 mmol) in water to a solution of 0.01 mmol of DOTA(COOH) 4 -(PEG) 8 -Pam in 0.85 mL of 0.05 M acetic acid buffer (HAc/Ac − ), pH 5.5. The reaction mixture is stirred at RT for 12 h and product [Gd 4+ -DOTA]-(PEG) 8 -Pam-Na is purified by preparative HPLC.
7. UTE MRI:
[0085] MRI can be performed on a 1.5 T GE Signa clinical scanner equipped with a custom low-pass birdcage coil (10 cm length, 6 cm diameter). The custom UTE sequence is based on previous work in the field {Irarrazabal, 1995; Song, 1998}.
8. In-Vitro UTE and GRE MRI of HA Crystals Bound by [Gd 3′ -DOTA]-Thr-Pam-Na:
[0086] 1 mM of [Gd 3+ -DOTA]-Thr-Pam-Na is added to 5 mg of HA crystals in 50 μL PBS (pH 7.4) and is vortexed for 1 h at RT in a 1.5 mL Eppendorf tube. 5 mg HA in 1 mM of [Gd 3+ -DOTA]-Thr and 50 μL PBS is used as a control. MRI, pre- and post-washing with 4×500 μL PBS, are acquired using an UTE sequence (TR=200 msec, TE=100 μsec) or conventional GRE sequence (TR=200 msec, TE=1.8 msec). Other acquisition parameters includes FOV=6 cm, slice thickness=5 mm, matrix size=256×256, NEX=4.
9. Contrast Agent Concentration and TR Dependence of UTE MRI Signals:
[0087] 5 mg HA is placed in 1.5 mL plastic Eppendorf tubes, then 0, 0.1, 1, 10, or 100 μM [Gd 3+ -DOTA]-Thr-Pam-Na in 50 μL PBS is added to each. After vortexing 1 h at RT, the crystals are washed with 4×500 μL PBS and UTE MRI acquisition is performed using a fixed TE=100 μsec and varying TR of 17, 50, 200, 500 msec. Other acquisition parameters includes FOV=11 cm, slice thickness=10 mm, matrix size=256×256, NEX=2.
10. Quantitation of Calcium Salt Specificity:
[0088] 5 mg of HA or the phosphate, oxalate, carbonate, or pyrophosphate salts of calcium is placed in 1.5 ml Eppendorf tube and is incubated with 10 μM [Gd 3+ -DOTA]-Thr-Pam-Na in 50 μL PBS for 1 h at RT with continuous vortexing. UTE MRI acquisition is performed pre- and post-washing with 4×500 μL PBS using TR=200 msec and TE=100 μsec. Other acquisition parameters includes FOV=9 cm, slice thickness=10 mm, matrix size=256×256, NEX=2.
11. In-Vivo Imaging of HA:
[0089] 50 mg of HA crystals is taken in 300 μL PBS, is implanted subcutaneously at right flank of anesthetized mice. UTE MRI is taken after implantation of HA crystal using TR/TE=200 msec/100 μsec, FOV=6 cm, slice thickness=5 mm, matrix size=256×256. 4 μmol of [Gd 3+ -DOTA]-Thr-Pam-Na in 300 μL saline is injected intravenously. After 4 h of clearance, an UTE MRI is taken with same parameters.
REFERENCES
[0090] 1. Caravan, P. Strategies for increasing the sensitivity of gadolinium based MRI contrast agents. Chem. Soc. Rev. 35, 512-523 (2006).
[0091] 2. Caravan, P., Ellison, J. J., McMurry, T. J. & Lauffer, R. B. Gadolinium (III) chelates as MRI contrast agents: structure, dynamics, and applications. Chem. Rev. 99, 2293-2352 (1999).
[0092] 3. Bottrill, M., Kwok, L. & Long Nicholas, J. Lanthanides in magnetic resonance imaging. Chem. Soc. Rev. 35, 557-571 (2006).
[0093] 4. Weinmann, H. J., Ebert, W., Misselwitz, B. & Schmitt-Willich, H. Tissue-specific MR contrast agents. Eur. J. Radiol. 46, 33-44 (2003).
[0094] 5. Alves, F. C. et al. Silencing of phosphonate-gadolinium magnetic resonance imaging contrast by hydroxyapatite binding. Invest. Radiol. 38, 750-760 (2003).
[0095] 6. Van Beek, E. R., Lowik, C. W., Ebetino, F. H. & Papapoulos, S. E. Binding and antiresorptive properties of heterocycle-containing bisphosphonate analogs: structure-activity relationships. Bone 23, 437-442 (1998).
[0096] 7. Ogawa, K. et al. Development of a rhenium-186-labeled MAG3-conjugated bisphosphonate for the palliation of metastatic bone pain based on the concept of bifunctional radiopharmaceuticals. Bioconjug. Chem. 16, 751-757 (2005).
[0097] 8. Lam, M. G. E. H., de Klerk, J. M. H., van Rijk, P. P. & Zonnenberg, B. A. Bone seeking radiopharmaceuticals for palliation of pain in cancer patients with osseous metastases. Anti - Cancer Agents in Medicinal Chemistry 7, 381-397 (2007).
[0098] 9. Lipton, A. et al. Pamidronate prevents skeletal complications and is effective palliative treatment in women with breast carcinoma and osteolytic bone metastases: long term follow-up of two randomized, placebo-controlled trials. Cancer 88, 1082-1090 (2000).
[0099] 10. Irarrazabal, P & Nishimura, D. G. Fast three dimensional magnetic resonance imaging. Magn. Reson. Med. 33, 656-662 (1995).
[0100] 11. Song, H. K & Wehrli, F. W. Variable TE gradient and spin echo sequences for in vivo MR microscopy of short T2 species. Magn. Reson. Med. 39, 251-258 (1998).
[0101] 12. Bydder, G. M. & Robson, M. D. Clinical ultrashort echo time imaging of bone and other connective tissues. NMR Biomed. 19, 765-780 (2006).
[0102] 13. Van Ongeval, C., Bosmans, H. & Van Steen, A. Current status of digital mammography for screening and diagnosis of breast cancer. Curr. Opin. Oncol. 18, 547-554 (2006).
[0103] 14. Morgan, M. P., Cooke, M. M. & McCarthy, G. M. Microcalcifications associated with breast cancer: an epiphenomenon or biologically significant feature of selected tumors. J. Mammary Gland Biol. Neoplasia 10, 181-187 (2005).
[0104] 15. Stomper, P. C., Geradts, J., Edge, S. B. & Levine, E. G. Mammographic predictors of the presence and size of invasive carcinomas associated with malignant microcalcification lesions without a mass. AJR Am. J. Roentgenol. 181, 1679-1684 (2003).
[0105] 16. Haka, A. S. et al. Identifying microcalcifications in benign and malignant breast lesions by probing differences in their chemical composition using Raman spectroscopy. Cancer Res. 62, 5375-5380 (2002).
[0106] 17. Saslow, D. et al. American Cancer Society guidelines for breast screening with MRI as an adjunct to mammography. CA Cancer J. Clin. 57, 75-89 (2007).
[0107] 18. Lehman, C. D. et al. Cancer yield of mammography, MR, and US in high-risk women: prospective multi-institution breast cancer screening study. Radiology 244, 381-388 (2007).
[0108] 19. Bhushan, K. R., Tanaka, E. & Frangioni, J. V. Synthesis of conjugatable bisphosphonates for molecular imaging of large animals. Angew. Chem. Int. Ed. Engl. 46, 7969-7971 (2007). | The present invention discloses magnetic resonance compatible contrast agents for water-poor structures, such as bone and tissue calcification. In particular, the present invention discloses bisphosphonate-based magnetic resonance imaging contrast agents specific for hydroxyapatite, the calcium salt most commonly associated with malignant calcification. | 2 |
REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application Ser. No. 61/728,941, filed Nov. 21, 2012, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to wind power and, in particular, to an electrical generation system based upon sail craft that move between towers through wind power.
BACKGROUND OF THE INVENTION
The advantages of wind power are many. It is widely available and does not require flowing water or sources of fuel. Harnessing the wind dates back to the first sailboat. Wind-powered machines have ground grain and pumped water for hundreds of years. With the development of electricity, wind power found new applications in lighting buildings remote from centrally-generated power. Throughout the 20th century, small wind plants evolved for farms and residences, while larger utility-scale wind generators were connected to electricity grids for power in remote locations.
Today, wind powered generators range in size from small plants for battery charging at isolated residences, to expansive offshore wind farms that provide electricity to national electrical networks. Multi-megawatt turbine technologies in use today include advanced aerodynamic, structural, and acoustic engineering design features such as steel tube towers, variable-speed generators, composite blade materials and partial-span pitch control. In 1987, the MOD-5B was the largest single wind turbine operating in the world with a rotor diameter of nearly 100 meters and a rated power of 3.2 megawatts.
However, not all the energy of blowing wind can be harvested, since conservation of mass requires that as much mass of air exits the turbine as enters it. Betz' law gives the maximal achievable extraction of wind power by a wind turbine as 59 percent of the total kinetic energy of the air flowing through the turbine. Further inefficiencies, such as rotor blade friction and drag, gearbox losses, generator and converter losses, reduce the power delivered by a wind turbine. Commercial utility-connected turbines deliver about 75 percent of the Betz limit of power extractable from the wind, at rated operating speed.
Conventional wind turbines face a number of obstacles, including intermittency, space requirements, complaints from homeowners; as such, alternative technologies are being given more serious consideration. One alternative is the airborne generator, the basic premise of which is to tether a device to the ground and let it fly around in the strong winds like a kite, either generating power and sending it down a tether to the ground or using the tether itself to produce electricity at its base.
One example, the Ampyx's PowerPlane, is a glider that generates electricity by pulling on its tether, which is connected to a ground-mounted generator. The PowerPlane glides around between 1,000 and 2,000 feet; the next iteration of this design should generate 250 to 500 kilowatts continuously. There are also inflatable designs, as well as a soft-wing kite design from North Carolina-based Windlift that uses a 40-square-meter wing flying at a maximum altitude of 500 feet, with the controls and generator on the ground.
But scaling up airborne prototypes will not be easy without strong government support. In order to be viable, airborne devices would need to stay aloft for long periods of time with little maintenance required. Another challenge is regulation, since airborne systems are so large and consume such a large volume of airspace.
SUMMARY OF THE INVENTION
This invention resides in an electrical generation system based upon sail craft that move between towers through wind power. A wind energy generator constructed in accordance with the invention comprises at least two support towers extending up from the ground and upper and lower cables extending from one tower to another. At least one sail craft is coupled to the upper and lower cables such that wind moves the sail craft along the cables. Each sail craft is coupled to the upper and lower cables with respective upper and lower modules, one or both of which includes a wheel that rotates as the craft moves along the cables. The wheel is coupled to an electrical generator that that feeds one or both of the cables for further distribution through at least one of the towers.
A structure at each tower causes the craft to reverse its direction and travel back and forth between the towers. In the preferred embodiment, the system includes four cables between the towers, including an upper pair of cables and a lower pair of cables. The structure at the end towers causes each craft to reverse its direction is a spiral track interconnecting the upper and lower cables, causing the sail craft to travel to one tower on the upper pair of cables and travel to the other tower on the lower pair of cables. In this way, sail craft travelling in opposite directions to not block the wind to other craft. There may also be support towers like the center tower shown in FIG. 14 . There may be one or more cable support towers that are placed between the end towers that do not cause the cable sailor to turn around.
Each craft further preferably includes a mast extending between the upper and lower modules, with at least one having a forward edge connected to the mast. In the preferred embodiment, each sail is an elliptical sail, and more preferably, each craft uses upper and lower mirrored elliptical sails connected to the mast. A boom may be provided which extends outwardly from the mast and terminates in a distal end, and wherein a portion of the sail is fastened to the boom. In this configuration, upper and lower trailing modules that ride along the upper and lower cables, with a vertical cable extending between the upper and lower trailing modules. A mechanism disposed at the distal end of the boom includes a pulley for engaging a portion of the vertical cable and a motor for operating the pulley to change the angle of the boom relative to the upper and lower cables.
The system may further include one or more sensors for determining wind direction or wind speed, and an electronic controller operative to adjust the angle of the boom as a function of wind direction or wind speed. One or more sensors may be used for determining the power output of each generator, with the electronic controller being operative to adjust the speed of the sail craft or generator loading to maximize power output. In preferred embodiments, the generator functions as a motor/generator, with the electronic controller being operative to switch between motor and generator modes of operation, including the ability to stop the movement of a sail craft or cause a sail craft to move to a tower for maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of a sail craft constructed in accordance with the invention;
FIG. 2A is a system overview from an orthographic perspective;
FIG. 2B is a side view of the system;
FIG. 2C is a top view of the system
FIG. 3A is an orthographic illustration of a motor/generator module;
FIG. 3B is a right side view of the motor/generator module;
FIG. 3C is a front view of the motor/generator module;
FIG. 3D illustrates a motor/generator module with an open side;
FIG. 3E is a view of a motor/generator module seen from a different perspective;
FIG. 4 depicts a motor/generator assembly;
FIG. 5A is a frontal, detail drawing of a motor/generator assembly;
FIG. 5B is a side detail drawing of the motor/generator assembly of FIG. 5A ;
FIG. 6 illustrates a boom deployment system;
FIG. 7 is a detail drawing of a sail craft;
FIG. 8 is another detail drawing of a sail craft;
FIG. 9 depicts a motor/generator aero pod;
FIG. 10 shows a boom and pulley assembly;
FIG. 11 illustrates turn-around towers also shown in FIGS. 14 and 15 ;
FIG. 12 is a graph that shows the cable sailor power output versus its speed along the tower cables;
FIG. 13 shows a graph comparing the cable sailor power output and the wind turbine output with the cable sailor sail area and the wind turbine swept area being equal;
FIG. 14 shows a service station, a tower, main tower cables and tower bases; and
FIG. 15 illustrates a turnaround tower.
DETAILED DESCRIPTION OF THE INVENTION
This invention is directed to a wind energy system referred to herein as the “cable sailor.” The cable sailor craft ( FIG. 1 ) is a wind energy device that travels along cables suspended above the ground by support towers. A minimum of two parallel cables ( 11 ) are required to support the cable sailor craft and carry electrical power generated or received by the cable sailor craft to the power grid. The two cables are attached to the cable sailor craft and separated vertically by a distance equal to the mast ( 12 ) of the cable sailor craft plus some additional distance needed for compliance to account for uneven cable sag.
In the simplest form, the cable sailor system requires only two support towers ( FIG. 2 ). The support towers ( 21 ) would nominally be positioned such that the cables ( 22 ) suspended between the support towers are perpendicular or at least transverse to the prevailing winds. The suspended cables are attached to the support towers by a round section of steel ( 23 ) or other high-strength material that guides the cable sailor in a 180 degree turn at the end of each cable sailor system. The helical turn rails ( 24 ) redirect the cable sailor craft 180 degrees and raise or lower the cable sailor craft altitude. The change in altitude is intended to prevent wind blockage by passing cable sailor craft. The suspended cables will typically be a high tensile stainless steel to prevent corrosion and carry electrical power to or from the cable sailor craft.
The cable sailor craft generates electrical power through two or more teardrop shaped motor/generator (MG) modules ( 31 shown in FIG. 3 ). The MG modules contain one or more alternating or direct current, radial or pancake electrical motor/generators ( 32 ) ( FIGS. 4 and 5 ). In one embodiment, each motor/generator is rated for between 10 and 20 horsepower, or in alternative units, 7.5 to 15.0 kW. Multiple motor generators within each MG module may be used to increase the power output of an individual cable sailor craft while not compromising the tear drop shape of the MG module.
As an example, consider a single cable sailor craft in a 30 mile per hour crosswind, with two of its MG modules each containing four motor/generators producing electrical power at a rate of 15 horse power. By simple arithmetic we see that the cable sailor craft is producing nearly 94 kilowatts of electrical power. Furthermore, by considering that multiple cable sailor craft may occupy the same suspended cable and support tower system, we see that nearly 1 mega-watt of electrical power may be produced by as few as 11 cable sailor craft.
Each cable sailor craft will actively monitor and control the generated electrical voltage phase such that the electrical power is transferred to the upper and lower suspended cables. If the electrical voltage phase is not actively monitored, high circulating currents may flow within the suspended cables and dissipate the generated electrical power as wasted heat. This voltage monitoring and control will be carried out by a system central, or cable sailor craft embedded computer that controls power switching devices such as insulated-gate bipolar transistors.
The trailing MG modules contain idler pulleys ( 14 ) which ride along the suspended cables and are connected to smaller diameter cables ( 61 ) which run to the Boom Deployment (BD) system ( 15 ) ( FIG. 6 ). The BD system is composed or an electrical servo motor ( 62 ) that drives a cable spindle separated into two sections ( 63 ). Each section of the cable spindle is fastened to and contains the spooled cable that runs to the upper and lower trailing MG modules. The electrical servo motor is controlled by an embedded computer that accounts for various input variables such as electrical power generation output, apparent wind speed, apparent wind direction, cable sailor craft speed, and inter cable sailor craft distance.
The embedded computer calculates the appropriate boom angle and directs the electrical servo motor to let out or spool the cable accordingly. When executing a turn at the end of the cable sailor system, the BD system will act to spool the cable, bringing the boom to mid craft and preventing the boom from swinging violently from one side to another due to the change in apparent wind direction. To perform these actions, the cable sailor embedded controller will operate in two distinct modes.
The first mode will be used as the cable sailor travels between supporting towers and is generating power. During this time, a vane anemometer determines the apparent wind direction and speed with respect to the moving cable sailor craft and feeds this information to the embedded controller. The embedded controller will then process the apparent wind direction and speed using an algorithm tailored to the particular locale and actuate the BD system to achieve the appropriate boom angle. The position of the BD system electrical servo motor, and corresponding angle of the boom, will typically be detected using a commercially available optical shaft encoder or Hall Effect sensor. These particular sensors are well suited to this application due to their nearly solid-state design, aside from the bearings and shaft of the optical encoder or Hall Effect sensor.
In addition, voltage and current sensors will be used to determine the power output conditions of the electrical generators and the embedded controller will adjust the cable sailor craft speed and generator loading to provide peak power output without overloading any of the electrical or mechanical systems. In the event of a failure by the vane anemometer, the voltage and current sensors may be used to determine the cable sailor craft's speed and bring the craft safely to a stop or a location designated for maintenance. Ideally, the cable sailor craft will be equipped with redundant sensors for the most important functions.
The second mode will be used as the cable sailor rounds the turn at the end of each cable sailor system. Here the supporting cables terminate and the cable sailor craft is transitioned to a pair of helical turn rails which allow the cable sailor craft to execute a 180 degree turn before returning in the direction from which it came. During this turn, the embedded controller will no longer attempt to maximize electrical power generation by the electrical generators, but will instead instruct the BD system to swing the boom in a controlled manner to a position suited for traveling in the opposite direction. This motion is analogous to a sail boat executing a “tack” maneuver.
The supporting towers would typically be at least 300 feet tall to reach the more quickly moving air beyond the air boundary layer at ground level. Alternatively, the cable sailor system may be suspended between tall neighboring buildings. Depending on their particular geometry, the buildings may act to accelerate the nearby wind which in turn drives the cable sailor craft, increasing the maximum possible electrical power output. Furthermore, by situating the cable sailor system near electrical power consuming communities, the voltage drop (IR-drop) that would normally occur from long distance electrical power transmission may be mitigated. The overall benefit would be to lower energy cost and reduce electrical energy dissipated into waste heat.
The cable sailor craft ideally has mirrored elliptical sails ( FIG. 7 ). The elliptical sail shape was determined to be the most effective at capturing wind energy as compared to other traditional sail shapes. Compared to a triangular shaped sail of equal area, the elliptical shaped sail was shown to be 27 percent more efficient at capturing wind energy in wind tunnel testing. Furthermore, the combination of the twin sails yields 115 percent the power of a single sail and reduces the number of motor/generators, masts, booms, and idler pulleys. The overall effect of the mirrored sail design is to reduce the complexity of the cable sailor craft by a factor of nearly two.
In cold climates, it is conceivable that ice my form on the stationary supporting cables by which the cable sailor craft travel and transmit the generated electrical power. Such ice formation could be detrimental to the cable sailor craft and power transmission by insulating the electrical contact between the cable sailor craft and the supporting cable. To mitigate this, one or more methods may be employed. The supporting cables maybe slightly heated by an induction device or a small gas flame housed within the MG modules prior to encountering the oncoming cable sailor craft. Alternatively, a scrapper device may run along the supporting cable within or attached to the MG modules.
The cable sailor system, composed of one or more cable sailor craft, the supporting cables, and supporting towers, will be electrically interfaced with the commercial power grid through one or more electrical transformers which will boost the cable sailor generated voltage to the appropriate level. In the United States of America, the commercial power grid is typically operated at 117 volts alternating current at 60 Hertz or at 220 volts alternating current at 50 Hertz in many foreign countries. As an alternative to grid interfacing, industrial or residential installations may connect directly to a dedicated cable sailor system if the situation so warrants.
In FIG. 8 , items 800 , 806 , 808 and 810 are the motor/generator housings that can be seen in more detail in FIG. 9 . Items 801 , 805 are cables that are used for both mechanical and electrical connections between the mast and the motor/generator pods 800 and 806 . These cables may be a combination of materials such as copper and stainless steel to have both good electrical conductivity and mechanical strength. Boom/mast connector 802 may be made of a combination of wood and fiberglass, or a composite material such as carbon fiber.
Reference 803 shows the bottom of the over/under elliptical sail. This can be made of common sail cloth, or of photo/voltaic material which can be added to the motor generator voltage to further increase the power output of the cable sailor. Mast 804 may be made of an aluminum tube. If the sails are photo-voltaic, the mast is also used to carry the wire cables connecting to the photo-voltaic cells.
Cables 807 and 811 connect to the towers shown in FIGS. 11, 14 and 15 . As mentioned, the cables serve a dual purpose, one to provide mechanical support for the cable sailors and second to carry electricity generated by primarily the cable sailors, but in some cases the power grid that the cable sailor towers are connected to. These cables may be a combination of materials such as copper and stainless steel to have both good electrical conductivity and mechanical strength. Electrically conductive cables 809 serve a dual purpose. The first is a mechanical support for the boom to the tower cables 807 and 811 . The second function is to electrically connect the motor/generators contained in aero-pods 808 and 810 .
FIG. 9 shows the motor/generator aero pod. Reference 901 shows the top access cover in the open position. 902 is an air inlet used for cooling the motor/generators contained in the pod, and 907 is the air exit point. Item 903 is the tower main cable that the motor/generator pulley rides on. Reference 904 is the motor/generator, and 905 is the cable that connects to the mast for both mechanical support and electrical connectivity. Tower cables 900 , 906 provide for both mechanical support and carrying the voltage and current to and from the motor generators to the towers.
The boom and its pulley assembly are shown in FIG. 10 . The pulley 1001 is turned by the motor gearbox assembly 1002 to control the boom position. 1003 is the boom and 1000 and 1004 are the cables that connect to the motor/generator assembly. FIG. 11 shows the turn-around towers, also shown in FIG. 14 . Item 1100 is a support rail for the cable sailors 1101 , 1105 to both turn 180 degrees and also change altitude to prevent wind blockage to cable sailors traversing in the opposite direction. The support rail is also shown on FIG. 15 as 1503 . Service cables 1102 are connected between the service station 1103 and the switch assembly 1104 and 1106 . The service cables 1102 provide both mechanical support and electrical energy to the cable sailor motor/generator traversing from the Service station 1103 and the tower.
FIG. 12 is a graph that shows the cable sailor power output versus its speed along the tower cables. The three different curves show two different versions of the cable sailor in the University of Michigan 5×7 foot wind tunnel and also a Computational Fluid Dynamics (CFD) simulation. FIG. 13 is a graph comparing the cable sailor Power output and the Wind Turbine output with the cable sailor sail area and the wind turbine swept area being equal. The cable sailor exhibits a factor of 2.23 advantage over the average wind turbine power output at 28 MPH wind speed. FIG. 14 shows the service station 1402 , a tower 1400 , main tower cables 1401 and tower bases 1403 . FIG. 15 shows a turnaround tower showing the cable sailor reversing directions as well as changing heights. | An electrical generation system is based upon sail craft that move between towers through wind power. The system includes at least two support towers (or support structures on buildings, for example), and upper and lower cables extending from one tower to another. At least one sail craft is coupled to the upper and lower cables such that wind moves the sail craft along the cables. Each sail craft is coupled to the upper and lower cables with respective upper and lower modules, one or both of which includes a wheel that rotates as the craft moves along the cables. The wheel is coupled to an electrical generator that that feeds one or both of the cables for further distribution through at least one of the towers. A structure at each tower causes the craft to reverse its direction and travel back and forth between the towers in such a way that sail craft travelling in opposite directions to not block the wind to other craft. | 5 |
RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. patent application Ser. No. 14/036,620 filed on Sep. 25, 2013 (now U.S. Pat. No. 8,579,620 issued Nov. 12, 2013), which is a divisional application of U.S. patent application Ser. No. 13/039,048 filed on Mar. 2, 2011, both of which are hereby incorporated by reference in its entirety.
FIELD OF TECHNOLOGY
[0002] The present invention is in the technical field of three-dimensional (“3D”) printing and rapid prototyping. In particular, the present invention is in the technical field of 3D printing and rapid prototyping using three or n-dimensional image data sets, such as CT (computerized tomography) or MRI (magnetic resonance imaging) images.
BACKGROUND
[0003] Three-dimensional (“3D”) printing of physical models is useful in a wide variety of settings. Some potential uses include production of anatomical bodies like bones for research and clinical applications, medical product development, machine design, and equipment design, to name just a few. 3D printing or rapid prototyping refers to a collection of technologies for producing physical parts directly from digital descriptions. Digital descriptions include output of any software that produces a 3D digital model. One example of such software is Computer-Aided Design (CAD) software. Creating a 3D digital model from a 3D image data set requires specialized imaging or CAD software. Rapid prototyping machines have been commercially available since the early 1990's, the most popular versions of which build a desired structure by adding building material layer-by-layer based on a digital three-dimensional model of the structure.
[0004] However, because of the amount of user interaction time involved and the complexity of data conversion process between image data formats and data formats supported by 3D printers or rapid prototyping machines, applications of the present technology of producing 3D physical models from three or n-dimensional images are rather limited.
[0005] FIG. 1 illustrates the current method of creating a physical model from an input image data set. The input image data set comes in the form of 3D voxel data or serial, sequenced two-dimensional (“2D”) images. A voxel (volumetric pixel or, more correctly, Volumetric Picture Element) is a volume element on a regular grid in a three dimensional space, having one or more numerical values as attributes such as intensity or color. This is analogous to a pixel (Picture Element), which has one or more numerical values as attributes on a regular grid in a 2D image data set. A 3D image data set may be organized as a series of 2D images and a voxel in a two-dimensional image plane may be referred to as a pixel.
[0006] In FIG. 1 , when a user 11 needs to create a physical model 35 from an image data set 10 , the user 11 looks up the image on his/her computer 15 and transfers the image data 10 to an image processing operator 21 . The image processing operator 21 loads the image data 10 set on his computer 20 where special image modeling software is available. The image processing operator 21 reads the instructions sent by the user 11 to understand what type of model is required. If the image processing operator 21 still has questions or needs additional information, he will communicate with the user 11 to get the information. The image processing operator 21 then starts the process to create a 3D digital model 22 from the image data sets 10 on his computer 20 using specialized modeling software. The creation of the 3D digital model 22 requires a trained operator 21 , specialized imaging software, and a significant amount of user interaction. The image processing operator 21 needs to communicate frequently with the user 11 who has ordered the physical model to understand the requirements and applications of the model. The image processing operator is also required to spend a significant amount of time to perform image segmentation and to trace manually certain image areas. After the 3D digital model 22 has been created, it is then saved to a file format supported by a 3D printer or rapid prototyping machine 30 , for example, the STL (stereolithography) file format. The digital model file is then sent to the 3D printer or rapid prototyping machine 30 to generate a 3D physical model 35 . The three-dimensional (“3D”) printer 30 is likely located at a different location and operated by a 3D printing operator 31 . When the physical model 35 is printed or fabricated, the 3D printing operator 31 sends it to the imaging processing operator 21 who then sends the finished physical model 35 back to the original user 11 . The present 3D printing techniques are complex and cost ineffective. The physical models may take too long to create to be useful, for example, to an emergency-care doctor.
[0007] As a particular example of the need for an efficient 3D physical model printing process, we consider 3D printing applications in the medical field. In a typical application of 3D printing techniques in the medical field, medical images are first ordered and acquired on a hospital computer by a doctor. The doctor then sends the images to a trained image processing operator to create a digital model. The image processing operator communicates with the doctor to understand the requirements for the model. The image processing operator loads the image data set into a 3D image processing software to identify features such as bones, tissues, etc. by using image segmentation software tools. Because image processing of medical data is complex and time-consuming, it remains a challenging task even to a professional image processing operator.
[0008] After loading the image data, the image processing operator 21 then creates a digital 3D model, for example, a 3D polygonal surface model by using software-based modeling tools. As an example, one commercially available software solution, “3D-DOCTOR”, can be used to produce 3D digital models of anatomical structures, as described in Yecheng Wu, From CT Image to 3 D Model , Advanced Imaging, Aug. 2001, 20-23. After creating the digital 3D model, the image processing operator 21 sends the digital model to a 3D printing service provider. The 3D printing operator 30 at the 3D printing service provider loads the digital model data on his computer, controls the 3D printer to produce a physical model, and then delivers the finished physical model to the doctor who ordered the model. The above-described process is user intensitive and requires operators to possess advanced software training, knowledge of the intended applications, and a good understanding of the difference between image data formats and the various data formats supported by 3D printer and rapid prototyping machines.
[0009] In the above described process, one procedure employed in image processing is image segmentation. Image segmentation refers to the delineation and labeling of specific image regions in an image data set that defines distinct structures. Image segmentation may include steps such as differentiating a particular structure from adjacent material having different composition and identifying distinct objects having the same or similar composition. For example, when constructing bone models from Computerized Tomography (“CT”) and/or Magnetic Resonance (“MR”) images, bony structures need to be delineated from other structures (soft tissues, blood vessels, etc.) in the images. Also, each bone must typically be separated from adjacent bones when modeling anatomical structures such as cervical spine or foot.
[0010] In 3D printing applications in the medical field, a useful feature is the capability of building a prototype of a patient-specific anatomical region quickly. For example, if a patient comes in with a broken ankle, the surgeon may use a physical model of the bone fragments of the patient to aid surgical planning, if the physical model can be generated rapidly. For orthopedic surgeons, the ability to visualize and manipulate a physical model of a bone or joint in need of repair prior to surgery can aid in the selection and design of surgical implants for fracture fixation or joint replacement. Rapid prototyping of patient specific models increases efficiency and reduces costs by cutting operating room time. Rapid prototyping of patient specific models offers tremendous promise for improved pre-operative planning and preparation. While the technique of sizing surgical implants using newer imaging modalities such as Computerized Tomography (“CT”) and/or Magnetic Resonance (“MR”) imaging is an improvement over standard X-ray films, the ability to work with an accurate physical model of the region of interest would produce further benefits, such as providing tactile 3D feedback of the relevant patient anatomy. Rapid prototyping or 3D printing refers to a collection of technologies for producing physical parts directly from digital descriptions, which frequently are the output from Computer-Aided Design (CAD) software. Rapid prototyping machines have been commercially available since the early 1990's, and the most popular versions involve adding material to build the desired structure layer-by-layer based on a digital three dimensional model of the structure. For example, a physical model may be fabricated using a rapid prototyping system using stereolithography, fused deposition modeling, or three dimensional printing. In stereolithography, a laser is used to selectively cure successive surface layers in a vat of photopolymer. In fused deposition modeling, a thermal extrusion head is used to print molten material (typically a thermoplastic) that fuses onto the preceding layer. A typical three-dimensional printer uses a printer head to selectively deposit binder onto the top layer of a powder bed.
SUMMARY
[0011] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0012] The present application discloses systems and methods for single-action printing of 3D physical models from a three or n-dimensional image data set. The methods may be applied to image data set obtained from any of a wide variety of imaging modalities, including Computerized Tomography (“CT”), Magnetic Resonance (“MR”), positron emission tomography (“PET”), optical coherence tomography (“OCT”), ultrasonic imaging, X-ray imaging, sonar, radar including ground penetrating radar, acoustic imaging, microscopy imaging, simulated image data and the like, or combinations of one or more imaging modalities. The systems and methods are applicable to a wide range of applications from creating physical models of anatomical structures such as bones and organs to creating physical models of mechanical components, archaeological sites, and natural geological formations.
[0013] The systems and methods described herein generally contemplate combining printing template methods with a 3D printer or rapid prototyping machine. The printing template methods usually include predefined data processing steps comprising identifying voxels in an image data set, generating a geometric representation, and sending the geometric representation to the 3D printer to produce a 3D physical model. A 3D printer or rapid prototyping machine refers to a collection of devices capable of producing three-dimensional physical parts directly from digital models using stereolithography, fused deposition modeling, three dimensional printing, sheet laminating or other technologies.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a current method of printing a 3D model from an image data set.
[0015] FIG. 2 illustrates a proposed method for printing a 3D model from an image data set.
[0016] FIG. 3 illustrates a flowchart of an exemplary single-action 3D model printing method.
[0017] FIG. 4 illustrates a flowchart of image data conversion steps included in a printing template.
[0018] FIG. 5 illustrates a list of 3D printing templates accompanied and described with text.
[0019] FIG. 6 illustrates a list of 3D printing templates accompanied and described with text and graphics.
[0020] FIG. 7 illustrates 3D points as an exemplary geometric representation generated by a printing template from image data.
[0021] FIG. 8 illustrates a 3D contour as an exemplary geometric representation generated by a printing template from image data.
[0022] FIG. 9 illustrates a 3D triangle-based surface model as an exemplary geometric representation generated by a printing template from image data.
[0023] FIG. 10 provides a table of sample CT numbers for various human tissues.
[0024] FIG. 11 illustrates an exemplary printing template of printing a bone structure from a CT image data set.
[0025] FIG. 12 illustrates an exemplary printing template of printing a solid body structure from an image data set.
[0026] FIG. 13 illustrates an exemplary printing template of printing a physical model using predefined value ranges from an image data set.
[0027] FIG. 14 illustrates an exemplary process of printing a physical model of selected organs or parts from an image data set.
[0028] FIG. 15 illustrates an exemplary image with seed voxels marked before image segmentation.
[0029] FIG. 16 illustrates a segmentation result of a first round region growing.
[0030] FIG. 17 illustrates a segmentation result of a second round region growing.
[0031] FIG. 18 illustrates a segmentation result of a last round region growing.
[0032] FIG. 19 illustrates a segmented image using a region growing technique.
[0033] FIG. 20 illustrates an example of user adjustable physical model printing method.
DETAILED DESCRIPTION
[0034] Certain specific details are set forth in the following description and figures to provide a thorough understanding of various embodiments of the invention. Certain well-known details often associated with computing and software technology are not set forth in the following disclosure, however, to avoid unnecessarily obscuring the various embodiments of the invention. Further, those of ordinary skill in the relevant art will understand that they can practice the invention without one or more of the details described below. Finally, while various methods are described with reference to steps and sequences in the following disclosure, the description as such is for providing an implementation of embodiments of the invention, and the steps and sequences of steps should not be taken as required to practice this invention.
[0035] FIG. 2 illustrates an exemplary system using a single-action 3D printing method to print a 3D physical model from an input image data set 10 . The 3D model can be, for example, a patient-specific anatomical model. First, the image data set 10 such as CT data, MR data etc, is loaded on a computer 15 . The image data set 10 is typically a voxel-based image data set depicting a 3D region with each voxel of the image data set 10 encoding at least one image attribute, such as image intensity, color or the like. A user 11 at the computer 15 selects one printing template 18 from a list of printing templates ( 300 in FIG. 5 ) for printing a 3D physical model. The computer 15 applies the selected printing template 18 to identify voxels in the image data, generate a geometric representation in a data format supported by a 3D printer, and send the data to a connected or networked 3D printer 30 for producing a physical model 35 . For example, the 3D printer 30 may comprise a rapid prototyping device as discussed above. The 3D printer 30 may be connected to the computer directly through a local computer port, local area network, or the Internet.
[0036] When a 3D printer 30 is not directly connected to the computer where a printing template is used, the data generated from the printing template may be saved to a storage media (for example, a CD or DVD) or storage device (for example, a external hard drive). The saved data can then be ported to the 3D printer 30 to generate the physical model 35 .
[0037] FIG. 3 is a flowchart of a single-action 3D printing method. In FIG. 3 , an image data set 10 is first received in step 210 . In step 218 , a selected printing template 18 is executed to identify the voxel categories and generate a geometric representation for printing a 3D model. In step 230 , the generated geometric representation is sent to a 3D printer 30 and in step 235 , a 3D physical model 35 is produced.
[0038] In FIG. 3 , step 218 represents a single user action involved in the printing process of a 3D model. In step 218 , selecting a printing template includes a selection action by using a pointing device to position on a specific printing template from a list of predefined printing templates and select the printing template for execution. The single-action may be a clicking of a mouse button when a cursor is positioned over a predefined area of a displayed list of printing templates or a depressing of a key on a key pad to select a specific printing template.
[0039] A printing template as defined herein is a software program for identifying voxels in an image data set, generating a geometric representation of a 3D physical model in a data format supported by a 3D printer, and sending the geometric representation to a 3D printer to create a 3D physical model.
[0040] In general, 3D printers require a geometric representation of an object in order to fabricate the geometric shapes required in making a 3D physical model. The geometric representation of an object may include one or a combination of the following forms: a list of 3D points 501 - 506 for the entire body of the object with locational and material information defined at each 3D point ( FIG. 7 ), a group of 3D contours 552 - 561 to define the shape of the object on each image plane ( FIG. 8 ), or surface models 580 ( FIG. 9 ) consisting of triangles or polygons or surface patches delineating the body of the object.
[0041] In the present application, a 3D physical model 35 may have one or more pieces and one or multiple colors, and may be made of one or multiple materials. The conversion process from input image date set to a geometric representation understood by a 3D printer may be either dependent on or independent of imaging modality or any other image information. A printing template may be implemented as a software program on a computer, a computer processing board, or the controller board of a 3D printer. It may be implemented as but not limited to: a program script file with processing instructions and parameters, a binary executable program with processing instructions and parameters, a dynamically linked library (DLL), an application plug-in, or a printer device driver. A printing template may be implemented as a stand-alone solution or a component of a system used for printing 3D physical model from image data sets. A printing template program may be loaded locally on a user's computer or reside on a remote server connected through computer network.
[0042] FIG. 4 illustrates a flowchart of the image data conversion step in a printing template. An input image data set 10 is received by a printing template 15 . The printing template starts its predefined voxel identifying function 310 to identify voxel categories in the image data. After identifying the voxel categories, the printing template generates one of three geometric representations (3D points 315 , 3D contours 320 or surface models 325 ) supported by a 3D printer and sends the generated geometric representation to the 3D printer 30 to produce a 3D physical model 35 .
[0043] The image data conversion process generates a geometric representation and any additional data needed for a 3D printer to print out the physical model. The voxel identifying process is generally done using image processing techniques such as image segmentation and classification. One purpose of image segmentation and classification is to identify the voxel categories at each voxel location for the entire image data set. Commonly used image classification techniques include trained classifiers (such as artificial neural networks), image clustering using voxel similarity measures, etc. Commonly used image segmentation techniques include image thresholding, histogram thresholding, region growing, region splitting, watershed method, graph partitioning, clustering, artificial neural network, and other methods.
[0044] The geometric representation generated from the input image data set for 3D printing may be a list of 3D points 501 - 506 in the body of an object with locational and material information ( FIG. 7 ) specified at each point, or a set of 3D contours 551 - 561 to define the shape of an object in the image planes ( FIG. 8 ), or surface models of an object 580 ( FIG. 9 ), or a combination of them. The data generated for 3D printing is not limited to geometrical representations such as points, contours or surfaces as described. The data may also be organized as a list of printing instructions, such as “move to a location”, “deposit a specified amount of building material”, “move to a new location”, etc., that can be used to complete the physical model printing process.
[0045] The list of printing templates may be displayed as either text 300 ( FIG. 5 ) or graphics 301 ( FIG. 6 ) on the computer 15 . For example, the text may use a description such as “bone structure” or “brain.” The graphic display may use pre-drawn graphic icons to indicate “bone”, “skull”, or “brain.” The graphic display of a printing template may also use a 3D graphic rendering of the geometric representation generated from the image data by the printing template. The number of printing templates is not limited. Additional printing templates may be added for specific physical model printing needs. New printing templates may be created with different processing steps and parameters. A printing template may also be implemented as a part of the input image; in which case user interaction is not required. For example, when the the input image is received with a specific printing template attached, the printing process starts automatically by executing the attached printing template. The execution of the attached printing template may include steps of first generating a geometric representation from the image and then producing a physical model without any user interaction.
[0046] As described above, rapid prototyping systems build a physical model by adding consecutive layers, as opposed to subtractive rapid prototyping or conventional machining that uses a tool to remove material from blank stock. However, generation of a physical model may just as well use other processes and equipment. For example, rapid prototyping processes may be adapted to produce functional objects (“parts”) rather than just geometric models. In such case, rapid prototyping may be referred to by the alternative names such as additive fabrication, layered manufacturing, and solid free form fabrication.
[0047] Many commercial rapid prototyping machines currently employ standard input formats comprising of a polygonal representation of the boundary of the object. For example, a CAD model or other three-dimensional (“3D”) digital model is converted to a list of triangles defining the surface of the object. The machine slices through the collection of triangles to generate a geometric representation that comprises the boundary of each layer to be printed or deposited. In the following sections, different embodiments of 3D printing templates are discussed.
[0000] (1) Printing Bone Structure from CT Image Date Set
[0048] This embodiment is implemented as a printing template for printing a physical model of a bone structure from a CT image data set.
[0049] In a CT image, the intensity value at each voxel may be converted to a value in Hounsfield units (HU). The Hounsfield unit system measures the attenuation coefficient of tissues in computerized tomography. Hounsfield units are also termed CT numbers. FIG. 10 provides a table of sample CT numbers for various human tissues. The table lists some of the voxel values of different tissues or materials in Hounsfield units for a typical CT scanner. The values may differ on a different CT image scanner due to specific settings on that particular imaging device and custom calibrations of image data. The formula to calculate the CT number in Hounsfield units from the voxel intensity is normally provided as part of the image data. For example, the formula used by many CT scanner vendors is:
[0000] HU=Voxel Intensity*Scale+Intercept;
[0000] where HU is the voxel value in Hounsfield units, Voxel Intensity is the attribute value of each voxel provided in an image data set, and Scale and Intercept are parameters provided with the formula. For example, for many CT images, Scale=1 and Intercept=−1000. Other values for Scale and Intercept may also be used.
[0050] As indicated in the table of FIG. 10 , bone tissues may be identified using a range of CT numbers (>1000). The value of every voxel in the image data set can be checked to identify bone tissues. For example, if a voxel has a value above 1000 HU, it is marked as bone tissue. Often an upper limit is used to prevent other hard materials such as metal implants from being marked as bone tissue. A similar technique may be applied to other tissues, such as soft tissue (fat, muscle, etc), blood, liver tissue, and white and grey matter in the brain.
[0051] FIG. 11 is a flowchart of an exemplary printing template for printing bone structures from a CT image set. The printing template identifies voxels that are part of the bone structure in the CT image 600 , generates a geometric representation (in the format of 3D points 605 , Contours 606 , 606 , or Surfaces 607 ) in a 3D printer supported data format and sends the geometric representation to the 3D printer 608 to generate a physical model 610 . The printing template includes the following processing steps:
[0000] a) Go through the entire image data set 600 to check the HU value of each voxel (Step 601 ).
b) For each voxel with a HU value larger than 1000 HU but less than an upper bound, mark the voxel with value 1 to indicate the voxel as representing bone tissue (Step 602 ). Otherwise, mark it with value 0 to indicate non-bone tissue (Step 603 ). Repeat Step “a” and “b” until all voxels are checked, in which case a geometric representation is generated (Step 604 ). The value 1000 HU is used here as an example. Different values or ranges may be used for different images.
c) If the 3D printer ( 608 ) supports input data in the format of 3D points, a geometric representation comprising a list of 3D points for all voxels marked with value 1 may be generated (Step 605 ) and sent to the printer (Step 608 ) to generate a physical model 610 . If other information such as material or color is supported, we may include the other information in the geometric representation. FIG. 7 shows an example of the 3D points generated from an image data set. In this example, every 3D point has an identification value which is either 0 or 1. In this case, 0 indicates non-bone tissue and the voxels with value 0 are represented here by a white color. 1 indicates bone tissue and the voxels with value 1 are represented here by a dark color. In other embodiments, every voxel may have one or multiple identification values which may be any value, not limited to 0 or 1.
In FIG. 7 , the list of 3D points are represented as:
Point 501 : (5, 0, 0, 1)
Point 502 : (5, 1, 1, 1)
Point 503 : (4, 1, 1, 1)
Point 504 : (4, 2, 2, 1)
Point 505 : (5, 2, 2, 1)
Point 506 : (4, 3, 2, 1)
[0052] where each point has a data format of (X, Y, Z, Value). X, Y, Z are the three-dimensional coordinates of a voxel and Value is the attribute with a value of, in this case, 1 for all the voxels identified as bone tissue and 0 otherwise. Other values may be used for identification purposes. Additional values may be also used to indicate attributes such as color or material.
d) If the 3D printer supports input data in the format of 3D contours, a geometric representation comprising the contours are generated by tracing along the outer edge of all voxels marked with the value of 1 (Step 606 ). The contour tracing method is straight forward, and is normally done by walking along the edge voxels in a fixed order within each 2D image plane. For example, we may start the walk on an edge voxel and follow the next edge voxel in a clockwise fashion until the starting position is encountered. The walking process is then repeated for all image planes. FIG. 8 shows an example of tracing a contour in a 2D image plane. In this example, the tracing process starts at one edge voxel 551 and the contour starts with no point data. Voxel 551 is added to the contour as the starting point. In a clockwise order, the next voxel on the edge to be traced is voxel 552 . Voxel 552 is added to the contour. Repeat the process to add voxels 553 , 554 , 555 , 556 , 557 , 558 , 559 , 560 and 561 to the contour. When the next edge voxel is the starting point (Voxel 551 ), the tracing process for this contour is complete. The contour may be represented as:
551 : (4, 5, N, 1)—Start Point
552 : (5, 5, N, 1)
553 : (6, 5, N, 1)
554 : (7, 5, N, 1)
555 : (8, 4, N, 1)
556 : (7, 3, N, 1)
557 : (6, 3, N, 1)
558 : (5, 3, N, 1)
559 : (4, 3, N, 1)
560 : (3, 3, N, 1)
561 : (3, 4, N, 1)—End Point
[0053] where each point has a data format of (X, Y, Z, Value). X, Y, Z are the three-dimensional coordinates of a voxel and Value is the attribute with a value of, in this case, 1 for all the voxels identified as bone tissue and 0 otherwise. Other values may be used for the attribute and additional attributes such as color or material may be included as well. In this example, the particular tracing technique is described as an example. Other tracing methods and variations may be used to generate similar results.
e) If the 3D printer supports input data in the format of a surface model, then a geometric representation in the format of a surface model is generated using the “Marching Cubes” (U.S. Pat. Nos. 4,710,876, 4,751,643, 4,868,748) method or other surface modeling methods (Step 607 ). The generated geometric representation is sent to the 3D printer to produce a physical model 610 (Step 608 ). Most commercially available 3D printers and rapid prototyping machines support the “STL” format, which stores surface geometry data as a set of raw unstructured triangles. For this example, the surface model 607 is sent to the three-dimensional (“3D”) printer in the “STL” format.
[0054] “Marching cubes” is a computer graphics algorithm for extracting a polygonal mesh of an isosurface from three-dimensional voxels. The algorithm proceeds through the voxels marked with 1, taking eight neighbor locations at a time (thus forming an imaginary cube) and then determining the polygon(s) needed to represent the part of the isosurface that passes through this cube. The individual polygons are then fused into the desired surface. The “Marching Cubes” algorithm generates triangle-based surface models. Additional post processing steps such as surface smoothing and surface decimation may be applied to improve the surface quality but are not required.
[0055] FIG. 9 shows an example of a three dimensional triangle-based surface model 580 . In this example, the triangle-based surface model has 8 vertexes: P0, P1, P2, P3, P4, P5, P6, P7 and 12 surface triangles with T1, T2, T3, T4, T5, T6 displayed at the front of the model and T7, T8, T9, T10, T11, T12 displayed at the back of the model. Each vertex is a 3D point: (X, Y, Z). Each triangle has 3 vertexes, for example (P0, P2, P1). This surface model may be represented as:
Triangle 1—T1, Front: (P0, P2, P1)
Triangle 2—T2, Front: (P1, P2, P3)
Triangle 3—T3, Front: (P2, P4, P3)
Triangle 4—T4, Front: (P4, P2, P0)
Triangle 5—T5, Front: (P4, P0, P5)
Triangle 6—T6, Front: (P5, P0, P7)
Triangle 7—T7, Back: (P6, P0, P7)
Triangle 8—T8, Back: (P6, P1, P0)
Triangle 9—T9, Back: (P6, P3, P1)
Triangle 10—T10, Back: (P6, P4, P3)
Triangle 11—T11, Back: (P6, P5, P4)
Triangle 12—T12, Back: (P6, P7, P5)
[0056] In this example, the surface model representation is similar to the commonly used “STL” format and may be sent to the the 3D printer in the “STL” format for printing a physical model. Other representations and variations, such as surface patches or polygon-based surfaces, may also be used.
[0057] The above example describes one embodiment of the single-action 3D image printing methods. The steps in the printing template may be combined or varied. For example, the voxel checking and marking Steps “a” and “b” can be combined into Step “e” that checks the voxel values and generates the surface triangles without marking the voxels.
[0000] (2) Printing Solid Body Structure from an Image Data Set
[0058] This embodiment is implemented as a printing template for printing a physical model of a solid body from an image data set.
[0059] For a known imaging modality, such as Computerized Tomography (“CT”) or Magnetic Resonance (“MR”) imaging, the voxels in an empty or no-tissue region in an image typically have a known value range. For example, air would be considered a no-tissue region. A voxel representing air has a value range around −1000 HU as shown in the CT values table ( FIG. 10 ). In other words, we can check the value of each voxel in the image data set to identify whether the voxel represents an empty region or not. For example, if a voxel in a CT image has a value between −1000 HU and −200 HU (the value below the lowest tissue value in Hounsfield unit), the voxel may be identified as air. Otherwise the voxel may be identified as body tissue. The same method may be applied to other imaging modalities to identify empty regions that are defined with known voxel value ranges.
[0060] FIG. 12 illustrates an exemplary printing template for printing a solid body structure from an image data set. The printing template identifies voxels (Step 621 ) in empty regions and body regions in the image, generates a geometric representation (Steps 625 , 626 , or 627 ), and sends the geometric representation to the 3D printer to create a physical model 629 (Step 628 ). The printing template includes the following processing steps:
[0000] a) Go through the entire image data set 620 to check the value of each voxel in Hounsfield units (Step 621 ).
b) For each voxel, if its value is within the value range of no-tissue (empty region, for example, air), mark the voxel with value 0 to indicate it is empty (Step 623 ). Otherwise, mark it with value 1 to indicate it has tissue (Step 622 ). Repeat Step “a” and “b” until all voxels are checked, in which case, a geometric representation is generated (Step 624 ).
c) If the output printing device supports input data in the format of 3D points, we then generate a list of 3D points for all voxels marked with value 1 (Step 625 ) and send the list to the printer to generate a physical model 629 (Step 628 ). If other information such as material or color is supported, we can extract such information from the input image data and send it together with the geometric representation in the format of 3D points. See FIG. 7 for an example of the 3D points generated from an image data set.
d) If the 3D printer supports input data in the format of contours, then a geometric representation may be generated by tracing the contours along the outer edge of all voxels marked with value 1 (Step 626 ). See FIG. 8 for an example of tracing a contour in a 2D image plane.
e) If the 3D printer supports input data in the format of a surface model, then a geometric representation in the format of a surface model is generated (Step 627 ) using the “Marching Cubes” (U.S. Pat. Nos. 4,710,876, 4,751,643, 4,868,748) method or other surface modeling methods. The geometric representation is then sent to the 3D printer to produce a physical model 629 (Step 628 ).
[0061] The above example describes one embodiment of the single-action 3D image printing methods. The steps in the printing template may be combined or varied, for example, the voxel checking and marking Steps “a” and “b” can be combined into Step “e” that checks the voxel values and generates the surface triangles without marking the voxels.
(3) Printing Physical Model Using Predefined Voxel Value Ranges
[0062] This embodiment is implemented as a printing template for printing a physical model from an image data set using predefined voxel value ranges.
[0063] FIG. 13 illustrates an exemplary printing template for printing a physical model from an image data set 630 using one or more predefined voxel value ranges. A predefined value range may be in voxel intensity, color, texture, location, region, or any derived value from them. A typical range has a low value and a high value to define the bounds of the range. A list of ranges may be used to define multiple value ranges that are not adjacent to each other.
[0064] In this embodiment, the method identifies voxels using the predefined voxel value range (Step 631 ), generates a geometric representation (Steps 635 , 636 , or 637 ), and sends the data to the 3D printer to generate a physical model 639 (Step 638 ). It includes the following steps:
[0000] a) Go through the entire image data set to check the value of each voxel against the value ranges defined in the printing template (Step 631 ).
b) For each voxel with a value within the bound of one of the defined ranges, mark the voxel with value 1 to indicate it is within the specified range (Step 632 ). Otherwise, mark with value 0 to indicate it is outside (Step 633 ). Repeat Step “a” and “b” until all voxels are checked and identified. A geometric representation is generated in Step 634 .
c) If the 3D printer supports input data in the format of three-dimensional points, we generate a geometric representation comprising a list of 3D points for all voxels marked with value 1 (Step 635 ) and send the geometric representation to the 3D printer (Step 638 ) to create a physical model 639 . If other information such as material or color are supported in the input image data 630 , we may include the information and send it together with the geometric representation to the printer. FIG. 7 shows an example of the 3D points generated from an image data set.
d) If the 3D printer supports input data in the format of contours, a geometric representation can be generated by tracing the contours along the outer edge of all voxels marked with value 1 (Step 636 ). See FIG. 8 for an example of tracing a contour in a 2D image plane.
e) If the 3D printer supports input data in the format of a surface model, a geometric representation may be generated using the “Marching Cubes” (U.S. Pat. Nos. 4,710,876, 4,751,643, 4,868,748) method or other surface modeling methods (Step 637 ). The geometric representation is then sent to the 3D printer (Step 638 ) to produce a physical model 639 . Most commercially available 3D printers and rapid prototyping machines support the “STL” format, which stores surface geometry data as a set of raw unstructured triangles. In a particular example, the surface model 637 is sent to the 3D printer in the “STL” format.
[0065] The above example describes one embodiment of the single-action 3D image printing methods. The steps in the printing template may be combined or varied. For example, the voxel checking and marking Steps “a” and “b” can be combined into Step “e” that checks the voxel values and generates the surface triangles without marking the voxels.
(4) Printing Physical Model of Selected Organs or Parts
[0066] This embodiment is implemented as a printing template for printing a physical model of selected organs or parts from an image data set.
[0067] FIG. 14 illustrates an example of printing a physical model 649 of selected organs or parts from an image set 640 . To generated a physical model of selected organs or parts, the image regions of the selected organs need to be identified using image segmentation techniques (Step 644 ). A typical segmentation technique used for identifying specific image regions starts with either a set of automatically generated (Step 642 ) or user selected seed locations or regions (Step 641 ), grows each region by merging neighboring voxels that are within a certain similarity criterion, and repeats the process until no more neighboring voxels are available for merging. For example, the criterion could be a difference of voxel intensity, gray level, texture, or color between the voxels already identified and the ones being checked. After the identification process is complete, the identified regions are then used to generated a geometric representation for the 3D printer. Other image segmentation methods, such as region growing, active contours, graph partitioning, watershed, and clustering, may be used in the image region identifying step of this embodiment.
[0068] In this example, the method identifies voxels using a region growing technique (Step 644 ), generates a geometric representation of the identified voxels in a format supported by a 3D printer 648 (Steps 645 , 646 , or 647 ) and sends the geometric representation to the 3D printer to generate a physical model of selected organs or parts 649 (Step 658 ).
[0069] In this embodiment, a user 11 (referenced in FIG. 2 ) selects some voxels or regions on the input image as seed voxels or regions. FIG. 15 illustrates an example where two selected seed voxels 701 at location (4, 4, Z) and (5, 4, Z) are marked with dark color. The location is represented by the X, Y, Z coordinates of a voxel. FIG. 15 shows the original image as a grayscale image. The grayscale value of this image is from 0 to 255. Seed voxels are checked (Step 641 ) to see whether they are available and whether they are within the bound of the image set. If seed voxels are available, continue to Step “b” to start the image segmentation process (Step 644 ) through region growing. If seed voxels are not available, Step 642 is carried out to generate seed voxels automatically. For example, a predefined value range may be used to select seed voxels within a value range.
[0000] b) The image segmentation process through region growing starts at the seed voxel locations. The process grows each region by merging neighboring voxels that are within a certain similarity criterion and repeats the process until no more neighboring voxels are available for merging. In this example, we choose a simple criterion for measuring voxel similarity, that is, for a neighboring voxel to qualify as similar to a reference voxel, the grayscale value difference between the neighboring voxel and the reference voxel must be less than 20. In other words, if the grayscale value difference is less than 20, the neighboring voxel is added to the region and the region grows by one voxel. If the grayscale value difference is equal to or greater than 20, the voxel is not added to the region. For example, voxel 702 (4, 3, Z) in FIG. 15 has a grayscale value of 103. The difference between this value and the grayscale value ( 102 ) of the voxel located at (4, 4, Z) 701 is 1. The difference is within the similarity criterion, so the neighboring voxel 702 is added to the region. FIG. 16 illustrates the first round of region growing for the image example shown in FIG. 15 . All neighboring voxels with grayscale difference less than 20 are marked with a dark color. 8 voxels 702 (marked with horizontal hatch lines) at locations (4, 3, Z), (5, 3, Z), (3, 4, Z), (6, 4, Z), (3, 5, Z), (4, 5, Z), (5, 5, Z), (6, 5, Z) are added to the region. Here the image plane is assumed to be parallel to the XY plane therefore all voxels have the same Z value.
[0070] FIG. 17 illustrates the result of the second round region growing. 3 voxels 703 (marked with vertical hatch lines) at locations (4, 6, Z), (5, 6, Z), (6, 6, Z) are added to the region.
[0071] FIG. 18 illustrates the result of the last round region growing. 1 voxel 704 (marked with diagonal hatch lines) at locations (5, 7, Z) is added to the region. After this round, no more voxels meet the similarity criteria. The region growing process stops. All voxels added to the region are marked with value 1 and the rest of the voxels are marked with value 0 as shown in FIG. 19 .
[0072] In FIG. 14 , after the image region of the selected organ has been idenfitied (Step 644 ), a geometric representation is generated in the format of either 3D points, or contours, or surfaces (Step 645 , 646 , or 647 ). The geometric representation is then sent to a 3D printer to create a physical model 649 (Step 648 ).
[0073] The above example describes one embodiment of the single-action 3D image printing methods in which the image segmentation technique uses a region growing method. Other image segmentation methods may be used to generate similar results.
(5) User Adjustable Physical Model Printing Method
[0074] This embodiment is implemented as a printing template for printing a physical model from an image data set using user adjustable image processing parameters and steps.
[0075] FIG. 20 illustrates an exemplary printing template that adopts a user adjustable physical model printing method. This printing template provides a user with a list of selectable processing options and adjustable parameters for image segmentation and data conversion. The user 11 makes the initial selection of parameters and segmentation methods (Step 651 ). The segmentation methods may include the ones described in the above examples, such as region growing, image thresholding, graph partitioning, and others. The parameters may include value ranges that are adjustable, user defined seed regions, and others. The image segmentation process (Step 654 ) segments the input image using the selected methods and parameters. The geometric representation generated from the image segmentation process is used to create a 3D rendering (Step 660 ) to show how a final physical model may look on a computer. The computer 15 ( FIG. 2 ) can be used to display a three-dimensional rendering 660 of the model generated by the image segmentation process. The three-dimensional rendering may be implemented using volume rendering of the segmented image or surface rendering from the surface model 657 . If the rendering meets the user's requirements, the segmented image is converted to a format supported by the 3D printer 658 for printing (Steps 655 , 656 , or 657 ). Otherwise, the user can make additional adjustments. The user can decide to print the 3D model on a 3D printer using the current settings or continue the adjustment (Step 651 ) until the user is satisfied with the settings for printing.
[0076] Similar to other embodiments as described above, this embodiment further includes the processing steps of converting an image data set 650 to a geometric representation in a data format supported by the 3D printer and sending the geometric representation to the 3D printer to generate a physical model of selected organs or parts 659 (Step 658 ).
[0000] (6) Extension to n-Dimension
[0077] Although the present method has been described with reference to 3D image data sets, it will be immediately apparent to persons of skill in the art that the methods described above are readily applicable to any number of dimensions. It is contemplated that the methods may be applied to n-dimensional data, where n may be 2, 3, 4 or any number larger than 4. In particular, it is contemplated that the invention may be applied to n-dimensional data in which one of the dimensions is time and there are two or three spatial dimensions. For example, we can use the above described methods to produce multi-dimensional physical models that evolve over time.
[0078] It should be appreciated that the present method greatly reduces the time required for printing physical models from an n-dimensional data set, including a 3D data set. Therefore practical applications capable of producing a series of physical models from time-sequence image data sets to show changes of shape or motions can be implemented. For example, time-sequence 3D image data of a chest containing a beating heart may be used to generate a series of chest models to show the shape and motion of the beating heart at different time points.
[0079] Although the present invention has been described in terms of various embodiments, the invention is not limited to these embodiments. Modification within the spirit of the invention will be apparent to those skilled in the art. For example, various different single-actions can be used to effect the printing of a physical model from an image data set. For example, a voice command may be spoken by the user. A key may be depressed by the user. A button on a 3D printing device may be pressed by the user. Selection using any pointing device may be effected by a user to start the execution of a printing template. Although a single-action may be preceded by multiple physical movements of the user (e.g., moving a mouse so that a mouse pointer is over a button), the single-action generally refers to a single event received by a system that commands the system to print a physical model from an image data set or a derived representation of the image. Finally, various techniques for identifying voxel categories and generating a geometric representation can be used to print a physical model from an image data set. | Methods and techniques of using 3D printers to create physical models from image data are discussed. Geometric representations of different physical models are described and complex data conversion processes that convert input image data into geometric representations compatible with third party 3D printers are disclosed. Printing templates are used to encapsulate complex geometric representations and complicated data conversion processes from users for fast and simple 3D physical model printing applications. | 1 |
CROSS-REFERENCE TO OTHER APPLICATION
[0001] This application claims priority from U.S. provisional application No. 60/098,466 filed Aug. 31, 1998, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to down-hole drilling, and especially to the optimization of drill bit parameters.
[0003] Background: Rotary Drilling
[0004] Oil wells and gas wells are drilled by a process of rotary drilling, using a drill rig such as is shown in FIG. 10. In conventional vertical drilling, a drill bit 10 is mounted on the end of a drill string 12 (drill pipe plus drill collars), which may be miles long, while at the surface a rotary drive (not shown) turns the drill string, including the bit at the bottom of the hole.
[0005] Two main types of drill bits are in use, one being the roller cone bit, an example of which is seen in FIG. 11. In this bit a set of cones 16 (two are visible) having teeth or cutting inserts 18 are arranged on rugged bearings on the arms of the bit. As the drill string is rotated, the cones will roll on the bottom of the hole, and the teeth or cutting inserts will crush the formation beneath them. (The broken fragments of rock are swept uphole by the flow of drilling fluid.) The second type of drill bit is a drag bit, having no moving parts, seen in FIG. 12.
[0006] There are various types of roller cone bits: insert-type bits, which are normally used for drilling harder formations, will have teeth of tungsten carbide or some other hard material mounted on their cones. As the drill string rotates, and the cones roll along the bottom of the hole, the individual hard teeth will induce compressive failure in the formation. The bit's teeth must crush or cut rock, with the necessary forces supplied by the “weight on bit” (WOB) which presses the bit down into the rock, and by the torque applied at the rotary drive.
[0007] Background: Drill String Oscillation
[0008] The individual elements of a drill string appear heavy and rigid. However, in the complete drill string (which can be more than a mile long), the individual elements are quite flexible enough to allow oscillation at frequencies near the rotary speed. In fact, many different modes of oscillation are possible. (A simple demonstration of modes of oscillation can be done by twirling a piece of rope or chain the rope can be twirled in a flat slow circle, or, at faster speeds, so that it appears to cross itself one or more times.) The drill string is actually a much more complex system than a hanging rope, and can oscillate in many different ways; see W AVE P ROPAGATION IN P ETROLEUM E NGINEERING , Wilson C. Chin, (1994).
[0009] The oscillations are damped somewhat by the drilling mud, or by friction where the drill pipe rubs against the walls, or by the energy absorbed in fracturing the formation: but often these sources of damping are not enough to prevent oscillation. Since these oscillations occur down in the wellbore, they can be hard to detect, but they are generally undesirable. Drill string oscillations change the instantaneous force on the bit, and that means that the bit will not operate as designed. For example, the bit may drill oversize, or off-center, or may wear out much sooner than expected. Oscillations are hard to predict, since different mechanical forces can combine to produce “coupled modes”; the problems of gyration and whirl are an example of this.
[0010] Background: Optimal Drilling with Various Formation Types
[0011] There are many factors that determine the drillability of a formation. These include, for example, compressive strength, hardness and/or abrasiveness, elasticity, mineral content (stickiness), permeability, porosity, fluid content and interstitial pressure, and state of underground stress.
[0012] Soft formations were originally drilled with “fish-tail” drag bits, which sheared the formation. Fish-tail bits are obsolete, but shear failure is still very useful in drilling soft formations. Roller cone bits designed for drilling soft formations are designed to maximize the gouging and scraping action, in order to exploit both shear and compressive failure. To accomplish this, cones are offset to induce the largest allowable deviation from rolling on their true centers. Journal angles are small and cone-profile angles will have relatively large variations. Teeth are long, sharp, and widely-spaced to allow for the greatest possible penetration. Drilling in soft formations is characterized by low weight and high rotary speeds.
[0013] Hard formations are drilled by applying high weights on the drill bits and crushing the formation in compressive failure. The rock will fail when the applied load exceeds the strength of the rock. Roller cone bits designed for drilling hard formations are designed to roll as close as possible to a true roll, with little gouging or scrapping action. Offset will be zero and journal angles will be higher. Teeth are short and closely spaced to prevent breakage under the high loads. Drilling in hard formations is characterized by high weight and low rotary speeds.
[0014] Medium formations are drilled by combining the features of soft and hard formation bits. The rock is failed by combining compressive forces with limited shearing and gouging action that is achieved by designing drill bits with a moderate amount of offset. Tooth length is designed for medium extensions as well. Drilling in medium formations is most often done with weights and rotary speeds between that of the hard and soft formations.
[0015] Background: Roller Cone Bit Design
[0016] The “cones” in a roller cone bit need not be perfectly conical (nor perfectly frustroconical), but often have a slightly swollen axial profile. Moreover, the axes of the cones do not have to intersect the centerline of the borehole. (The angular difference is referred to as the “offset” angle.) Another variable is the angle by which the centerline of the bearings intersects the horizontal plane of the bottom of the hole, and this angle is known as the journal angle. Thus as the drill bit is rotated, the cones typically do not roll true, and a certain amount of gouging and scraping takes place. The gouging and scraping action is complex in nature, and varies in magnitude and direction depending on a number of variables.
[0017] Conventional roller cone bits can be divided into two broad categories: Insert bits and steel-tooth bits. Steel tooth bits are utilized most frequently in softer formation drilling, whereas insert bits are utilized most frequently in medium and hard formation drilling.
[0018] Steel-tooth bits have steel teeth formed integral to the cone. (A hard facing is typically applied to the surface of the teeth to improve the wear resistance of the structure.) Insert bits have very hard inserts (e.g. specially selected grades of tungsten carbide) pressed into holes drilled into the cone surfaces. The inserts extend outwardly beyond the surface of the cones to form the “teeth” that comprise the cutting structures of the drill bit.
[0019] The design of the component elements in a rock bit are interrelated (together with the size limitations imposed by the overall diameter of the bit), and some of the design parameters are driven by the intended use of the product. For example, cone angle and offset can be modified to increase or decrease the amount of bottom hole scraping. Many other design parameters are limited in that an increase in one parameter may necessarily result in a decrease of another. For example, increases in tooth length may cause interference with the adjacent cones.
[0020] Background: Tooth Design
[0021] The teeth of steel tooth bits are predominantly of the inverted “V” shape. The included angle (i.e. the sharpness of the tip) and the length of the tooth will vary with the design of the bit. In bits designed for harder formations the teeth will be shorter and the included angle will be greater. Gage row teeth (i.e. the teeth in the outermost row of the cone, next to the outer diameter of the borehole) may have a “T” shaped crest for additional wear resistance.
[0022] The most common shapes of inserts are spherical, conical, and chisel. Spherical inserts have a very small protrusion and are used for drilling the hardest formations. Conical inserts have a greater protrusion and a natural resistance to breakage, and are often used for drilling medium hard formations.
[0023] Chisel shaped inserts have opposing flats and a broad elongated crest, resembling the teeth of a steel tooth bit. Chisel shaped inserts are used for drilling soft to medium formations. The elongated crest of the chisel insert is normally oriented in alignment with the axis of cone rotation. Thus, unlike spherical and conical inserts, the chisel insert may be directionally oriented about its center axis. (This is true of any tooth which is not axially symmetric.) The axial angle of orientation is measured from the plane intersecting the center of the cone and the center of the tooth.
[0024] Background: Bottom Hole Analysis
[0025] The economics of drilling a well are strongly reliant on rate of penetration. Since the design of the cutting structure of a drill bit controls the bit's ability to achieve a high rate of penetration, cutting structure design plays a significant role in the overall economics of drilling a well.
[0026] It has long been desirable to predict the development of bottom hole patterns on the basis of the controllable geometric parameters used in drill bit design, and complex mathematical models can simulate bottom hole patterns to a limited extent. To accomplish this it is necessary to understand first, the relationship between the tooth and the rock, and second, the relationship between the design of the drill bit and the movement of the tooth in relation to the rock. It is also known that these mechanism are interdependent.
[0027] To better understand these relationships, much work has been done to determine the amount of rock removed by a single tooth of a drill bit. As can be seen by the forgoing discussion, this is a complex problem. For many years it has been known that rock failure is complex, and results from the many stresses arising from the combined movements and actions of the tooth of a rock bit. (Sikarskie, et al, P ENETRATION P ROBLEMS IN R OCK M ECHANICS , ASME Rock Mechanics Symposium, 1973). Subsequently, work was been done to develop quantitative relationships between bit design and tooth-formation interaction. This has been accomplished by calculating the vertical, radial and tangential movement of the teeth relative to the hole bottom, to accurately represent the gouging and scrapping action of the teeth on roller cone bits. (Ma, A N EW W AY TO C HARACTERIZE THE G OUGING -S CRAPPING A CTION OF R OLLER C ONE B ITS , Society of Petroleum Engineers No. 19448, 1989). More recently, computer programs have been developed which predict and simulate the bottom hole patterns developed by roller cone bits by combining the complex movement of the teeth with a model of formation failure. (Ma, T HE C OMPUTER S IMULATION OF THE I NTERACTION B ETWEEN THE R OLLER B IT AND R OCK , Society of Petroleum Engineers No. 29922, 1995). Such formation failure models include a ductile model for removing the formation occupied by the tooth during its movement across the bottom of the hole, and a fragile breakage model to represent the surrounding breakage.
[0028] Currently, roller cone bit designs remain the result of generations of modifications made to original designs. The modifications are based on years of experience in evaluating bit run records and dull bit conditions. Since drill bits are run under harsh conditions, far from view, and to destruction, it is often very difficult to determine the cause of the failure of a bit. Roller cone bits are often disassembled in manufacturers' laboratories, but most often this process is in response to a customer's complaint regarding the product, when a verification of the materials is required. Engineers will visit the lab and attempt to perform a forensic analysis of the remains of a rock bit, but with few exceptions there is generally little evidence to support their conclusions as to which component failed first and why. Since rock bits are run on different drilling rigs, in different formations, under different operating conditions, it is extremely difficult draw conclusion from the dull conditions of the bits. As a result, evaluating dull bit conditions, their cause, and determining design solutions is a very subjective process. What is known is that when the cutting structure or bearing system of a drill bit fails prematurely, it can have a serious detrimental effect of the economics of drilling.
[0029] Though numerical methods are now available to model the bottom hole pattern produced by a roller cone bit, there is no suggestion as to how this should be used to improve the design of the bits other than to predict the presence of obvious problems such as tracking. For example, the best solution available for dealing with the problems of lateral vibration, is a recommendation that roller cone bits should be run at low to moderate rotary speeds when drilling medium to hard formations to control bit vibrations and prolong life, and to use downhole vibration sensors. (Dykstra, et al, EXPERIMENTAL EVALUATIONS OF DRILL STRING DYNAMICS, Amoco Report Number F94-P-80, 1994).
[0030] Force-Balanced Roller-Cone Bits, Systems, Drilling Methods, and Design Methods
[0031] The present application describes improved methods for designing roller cone bits, as well as improved drilling methods, and drilling systems. The present application teaches that roller cone bit designs should have equal mechanical downforce on each of the cones. This is not trivial: without special design consideration, the weight on bit will NOT automatically be equalized among the cones.
[0032] Roller-cone bits are normally NOT balanced, for several reasons:
[0033] Asymmetric cutting structures. Usually the rows on cones are intermeshed in order to cover fully the hole bottom and have a self-clearance effects. Therefore, even the cone shapes may be the same for all three cones, the teeth row distributions on cones are different from cone to cone. The number of teeth on cones are usually different. Therefore, the cone having more row and more teeth than other two cones may remove more rock and as a results, may spent more energy (Energy Imbalance). An energy imbalance usually leads to bit force imbalance.
[0034] Offset effects. Because of the offset, a scraping motion will be induced. This scraping motion is different from teeth row to teeth row and as a result, the scraping force (tangent force) acting on teeth is different from row to row. This will generate an imbalance force on bit.
[0035] Tracking effects. If at least one of the cones is in tracking, then this cone will gear with the hole bottom without penetration, the rock not removed by this cone will be partly removed by other two cones. As a result, the bit is unbalanced.
[0036] The applicant has discovered, and has experimentally verified, that equalization of downforce per cone is a very import (and greatly underestimated) factor in roller cone performance. Equalize downforce is believed to be a significant factor in reducing gyration, and has been demonstrated to provide substantial improvement in drilling efficiency. The present application describes bit design procedures which provide optimization of downforce balancing as well as other parameters.
[0037] A roller-cone bit will always be a strong source of vibration, due to the sequential impacts of the bit teeth and the inhomogeneities of the formation. However, many results of this vibration are undesirable. It is believed that the improved performance of balanced-downforce cones is partly due to reduced vibration.
[0038] Any force imbalance at the cones corresponds to a bending torque, applied to the bottom of the drill string, which rotates with the drill string. This rotating bending moment is a driving force, at the rotary frequency, which has the potential to couple to oscillations of the drill string. Moreover, this rotating bending moment may be a factor in biasing the drill string into a regime where vibration and instabilities are less heavily damped. It is believed that the improved performance of balanced-downforce cones may also be partly due to reduced oscillation of the drill string.
[0039] The disclosed innovations, in various embodiments, provide one or more of at least the following advantages:
[0040] The roller cone bit is force balanced such that axial loading between the arms is substantially equal.
[0041] The roller cone bit is energy balanced such that each of the cutting structures drill substantially equal volumes of formation.
[0042] The drill bit has decreased axial and lateral operating vibration.
[0043] The cutting structures, bearings, and seals have increased lifetime and improved performance and durability.
[0044] Drill string life is extended.
[0045] The roller cone bit has minimized tracking of cutting structures, giving improved performance and extending cutting structure life.
[0046] The roller cone bit has an optimized number of teeth in a given formation area.
[0047] Bit performance is improved.
[0048] Off-center rotation is minimized.
[0049] The roller cone bit has optimized (minimized and equalized) uncut formation ring width.
[0050] Energy balanced roller cone bits can be further optimized by minimizing cone and bit tracking.
[0051] Energy balanced roller cone bits can be further optimized by minimizing and equalizing uncut formation rings.
[0052] Designer can evaluate the force balance and energy balance conditions of existing bit designs.
[0053] Designer can design force balanced drill bits with predictable bottom hole patterns without relying on lab tests followed by design modifications.
[0054] Designer can optimize the design of roller cone drill bits within designer-chosen constraints.
[0055] Other advantages of the various disclosed inventions will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, a sample embodiment is disclosed.
[0056] U.S. patent application Ser. No. ______, filed Aug. 31, 1999, entitled “Roller-Cone Bits, Systems, Drilling Methods, and Design Methods with Optimization of Tooth Orientation” (Atty. Docket No. SC-9826), and claiming priority from U.S. Provisional Application No. 60/098,442 filed Aug. 31, 1998, describes roller cone drill bit design methods and optimizations which can be used separately from or in synergistic combination with the methods disclosed in the present application. That application, which has common ownership, inventorship, and effective filing date with the present application, and its provisional priority application, are both hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWING
[0057] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0058] [0058]FIG. 1 shows an element and how the tooth is divided into elements for tooth force evaluation.
[0059] [0059]FIG. 2 diagrammatically shows a roller cone and the bearing forces which are measured in the current disclosure.
[0060] [0060]FIG. 3 shows the four design variables of a tooth on a cone;
[0061] [0061]FIG. 4 shows the bottom hole pattern generated by a steel tooth bit.
[0062] [0062]FIG. 5 shows the layout of row distribution in a plane showing the distance between any two tooth surfaces.
[0063] [0063]FIG. 6 shows a flowchart of the optimization procedure to design a force balanced bit.
[0064] FIGS. 7 A-C compare the three cone profiles before and after optimization.
[0065] FIGS. 8 A-B compare the bottom hole pattern before and after optimization.
[0066] FIGS. 9 A-B compare the cone layout before and after optimization.
[0067] [0067]FIG. 10 shows an example of a drill rig which can use bits designed by the disclosed method.
[0068] [0068]FIG. 11 shows an example of a roller cone bit.
[0069] [0069]FIG. 12 shows an example of a drag bit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0070] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
[0071] Rock Bit Computer Model
[0072] The present invention uses a single element force-cutting relationship in order to develop the total force-cutting relationship of a cone and of an entire roller cone bit. Looking at FIG. 1, each tooth, shown on the right side, can be thought of as composed of a collection of elements, such as are shown on the left side. Each element used in the present invention has a square cross section with area S e (its cross-section on the x-y plane) and length L, (along the z axis). The force-cutting relationship for this single element may be described by:
F ze =k e *σ*S e (1)
F xe =μ x *F ze (2)
F ye =μ y *F ze (3)
[0073] where F ze is the normal force and F xe , F ye are side forces, respectively, σ is the compressive strength, S e the cutting depth and k e , μ x and μ y are coefficient associated with formation properties. These coefficients may be determined by lab test. A tooth or an insert can always be divided into several elements. Therefore, the total force on a tooth can be obtained by integrating equation (1) to (3). The single element force model used in the invention has significant advantage over the single tooth or single insert model used in most of the publications. The only way to obtain a force model is by lab test. There are many types of inserts used today for roller cone bit depending on the rock type drilled. If the single insert force model is used, a lot of tests have to be done and this is very difficult if not impossible. By using the element force model, only a few tests may be enough because any kind of insert or tooth can be always divided into elements. In other words, one element model may be applied to all kinds of inserts or teeth.
[0074] After having the single element force model, the next step is to determine the interaction between inserts and the formation drilled. This step involves the determination of the tooth kinematics (local) from the bit and cone kinematics (global) as described below.
[0075] (1) The bit kinematics is described by bit rotation speed, Ω=RPM (revolutions per minute), and the rate of penetration, ROP. Both RPM and ROP may be considered as constant or as function with time.
[0076] (2) The cone kinematics is described by cone rotational speed. Each cone may have its own speed. The initial value is calculated from the bit geometric parameters or just estimated from experiment. In the calculation the cone speed may be changed based on the torque acting on the cone.
[0077] (3) At the initial time, t0, the hole bottom is considered as a plane and is meshed into small grids. The tooth is also meshed into grids (single elements). At any time t, the position of a tooth in space is fully determined. If the tooth is in interaction with the hole bottom, the hole bottom is updated and the cutting depth for each cutting element is calculated and the forces acting on the elements are obtained.
[0078] (4) The element forces are integrated into tooth forces, the tooth forces are integrated into cone forces, the cone forces are transferred into bearing forces and the bearing forces are integrated into bit forces.
[0079] (5) After the bit is fully drilled into the rock, these forces are recorded at each time step. A period time usually at least 10 seconds is simulated. The average forces may be considered as static forces and are used for evaluation of the balance condition of the cutting structure.
[0080] Evaluation of a Force Balanced Roller Cone Bit
[0081] The applied forces to bit are the weight on bit (WOB) and torque on bit (TOB). These forces will be taken by three cones. Due to the asymmetry of bit geometry, the loads on three cones are usually not equal. In other words, one of the three cones may do much more work than other two cones. With reference to FIG. 2, the balance condition of a roller cone bit may be evaluated using the following criteria:
Max(ω1, ω2, ω3)−Min(ω1, ω2, ω3)<=ω0 (4)
Max(η1, η2, η3)−Min(η1, η2, η3)<=η0 (5)
Max(λ1, λ2, λ3)−Max(λ1, λ2, λ3)<=λ0 (6)=
ξ= F r /WOB* 100%<=t0 (7)
[0082] where ωi (i=1,2,3) is defined by ωi=WOBi/WOB*100%, WOBi is the weight on bit taken by cone i. ηi is defined by ηi=Fzi/ΣFzi*100% with Fzi being the i-th cone axial force. And λi is defined by λi=Mzi/ΣMz*100% with Mzi being the i-th cone moment in the direction perpendicular to i-th cone axis. Finally E is the bit imbalance force ratio with Fr being the bit imbalance force. A bit is perfectly balanced if:
[0083] ω1=ω2=ω3=33.333% or ω0=0.0%
[0084] η1=η2=η3=33.333% or η0=0.0%
[0085] λ1=η2=λ3=33.333% or λ0=0.0%
[0086] ξ=0.0%
[0087] In most cases if ω0, η0, λ0, ξ0 are controlled with some limitations, the bit is balanced. The values of ω0, η0, λ0, ξ0 depend on bit size and bit type.
[0088] There is a distinction between force balancing techniques and energy balancing. A force balanced bit uses multiple objective optimization technology, which considers weight on bit, axial force, and cone moment as separate optimization objectives. Energy balancing uses only single objective optimization, as defined in equation (11) below.
[0089] Design of a Force Balanced Roller Cone Bit
[0090] As we stated in previous sections, there are many parameters which affect bit balance conditions. Among these parameters, the teeth crest length, their positions on cones (row distribution on cone) and the number of teeth play a significant role. An increase in the size of any one parameter must of necessity result in the decrease or increase of one or more of the others. And in some cases design rules may be violated. Obviously the development of optimization procedure is absolutely necessary.
[0091] The first step in the optimization procedure is to choose the design variables. Consider a cone of a steel tooth bit as shown in FIG. 3. The cone has three rows. For the sake of simplicity, the journal age, the offset and the cone profile will be fixed and will not be as design variables. Therefore the only design variables for a row are the crest length, Lc, the radial position of the center of the crest length, Rc, and the tooth angles, α and β. Therefore, the number of design variables is 4 times of the total number of rows on a bit.
[0092] The second step in the optimization procedure is to define the objectives and express mathematically the objectives as function of design variables. According to equation (1), the force acting on an element is proportional to the rock volume removed by that element. This principle also applies to any tooth. Therefore, the objective is to let each cone remove the same amount of rock in one bit revolution. This is called volume balance or energy balance. The present inventor has found that an energy balanced bit will lead to force balanced in most cases. Consider FIG. 4 which shows the patterns cut by each cone on the hole bottom. The first rows of all three cones have overlap and the inner rows remove the rock independently. Suppose the bit has a cutting depth A in one bit revolution. It is not difficult to calculate the volumes removed by each row and the volume matrix may have the form:
V=[V ij ], i=1,2,3; j=1,2,3,4, (8)
[0093] where i represent the cone number and j the row number. For example, V 32 is the element in the volume matrix representing the rock volume removed by the second row of the third cone. The elements V ij of this matrix are all functions of the design variables.
[0094] In reality, the removed volume by each row depends not only on the above design variables, but also on the number of teeth on that row and the tracking condition. Therefore the volume matrix calculated in a 2D manner must be scaled. The scale matrix, K v , may be obtained as follows.
K v ( i,j )= V 3d0 ( i,j )/ V 2d0 ( i,j ) (9)
[0095] where V 3d0 is the volume matrix of the initial designed bit (before optimization). V 3d0 is obtained from the rock bit computer program by simulate the bit drilling procedure at least 10 seconds. V 2d0 is the volume matrix associated with the initial designed matrix and obtained using the 2D manner based on the bottom pattern shown in FIG. 4. The volume matrix has the final form:
V b ( i,j )= K v ( i,j )* V ( i,j )= f v ( L c , R c , α, β) (10)
[0096] Let V 1 , V 2 and V 3 be the volume removed by cone 1, 2 and 3, respectively. For the energy balance, the objective function takes the following form:
Obj=( V 1 −V m ){circumflex over ( )}2+( V 2 −V m ){circumflex over ( )}2+( V 3 −V m ){circumflex over ( )}2 (11)
[0097] where V m =(V 1 +V 2 +V 3 )/3;
[0098] The third step in the optimization procedure is to define the bounds of the design variables and the constrains. The lower and upper bounds of design variables can be determined by requirements on element strength and structural limitation. For example, the lower bound of a tooth crest length is determined by the tooth strength. The angle α and β may be limited to 0˜45 degrees. One of the most important constrain is the interference between teeth on different cones. A minimum clearance between teeth surface must be kept. Consider FIG. 5 where cone profile is shown in a plane. A minimum clearance between tooth surfaces is required. This clearance can be expressed as a function of the design variables.
Δ d=f d ( L c , R c , α, β) (12)
[0099] Another constraint is the width of the uncut formation rings on bottom. The width of the uncut formation rings should be minimized or equalized in order to avoid the direct contact of cone surface to formation drilled. These constraints can be expressed as:
Δ w min <=Δwi=fw i ( L c , R c , α, β)<=Δ w max (13)
[0100] There may be other constraints, for example, the minimum space between two neighbored rows on the same cone required by the mining process.
[0101] After having the objective function, the bounds and the constraints, the problem is simplified to a general nonlinear optimization problem with bounds and nonlinear constrain which can be solved by different methods. FIG. 6 shows the flowchart of the optimization procedure. The procedure begins by reading the bit geometry and other operational parameters. The forces on the teeth, cones, bearings, and bit are then calculated. Once the forces are known, they are compared, and if they are balanced, then the design is optimized. If the forces are not balanced, then the optimization must occur. Objectives, constraints, design variables and their bounds (maximum and minimum allowed values) are defined, and the variables are altered to conform to the new objectives. Once the new objectives are met, the new geometric parameters are used to re-design the bit, and the forces are again calculated and checked for balance. This process is repeated until the desired force balance is achieved.
[0102] As an example, FIGS. 7 A-C show the row distributions on three cones of a 9″ steel tooth bit before and after optimization. FIGS. 8A and 8B compare the bottom hole patterns cut by the different cones before and after optimization. FIGS. 9A and B compare the cone layouts before and after optimization.
[0103] In the preferred embodiment of the present disclosure, a roller cone bit is provided for which the volume of formation removed by each tooth in each row, of each cutting structure (cone), is calculated. This calculation is based on input data of bit geometry, rock properties, and operational parameters. The geometric parameters of the roller cone bit are then modified such that the volume of formation removed by each cutting structure is equalized. Since the amount of formation removed by any tooth on a cutting structure is a function of the force imparted on the formation by the tooth, the volume of formation removed by a cutting structure is a direct function of the force applied to the cutting structure. By balancing the volume of formation removed by all cutting structures, force balancing is also achieved.
[0104] As another feature of the preferred embodiment, a roller cone bit is provided for which the width of the rings of formation remaining uncut is calculated, as it remains between the rows of the intermeshing teeth of the different cutting structures. The geometric parameters of the roller cone bit are then modified such that the width of the uncut area for each row is substantially minimized and equalized within selected acceptable limits. By minimizing the uncut rings on the bottom of the hole, the bit will be able to crush the uncut rings upon successive rotations due to the craters of formation removed immediately adjacent to the uncut rings. By equalizing the width of the uncut rings, the force required to crush the rings will be even from any point on the hole face, such that as cutting elements (teeth) engage the rings on successive rotations, the rings act to uniformly retain the bit drilling on-center.
[0105] According to a disclosed class of innovative embodiments, there is provided: A roller cone drill bit comprising: a plurality of arms; rotatable cutting structures mounted on respective ones of said arms; and a plurality of teeth located on each of said cutting structures; wherein approximately the same axial force is acting on each of said cutting structure.
[0106] According to another disclosed class of innovative embodiments, there is provided: A roller cone drill bit comprising: a plurality of arms; rotatable cutting structures mounted on respective ones of said arms; and a plurality of teeth located on each of said cutting structures; wherein a substantially equal volume of formation is drilled by each said cutting structure.
[0107] According to another disclosed class of innovative embodiments, there is provided: A rotary drilling system, comprising: a drill string which is connected to conduct drilling fluid from a surface location to a rotary drill bit; a rotary drive which rotates at least part of said drill string together with said bit said rotary drill bit comprising a plurality of arms; rotatable cutting structures mounted on respective ones of said arms; and a plurality of teeth located on each of said cutting structures; wherein approximately the same axial force is acting on each said cutting structure.
[0108] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone drill bit, comprising the steps of: (a) calculating the volume of formation cut by each tooth on each cutting structure; (b) calculating the volume of formation cut by each cutting structure per revolution of the drill bit; (c) comparing the volume of formation cut by each of said cutting structure with the volume of formation cut by all others of said cutting structure: of the bit; (d) adjusting at least one geometric parameter on the design of at least one cutting structure; and (e) repeating steps (a) through (d) until substantially the same volume of formation is cut by each of said cutting structures of said bit.
[0109] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone drill bit; the steps of comprising: (a) calculating the axial force acting on each tooth on each cutting structure; (b) calculating the axial force acting on each cutting structure per revolution of the drill bit; (c) comparing the axial force acting on each of said cutting structures with the axial force on the other ones of said cutting structures of the bit; (d) adjusting at least one geometric parameter on the design of at least one cutting structure; (e) repeating steps (a) through (d) until approximately the same axial force is acting on each cutting structure.
[0110] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone drill bit, the steps of comprising: (a) calculating the force balance conditions of a bit; (b) defining design variables; (c) determine lower and upper bounds for the design variables; (d) defining objective functions; (e) defining constraint functions; (f) performing an optimization means; and, (g) evaluating an optimized cutting structure by modeling.
[0111] According to another disclosed class of innovative embodiments, there is provided: A method of using a roller cone drill bit; comprising the step of rotating said roller cone drill bit such that substantially the same volume of formation is cut by each roller cone of said bit.
[0112] According to another disclosed class of innovative embodiments, there is provided: A method of using a roller cone drill bit, comprising the step of rotating said roller cone drill bit such that substantially the same axial force is acting on each roller cone of said bit.
[0113] Modification and Variations
[0114] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0115] Additional general background, which helps to show the knowledge of those skilled in the art regarding implementations and the predictability of variations, may be found in the following publications, all of which are hereby incorporated by reference: A PPLIED D RILLING E NGINEERING , Adam T. Bourgoyne Jr. et al., Society of Petroleum Engineers Textbook series (1991), O IL AND G AS F IELD D EVELOPMENT T ECHNIQUES : D RILLING , J.-P. Nguyen (translation 1996, from French original 1993), MAKING HOLE (1983) and DRILLING MUD (1984), both part of the Rotary Drilling Series, edited by Charles Kirkley.
[0116] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle. | Roller cone drilling wherein the bit optimization process equalizes the downforce (axial force) for the cones (as nearly as possible, subject to other design constrain). Bit performance is significantly enhanced by equalizing downforce. | 4 |
This is a division of U.S. patent application Ser. No. 07/961,856, filed Oct. 16, 1992, now U.S. Pat. No. 5,292,301, which is a division of U.S. patent application Ser. No. 07/690,186, filed Apr. 19, 1991, now U.S. Pat. No. 5,187,920.
BACKGROUND OF THE INVENTION
The invention relates to a cuboidal pack made of (thin) cardboard, especially a hinge lid box for accommodating a group of cigarettes wrapped in an inner blank (cigarette block), the dimensions of said group of cigarettes being smaller in depth than the depth of the pack, with a filling piece being arranged in a cavity formed hereby within the pack, said filling piece consisting of (thin) cardboard, and with a filling piece wall abutting the pack contents (cigarette block), and with upright side panels and an upper cross-panel folded transversely relative to said filling piece wall. The invention furthermore relates to a process for producing the filling piece and for introducing the same into a pack. Finally, the invention relates to an apparatus for conducting said process.
Hinge lid boxes are used world-wide as cigarette packs. The structure of this pack type is mostly standardized. This applies to the dimensions as well. Any changes in size have far-reaching consequences. Vending machines for cigarette packs would for instance have to be altered. In some countries, revenue markings are stamped on the packs. The stamping machines are designed for standard pack dimensions.
On the other hand, cigarettes with a substantially smaller diameter than standard cigarettes are increasingly introduced. Consequently, an identical number of such cigarettes forms a pack filling, i.e. cigarette block, with a smaller dimension. The arrangement is mostly such that the cigarette block ha s a smaller depth then the inner space of the hinge lid box. As a result, a cavity is formed within the pack which is (partially) filled by filling pieces made of foamed material or corrugated cardboard.
Known in the art is also a pack of the aforementioned type, in which the filling piece facing the rear wall consists of three-dimensionally folded (thin) cardboard. The filling piece is part of a blank for a collar which is commonly used with packs of this type. The filling piece is connected with the collar blank and comprises a filling piece wall, transversely folded side panels and an upper cross-panel which is also transversely folded (EP-A-346 026).
By forming a uniform and single-piece blank from collar and filling piece, this known proposal requires a considerable expenditure of material, even more so since the portion of the blank designed for forming the collar is considerably larger than in ordinary packs. Moreover, the production of the pack, especially of the filling piece, and the filling of the pack is more complicated and disadvantageous in terms of machine technics.
Setting out from this state of the art, the invention is based on the object to further develop and improve a pack of the aforementioned kind, such that filling pieces made of folded (thin) cardboard can be simply produced and accomodated in the pack in a material-saving manner.
SUMMARY OF THE INVENTION
To attain this object, the pack according to the invention is characterized in that at least upper corner tabs extending as an extension of the (upper) cross-panel are severed by severing cuts from the adjoining side panels and are folded to a supporting position transverse to the filling piece wall and at right angles to the cross-panel.
The corner tabs and their folding position as taught by the invention effect a significantly higher stability of the filling pieces formed by folded thin cardboard within the pack. In particular, the loading capacity of the upper portion of the filling piece can be increased without any adhesive bonding. The outstanding feature of the invention is that as a result of the folding position of the corner tabs, the upper cross-panel of the filling piece is held in a stable and rigid position. The corner tabs wedged in between the pack contents (cigarette block) and the adjacent pack wa 11 (rear wa 11) prevent the upper cross-panel from folding back or even just tilting away from the transverse supporting position. Moreover, the corner tabs ensure a particularly stable corner structure of the filling piece.
The filling piece as taught by the invention can be produced by means of a simple process. After a severing cut has been applied between corner tabs and adjoining side panels, the corner tabs are folded to a position transverse to the remaining portion of the blank and to the cross-panel. Then, said cross-panel is folded into the supporting position (transverse to the filling piece wall). Finally, the side panels are folded into the supporting position which is also transverse to the filling piece wall. As a result, the corner tabs are located on the inside of the side panels. When the filling piece is in filling or supporting position within the pack, the width of the filling piece wall corresponds to the width of the cavity which is to be filled. Thus, all folded portions are retained in the proper filling piece position by pack walls and by locking themselves.
According to the invention, the filling pieces are folded from a flat blank, specifically by being moved relative to stationary folding means (folding edges).
After being finished, the filling piece is fed to a preferably rectilinear pack track via a special form-stabilizing filling piece track. The folded filling pieces are held ready in the region of the pack track below the plane of movement of the pack contents (cigarette block) and are taken along there with to a pack, that is to say to a folding turret. Then, cigarette block and filling piece can be packed in the customary way as a unit, for example in an apparatus according to DE-PS 24 40 006.
Further details of the invention relate to the structure and production of the filling piece and to feeding same to the pack contents. An exemplary embodiment of the filling piece and of an apparatus for producing and installing same are described below in more detail with reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a to
FIG. 1e show folding steps for the production of a filling piece from a blank,
FIG. 2 is a top plan view of an open pack (hinge lid box) with filling piece on a highly enlarged scale,
FIG. 3 shows a vertical section of the pack according to FIG. 2 in closed position, on a reduced scale,
FIG. 4 is a perspective view of details of an apparatus for producing filling pieces and for feeding same to a cigarette block,
FIG. 5 is a side view and longitudinal section of the apparatus according to FIG. 4,
FIG. 6 shows a detail of the apparatus according to FIG. 5 on an enlarged scale,
FIG. 7 is a plan view of the apparatus according to FIG. 5,
FIG. 8 is a cross-section of the apparatus taken along line VIII--VIII of FIG. 7, on an enlarged scale,
FIG. 9 is a longitudinal section of a conveying track for cigarette blocks taken along the line IX--IX in FIG. 7,
FIG. 10 shows a view in analogy to FIG. 9, but with a different relative position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings relate to details in connection with hinge lid boxes 20, as they are known for accommodating a cigarette group 21. The cigarette group 21 is wrapped in an inner blank 22 made of tin foil or the like. The resulting unit is a cigarette block 23 forming the pack contents.
The pack, i.e. the hinge lid box, consists of a box part 24 and a lid 25 pivotably attached thereto.
The box part 24 comprises a front wall 26, a rear wall 27, a bottom wall 28 and side walls 29 and 30. The lid 25 comprises lid front wall 31, lid rear wall 32, lid top wall 33 and lid side walls 34 and 35. The lid rear wall 32 is connected to the rear wall 27 of the box part via a hinge 36. A standard hinge lid box also comprises a collar 37 which is located in the box part 24 in the region of front wall 26 and side walls 29, 30 and which projects from the box part 24.
The hinge lid box 20 is dimensioned such that the inner space of the box is larger than the dimensions of the pack contents (cigarette block 23), so that a cavity 38 is formed within the hinge lid box. In the present case, the cigarette block 23 is facing towards the front wall 26, so that the cavity 38 is formed in the rear part of the hinge lid box 20. The cavity 38 extends across the full height and width of the hinge lid box.
Within the cavity 38 there is a filling piece 39 for (partially) filling out the cavity 38. In the shown embodiment, the filling piece 39 extends across the full width of the cavity 38, i.e. of the inner space of the hinge lid box 20, but only across part of its height. The filling piece 39, standing on the bottom wall 28, extends (approximately) up to the hinge 36, i.e. approximately across the full height of the rear wall 27. Depth and width of the filling piece 39 correspond to the dimensions of the cavity 38, so that the cigarette block 23 is fixed within the hinge lid box 20 by the filling piece 39.
The filling piece consists of a folded blank 40 made of (thin) cardboard. In the initial position (FIG. 1a), the blank (40) has a rectangular shape. Folded to its three-dimensional shape (FIG. 1e), the filling piece 39 forms a filling piece wall 41, approximately corresponding to the size of the rear wall 27 (in the hinge lid box 20). On the upright sides of said wall, side panels 42 and 43 being directed transverse to the filling piece wall 41 are formed. The upper limitation consists of a cross-panel 44 which is also folded transverse to the filling piece wall 41. In the present embodiment, side panels 42, 43 and cross-panel 44 are bearing against the rear wall 27 of the hinge lid box 20. The filling piece wall rests against the pack contents.
Corner tabs 45, 46 have a particular significance. They extend as an extension of the cross-panel 44 in the region of the side panel s 42, 43. The corner tabs 45, 46 are separated from the side panels 42, 43 by a severing cut 47.
When the filling piece 39 is in its folded three-dimensional shape, the corner tabs 45, 46 have a special function. They are folded into a position transverse to the filling piece wall 41 and transverse to the cross-panel 44 and they rest against the inside of the side panels 42, 43 in the upper region thereof. As a result, the folding position of the corner tabs 45, 46 is stable, as the folded side panels 42, 43 prevent the corner tabs 45, 46 from moving sideways. The corner tabs 45, 46 are not movable in their plane either, since they are bearing with their (upright) edges against the filling piece wall 41 as well as against the rear wall 27. Without adhesive bonding, the filling piece 39 thus receives a stable and pressure-withstanding shape in folded position for accurately positioning and supporting the cigarette block 23 within the larger hinge lid box 20.
The filling piece 39 is produced by folding the blank 40 simple successive folding steps which are conducted continuously. First, the side panels 42, 43 are folded with the corner tabs 45, 46 to an inclined intermediate position, at an obtuse angle to the plane of the filling piece wall 41 (FIG. 1b). Then, the corner tabs 45, 46 are folded to a position transverse to the plane of the filling piece wall 41 and the cross-panel 44 (FIG. 1c). Now, the cross-panel 44 is folded to its supporting position (transverse to the filling piece wall 41; FIG. 1d). Herewith, the corner tabs 45, 46 reach their final position. Finally, the side panels 42, 43 are folded to their final position transverse to the filling piece wall 41 (FIG. 1e).
The filling pieces 39, designed in the described--or in a different--way, are produced and directly conveyed further to the pack, i.e. to the separately produced or prepared cigarette blocks 23, by means of the apparatus shown in the drawings. A unit formed by cigarette block 23 and filling piece 39 is then fed to a packaging machine and introduced into a partially folded hinge lid box 20. The apparatus for producing the hinge lid box 20 may for instance be made like the apparatus shown in DE-A-24 40 006.
The blanks 40 are severed from a continuous web of material 48, specifically by means of a continuously operating punching and embossing unit 49 which consists of punching and embossing rollers 50, 51 between which the web of material 48 is fed through. The blanks 40 severed from the web of material 48 correspond to the embodiment shown in FIG. 1a, i.e. they have severing cuts 47 and embossments for folding side panels 42, 43 and cross-panels 44.
The blanks 40 are fed to a folding station 54 by pairs of conveying rollers 52 and 53. The conveying rollers 52 are driven such that they accelerate the severed blanks 40 relative to the web of material 48. The conveying rollers 53 effect another acceleration. For being fed into the folding station 54, the blanks are taken along by a continuously rotating blank conveyor 55 which comprises one (or more) carriers 56 which engage the blanks 40 at their rear side. These carriers 56 are moved along a two-dimensional path underneath the conveying plane of the blanks and with their returning movement move back into initial position.
The blanks 40 are conveyed by the blank conveyor 55 into a folding shaft 57 of the folding station 54. Said folding shaft 57 is (nearly completely) surrounded by walls with folding means. The blanks 40 are each deposited on a lifting plate 58 of an up and downwardly movable stamp 59. The lifting plate 58 is provided with lateral folding edges 60, 61 which in the upward movement of the lifting plate 58 (with blank 40) interact with stationary folding means.
In a first folding step during the continuous and constant upward movement of the lifting plate 58, the side panels 42, 43, including the corner tabs 45, 46, are folded into the inclined position as shown in FIG. 1b. For this purpose, inclined folding surfaces 62, 63 are arranged in the lower region of the folding shaft 57 on opposite sides. In the course of the upward relative movement, said lateral portions of the blank 40 are folded around the folding edges 60, 61 into a downwardly directed inclined position. The side panels 42, 43 (including corner tabs 45, 46) laterally project from the effective surface of the lifting plate 58.
As the lifting plate 58 continues to move up, the side panels 42, 43 being in inclined folding position enter the region of an indentation 64, 65 on both sides of the folding shaft 57. The lateral limitations of these indentations 64, 65 are designed such that the side panels 42, 43 slide along upright guide surfaces 66 while maintaining their inclined position.
Next to the indentations 64, 65, namely in the region of the corner tabs 45, 46 which are also projecting from the effective surface of the lifting plate 58, the inclined folding surfaces 62, 63 continue. They merge into upright side faces 67, 68 which are located only in the narrow region of the corner tabs 45, 46. The correspondingly longer folding surfaces 62, 63 cause the corner tabs 45, 46 to fold from the folding position as shown in FIG. 1b to the transverse folding position as shown in FIG. 1c. In this position, the corner tabs 45, 46 move upward and slide along the side surfaces 67, 68.
A transversely directed inclined folding surface 69 forming a lateral limitation of the folding shaft 57 serves for folding over the cross-panel 44 to the position as shown in FIG. 1d. The folding surface 69 extends in the lower region between the side faces 67, 68. This means that the folding step for the cross-panel 44 commences immediately after the corner tabs 45, 46 have been folded to the position as shown in FIG. 1c.
The above folding process is finished when the blank 40 reaches the region of further inclined folding surfaces 70, 71. These are arranged as extensions of the guide surfaces 66 for the side panels 42, 43 and cause the (inclined) side panels 42, 43 to fold over into their final position as shown in FIG. 1e. These folding surfaces 70, 71 reduce the folding shaft 57 in its upper region to the dimensions of the folded filling piece 39. The folded lateral blank portions surround the edges of the lifting plate 58.
The ready-folded filling pieces 39 are conveyed by the stamp 59 to an upper slide-off position. They are located in the path of movement of a slide means. In the shown embodiment, a slide lever 72 which is movable to and fro, i.e. pivotable, is provided. Here, this slide lever 72 has a double-arm design with two spaced apart webs 73, 74 for commonly engaging the filling pieces 39 at their rear side in slide-off direction. The lower ends of the slide lever 72 or the webs 73, 74 thereof have a hook-like shape, so that a lower short leg 75 engages and supports the filling pieces 39 at their bottom side while they are discharged.
The slide lever 72 can be moved by one conveying cycle at a time, each cycle corresponding to the width of a filling piece 39 (measurement in the direction of discharge). In this process, lower parts of the webs 73, 74 of the slide lever 72 enter slot-like recesses 93, 94 of the lateral limitations of the folding shaft 57, specifically on both opposite sides of the folding shaft 57. After each slide cycle, the upper part of the folding shaft 57 becomes vacant, so that the described folding process can again be conducted with the following blank after the stamp 59 has been lowered. As a result of the restoring stress of the material in the folded portions of the filling pieces 39, the side panels 42, 43 are in a slightly inclined position (FIG. 6) in which they bear against supporting edges 76, 77 at the upper end of the folding shaft 57. Thus, the stamp 59 can be moved downwards without taking along the filling piece.
The filling pieces 39 are conveyed by the slide lever 72 from the region of the folding shaft 57 into a filling piece track 78 consisting of a channel which has the same cross-sectional dimensions as the filling piece 39 and which is preferably closed on all sides. As a result, the folded filling pieces 39 are secured in folded shape during transport. Transport is conducted in cycles by one filling piece 39 at a time. A tightly arranged row is pushed forward, with a new filling piece 39 being pushed into the filling piece track 78 by the slide lever 72.
The filling piece track 78 extends transversely to a block path 79 which serves for (continuously) transporting the pack contents, i.e. in this case cigarette blocks 23. The block track 79, which in the present embodiment is upwardly open, is limited by lateral track guides 80, 81. A rotating conveyor is operating in the region of a track bottom 82, namely a chain conveyor 83 having carriers 85 arranged on traverses 84, said carriers engaging the rear side of one pack filling (cigarette block 23) at a time. The carriers 85 pass through a long slot 86 in the track bottom 82.
The filling piece track 78 laterally opens out into the block track 79, specifically with a track opening 87 having a greater vertical dimension than the filling piece 39. The block track 79 is designed such that up to the track opening 87 for the filling pieces 39, the track bottom 82 is located on a raised level, such that the incoming cigarette blocks 23 can be conveyed over and across the respective filling piece 39 in the region of the track opening 87. Here, the track bottom 82 forms a step 88 which the filling piece 39 abuts. The track bottom 82 is downwardly offset in the vertical direction in this region and forms an inclined surface 89 on which the filling piece 39 rests in a respective position, namely at an acute angle relative to the plane of movement of the cigarette block 23, rising in the conveying direction. The arrangement has been designed such that the filling piece rests below the plane of the track bottom 82 with the side (cross-panel 44) which is pointing towards the incoming cigarette block 23. The oppositely situated side of the filling piece 39 lies with its upper side directly in the plane of movement of the cigarette block 23 so that the filling piece 39 can be taken along by the continuously conveyed cigarette block 23 without jamming.
In the shown embodiment, the filling piece 39 is engaged below the cigarette block 23 by the carrier 85 of the chain conveyor 83 which is assigned to the cigarette block 23. Then, the unit consisting of cigarette block 23 and filling piece 39 is conveyed by the carrier 85 (FIG. 10).
The carrier 85 is designed in a special way. A ram head 90 engages the rear side of the cigarette block 23 or cigarette group 21. At this point, the cigarette block 23 is not yet finally folded. Rearward folding tabs 91 serving for forming an upper end fold of the inner blank 22 still project from the., rear of the cigarette block 23. In the region of the path of movement of the filling piece 39, the carrier 85 is provided with a carrier surface 92 which is offset to the rear with respect to the conveying direction. This carrier surface 92 engages the filling piece 39 during transport in a rearwardly offset position relative to the cigarette block 23. Only when the folding tabs 91 are folded or thereafter, the filling piece 39 is moved to its proper pack position by means of a displacement relative to the cigarette block 23. In this position, the filling piece 39 is flush with the limitation (bottom side) of the cigarette block 23 which is lying in front with respect to the conveying direction. | A pack for cigarettes or the like and a process and apparatus for the production thereof is described. Due to several reasons (cigarette) packs quite often have greater (inner) dimensions than the pack contents (cigarette block 23). In order to fill a cavity formed hereby within the pack, a filling piece (39) is provided which is formed from a flat blank (40) by means of folding up outer blank portions. The filling piece is formed to have a three-dimensional shape by means of being displaced in a folding shaft (57) with laterally arranged folding means. The filling pieces (39) produced in this way are conveyed along a filling piece track (78) and are introduced into a block track (79) in transverse direction so they can each be united with a cigarette block (23). | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a reciprocating piston-type compressor, such as those which are commonly used in automotive air conditioning systems. Specifically, the invention provides a solution to the problem of compressioninduced deformation of the cylinder bore in such a compressor.
2. Description of the Related Art
Reciprocating piston-type compressors are in use throughout the world, particularly in vehicle air conditioners. FIG. 9 illustrates a conventional compressor of this type. In this compressor, a front housing 55 is secured to a front end face of a front cylinder block 51 through a valve plate 53. A rear housing 56 is secured to a rear end face of a rear cylinder block 52 through a valve plate 54. The cylinder blocks 51 and 52, the valve plates 53 and 54, and the housings 55 and 56 are held together by a plurality of bolts 57. A drive shaft 58 is rotatably supported in center bores formed in both the cylinder blocks 51 and 52. A swash plate 59 is fixed to the drive shaft 58 and is disposed within a crank chamber 60 that is formed between the cylinder blocks 51 and 52. A plurality of aligned pairs of cylinder bores 51a and 52a are formed in the cylinder blocks 51 and 52 around the drive shaft 58. A double-headed piston 61 is retained in a corresponding pair of cylinder bores 51a and 52a and is connected to the swash plate 59 through a shoes 62.
As the drive shaft 58 is rotated, the rotation of the swash plate 59 is transmitted to each piston 61 through the shoes 62, and consequently, each piston 61 is reciprocated in a corresponding cylinder bore 51a and 52a. With the reciprocating motion of the piston 61, suction of refrigerant gas from suction chambers 63 and 64 into the cylinder bores 51a and 52a, compression of the refrigerant gas in the cylinder bores 51a and 52a, and discharge of the compressed refrigerant gas to discharge chambers 65 and 66 are carried out.
Suction passages 67 and 68 are formed in the cylinder blocks 51 and 52 around the bolt 57 for communicating suction chambers 63 and 64 with the crank chamber 60.
One problem that exists in compressors of the type that are shown in FIGS. 9-11 is the internal deformation that takes place as a result of the compression that is applied by the assembly bolts that hold the unit together. As shown in FIG. 9, the cylinder blocks 51 and 52, the valve plates 53 and 54, the housings 55 and 56 are clamped together by a plurality of bolts 57. The compression applied by bolts 57 causes the cylinder bores 51a and 52a to become slightly deformed, as shown by exaggerated scale in the broken line profile that is provided in FIG. 10. The deformation of the cylinder blocks 51 and 52 is greater at the adjoining surfaces thereof, as shown in exaggerated scale by the broken lines in FIG. 11. The amount of radial outward deformation of the cylinder bore 51a or 52a has been found to be about 8 μm at the maximum, while the radially inward deformation quantity of the cylinder bore 51a or 52a is about 10 μm at the maximum.
As the cylinder bore deforms, the clearance between the inner peripheral surface of each cylinder bore 51a or 52a and the outer peripheral surface of the piston 61 increases in places. As a result, refrigerant gas in the cylinder bore 51a or 52a leaks from the places at which the clearance is large, reducing the efficiency of the compressor. In addition, deformation of the cylinder bore causes portions of the inner peripheral surface of the cylinder bore 51a or 52a to press against the outer peripheral surface of the piston 61, interfering with the sliding motion of the piston within the bore. This contributes to uneven wear on the piston and the cylinder bore, and, in some cases, might even cause seizure of the piston within the bore.
It is clear that a need exists for an improved compressor assembly that is designed to minimize the undesired effects of internal deformation that takes place as a result of compression-induced deformation of the cylinder bore in such a compressor.
SUMMARY OF THE INVENTION
It is an objective of the invention to provide a reciprocating piston-type compressor which is capable of reducing the deformation of the inner peripheral surface of the cylinder bore at the time of the operation of the compressor.
To achieve the above and other objects of the invention, the compressor according to the present invention includes a housing body and a drive shaft rotatably supported in the housing body. A drive plate is mounted on the drive shaft. Cylinder bores are defined in the housing body. Pistons are operably coupled to the drive plate and are disposed in the cylinder bores. The drive plate converts a rotation of the drive shaft to a reciprocating movement of the pistons along an inner surface of the cylinder bores. Each piston compresses gas supplied from a suction chamber to the associated cylinder bore and discharges the compressed gas to a discharge chamber. A deformation of the inner surface of each cylinder bore is reduced by utilizing pressure of the gas compressed in the cylinder bore.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a longitudinal cross-sectional view of an overall compressor according to a first preferred embodiment of the invention;
FIG. 2 is a cross-sectional view taken substantially along the line 2--2 in FIG. 1;
FIG. 3 is a cross-sectional view taken substantially along the line 3--3 in FIG. 1;
FIG. 4 is an explanatory view showing the operation of a compressor constructed according to the first embodiment;
FIG. 5 is a cross-sectional view showing a second embodiment of the compressor of the invention;
FIG. 6 is a cross-sectional view showing the second embodiment of the compressor;
FIG. 7 is a cross-sectional view of essential parts showing a third embodiment of the compressor of the invention;
FIG. 8 is a cross-sectional view taken substantially along the line 8--8 in FIG. 7;
FIG. 9 is a longitudinal cross-sectional view showing a conventional swash plate-type compressor;
FIG. 10 is a cross-sectional view taken substantially along the line 10--10 in FIG. 9; and
FIG. 11 is a schematic cross-sectional side view showing the cylinder block shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of a swash plate-type compressor of the double-headed piston type embodying the present invention will be described below with reference to FIGS. 1 to 4.
As shown in FIG. 1, a front cylinder block 11 and a rear cylinder block 12 are secured to each other at facing ends thereof. A front housing 15 is secured to a front end face of the front cylinder block 11 through a valve plate 13. A rear housing 16 is secured to the rear end face of the rear cylinder block 12 through a valve plate 14. First plates 17 and 18 form suction valves 17a and 18a that are located between the cylinder block 11 and the valve plate 13 and between the cylinder block 12 and the valve plate 14, respectively. Second plates 19 and 20 form discharge valves 19a and 20a and are located between the valve plate 13 and the front housing 15 and between the valve plate 14 and the rear housing 16, respectively. Third plates 21 and 22 form retainers 21a and 22a and are located between the second plate 19 and the front housing 15 and between the second plate 20 and the rear housing 16, respectively. The retainer 21a regulates the degree of opening of the discharge valve 19a. Likewise, the retainer 22a regulates the degree of opening of the discharge valve 20a.
As shown in FIGS. 1 to 3, a plurality of bolts 23 (five bolts in this embodiment) are screwed from the front surface 25 of the front housing 15 into the internally threaded bore of the rear housing 16 so that the cylinder blocks 11 and 12, the valve plates 13 and 14, the housings 15 and 16, the first plates 17 and 18, the second plates 19 and 20, and the third plates 21 and 22 are integrally clamped and fixed. The cylinder blocks 11 and 12, and the housings 15 and 16 constitute a housing body.
A drive shaft 32 is rotatably supported in center bores 11b and 12b of both the cylinder blocks 11 and 12 through radial bearings 33 and 34. A plurality of aligned pairs of cylinder bores 11a and 12a are formed in the cylinder blocks 11 and 12 around the drive shaft 32. A double-headed piston 36 is housed in each corresponding pair of cylinder bores 11a 10 and 12a. Compression chambers 29 and 30 are formed in the cylinder bores 11a and 12a by the piston 36.
A crank chamber 31 is formed in both the cylinder blocks 11 and 12 so as to be positioned between the front and rear cylinder bores 11a and 12a. A swash plate 35 is fixed to the drive shaft 32 in the crank chamber 31 and is connected to the intermediate portion of each piston 36 through a pair of hemispherical shoes 37 and 38. As the drive shaft 32 is rotated, the rotation of the swash plate 35 is transmitted to each piston 36 through the shoes 37 and 38, and consequently, each piston 36 is reciprocated in the cylinder bores 11a and 12a. A pair of thrust bearings 39 and 40 are located, in the crank chamber 31, between the inner wall surface of the cylinder block 11 and one end face of the boss portion 35a of the swash plate 35 and between the inner wall surface of the cylinder block 12 and the other end face of the boss portion 35a, respectively.
Discharge chambers 27 and 28 are formed in the center portions of the front and rear housings 15 and 16, respectively. Suction chambers 25 and 26 are formed in the front and rear housings 15 and 16 around the discharge chambers 27 and 28. A partition wall 15a is formed in the front housing 15 so that the discharge chamber 27 and the suction chamber 25 are separated from each other, and likewise, a partition wall 16a is formed in the rear housing 16 so that the discharge chamber 28 and the suction chamber 26 are separated from each other. An annular projection 16b is formed in the inner wall surface of the rear housing 16 for pressing the second and third plates 20 and 22 against the valve plate 14. A plurality of notches 16c are formed in the projection 16b so that a space 28A enclosed by the projection 16b communicates with the discharge chamber 28. The space 28A, therefore, forms part of the discharge chamber 28.
A suction port 13a is formed in the valve plate 13 so that the suction chamber 25 and the compression chamber 29 are connected with each other. A suction port 14a is formed in the valve plate 14 so that the suction chamber 26 and the compression chamber 30 are connected with each other. Likewise, discharge ports 13b and 14b are formed in the valve plates 13 and 14 so that the discharge chamber 27 and the compression chamber 29 are connected with each other and that the discharge chamber 28 and the compression chamber 30 are connected with each other.
During the suction stroke, where the piston 36 moves from the top dead center to the bottom dead center, the refrigerant gas in the suction chambers 25 and 26 opens the suction valves 17a and 18a and is drawn from the suction ports 13a and 14a into the compression chambers 29 and 30. During the compression and discharge strokes, where the piston 36 moves from the bottom dead center to the top dead center, the refrigerant gas, which has been compressed in the compression chambers 29 and 30, opens the discharge valves 19a and 20a and is discharged from the discharge ports 13b and 14b to the discharge chambers 27 and 28.
A plurality of suction passages 11c and 12c are formed around the bolts 23 and in the cylinder blocks 11 and 12 so that the crank chamber 31 and the suction chambers 25 and 26 are connected with each other, respectively. The crank chamber 31 is connected to the introduction pipe of an external refrigerant circuit (not shown). The refrigerant gas flowing through the external refrigerant circuit is introduced into the crank chamber 31 through the introduction pipe. Discharge passages 11d (FIG. 2) and 12d (FIG. 3) are formed in the cylinder blocks 11 and 12 so that they connect with discharge chambers 27 and 28, respectively. The discharge passages 11d and 12d are connected to the discharge pipe of the external refrigerant circuit. The refrigerant gas in the discharge chambers 27 and 28 is discharged to the discharge pipe through the discharge passages 11d and 12d.
A plurality of cavities 41, which are connected with the discharge chamber 27 on the front side, are located around the center portion of the front cylinder block 11, as shown in FIG. 2, and each cavity 41 is located between adjacent cylinder bores 11a and is formed in the front cylinder block 11, the first plate 17, the valve plate 13, and the second plate 19. Likewise, a plurality of rear cavities 42, which are connected with the discharge chamber 28 on the rear side, are located around the center portion of the rear cylinder block 12, as shown in FIG. 3, and each cavity 42 is located between adjacent cylinder bores 12a and is formed in the rear cylinder block 12, the first plate 18, the valve plate 14, and the second plate 20. These cavities 41 and 42 are located in the vicinities of the parts of the cylinder bores 11a and 12a that are deformed in the radially outward directions (with respect to the cylinder bores 11a and 12a). In other words, cavities 41 and 42 are located in the positions where the radially outward deformations of the inner peripheral surfaces of the cylinder bores 11a and 12a need to be reduced. The cavities 41 and 42 extend along the axial direction of the cylinder bores 11a and 12a. The axial lengths of the cavities 41 and 42 are nearly the same as the axial lengths of the cylinder bores 11a and 12a.
The function of the compressor with the above-mentioned structure may be described as follows:
If the drive shaft 32 is rotated by an external power source such as an engine of an automobile, the rotation will be converted to the reciprocating motion of the piston 36 in the cylinder bores 11a and 12a through the swash plate 35. As the piston 36 is reciprocated, the refrigerant gas introduced from the introduction pipe of the external refrigerant circuit into the crank chamber 31 is introduced into the suction chambers 25 and 26 through the suction passages 11c and 12c and then from the suction chambers 25 and 26 into the compression chambers 29 and 30. The refrigerant gas in the compression chambers 29 and 30 is compressed by the piston 36 and then is discharged to the discharge chambers 27 and 28. The high-pressure refrigerant gas in the discharge chambers 27 and 28 is discharged to the discharge pipe of the external refrigerant circuit through the discharge passages 11d and 12d and is supplied to the condenser, expansion valve, and evaporator (not shown) of the external refrigerant circuit. Consequently, the interior of the vehicle is air-conditioned.
During the operation of the compressor, some of the high-pressure refrigerant gas in the discharge chambers 27 and 28 flows into cavities 41 and 42. The high pressure of the refrigerant gas acts on the inner peripheral surfaces of the cavities 41 and 42 such that the deformation of the inner peripheral surfaces of the cylinder bores 11a and 12a discussed above is reduced. More particularly, as shown in FIG. 4, the pressure of the refrigerant gas in each cavity 41 or 42 presses the inner peripheral surface of each cavity 41 or 42 in the radially outward direction (indicated by the arrow P1) of the cavity. This force presses the radially outwardly deformed portion of the inner peripheral surface of each cylinder bore 11a or 12a in the radially inward direction of the cylinder bore. Therefore, with this pressing force, the radially outward deformation of the inner peripheral surface of each cylinder bore 11a or 12a is reduced. In addition, as the radially outward deformation of the inner peripheral surface of each cylinder bore 11a or 12a is reduced, the radially inward deformation of the inner peripheral surface of each cylinder bore 11a or 12a is also reduced.
The broken lines in FIG. 2 represent the deformed configuration of the inner peripheral surface of each cylinder bore 11a or 12a during the operation of the compressor. The deformation degree is exaggerated for purposes of illustration. As is evident from a comparison between the broken line in FIG. 2 and the broken line in FIG. 10 showing a conventional compressor, even if the inner peripheral surfaces of the cylinder bores 11a and 12a are deformed when the cylinder blocks 11 and 12 are clamped together by the bolts 23, the deformations will be reduced at the time of the operation of the compressor in this embodiment. It has been confirmed in the compressor of this embodiment that the degree of radially outward deformation of each cylinder bore 11a or 12a is suppressed to about 2 μm at the maximum and that the degree of radially inward deformation of each cylinder bore 11a or 12a is suppressed to about 5 μm at the maximum.
For this reason, the clearance between the inner peripheral surface of each cylinder bore 11a or 12a and the outer peripheral surface of the piston 36 is more uniform over the entire circumference. Consequently, leakage of the refrigerant gas from the compression chambers 29 and 30 is suppressed and the compression efficiency of the refrigerant gas is enhanced. Moreover, portions of the inner peripheral surfaces of the cylinder bores 11a and 12a are prevented from being tightly pressed against the outer peripheral surface of the piston 36, thus reducing friction along the cylinder bores 11a and 12a. Therefore, the wear on the piston 36 and the wear on the cylinder bores 11a and 12a is suppressed, and the piston 36 is prevented from being damaged by seizing or the like. Thus, the durability of the compressor is enhanced.
The compressed refrigerant gas, discharged from the compression chambers 29 and 30 to the discharge chambers 27 and 28, also flows into the cavities 41 and 42. In other words, the cavities 41 and 42 form part of the discharge chambers 27 and 28, respectively. Furthermore, the space 28A forming part of the discharge chamber 28 is defined in the center portion of the rear housing 16. For these reasons, the volume of the entire discharge chamber is increased. Consequently, the compressed refrigerant gas, discharged from the compression chambers 29 and 30 to the discharge chambers 27 and 28, is reduced to a certain pressure at the discharge chambers 27 and 28 and then is supplied to the external refrigerant circuit through the discharge passages 11d and 12d. Therefore, pulsation resulting from the discharge of the compressed refrigerant gas and noise resulting from the pulsation is suppressed without increasing the outer size of the compressor.
Now, a second embodiment of the present invention will be described with reference to FIGS. 5 and 6. The same reference numerals will be applied to the same parts and members as those of the first embodiment and therefore the description will not be given. In the second embodiment, as shown in FIGS. 5 and 6, a plurality of cavities 43 and 44 communicating with suction chambers 25 and 26 are provided instead of the cavities 41 and 42 in the first embodiment. Each cavity 43 (or 44) is located between adjacent cylinder bores 11a (or 12a)and is formed in the cylinder block 11 (or 12), the first plate 17 (or 18), the valve plate 13 (or 14), and the second plate 19 (or 20). These cavities 43 and 44 are located in the vicinities of parts of the cylinder bores 11a and 12a that are deformed in the radially inward directions (with respect to the cylinder bores). In other words, the cavities 43 and 44 are located in the positions where the radially inward deformations of the inner peripheral surfaces of the cylinder bores 11a and 12a need to be reduced. The cavities 43 and 44 extend along the axial direction of the cylinder bores 11a and 12a. The axial length of the cavities 43 and 44 are nearly the same as that of the cylinder bores 11a and 12a.
The pressure of the refrigerant gas in the suction chambers 25 and 26, which is introduced into the cavities 43 and 44, is lower than that in the compression chambers 29 and 30, where the piston 36 is in the compression and discharge strokes. Furthermore, because of the existence of the cavities 43 and 44, the deformation of the cylinder bores 11a and 12a is allowed to a certain degree in the vicinities of the portions where the cavities 43 and 44 are formed. If a high pressure corresponding to the discharge pressure acts on the inner peripheral surfaces of the cylinder bores 11a and 12a during the compression and discharge strokes of the piston 36, then the pressure will press the inner peripheral surfaces of the cylinder bores 11a and 12a in the radially outward directions of the cylinder bores 11a and 12a. With this pressing force, the radially inwardly deformed portions of the inner peripheral surfaces of each cylinder bores 11a and 12a (i.e., portions in the vicinities of the cavities 43 and 44) are deformed in the radially outward directions. Consequently, the radial inward deformation of the inner peripheral surfaces of the cylinder bores 11a and 12a is reduced. In addition, as the radially inward deformations of the inner peripheral surfaces of the cylinder bores 11a and 12a are reduced, the radially outward deformation of the inner peripheral surfaces of the cylinder bores 11a and 12a is also reduced.
Therefore, in the second embodiment, as is similar to the first embodiment, leakage of the refrigerant gas is suppressed and the compression efficiency of the refrigerant as is enhanced. In addition, wear on the piston 36 and the cylinder bores 11a and 12a is reduced, and the piston 36 and the cylinder bores are prevented from being damaged. Thus, he durability of the compressor is enhanced.
Now, a third embodiment of the present invention will e described with reference to FIGS. 7 and 8. In this embodiment, the same reference numerals will be applied to the same parts and members as those of the first embodiment and therefore a description will not be given.
As has been described in the conventional compressor shown in FIG. 11, the degree of deformation in the outer diameter of the cylinder blocks 11 and 12 is greater at the adjoining faces thereof (in other words, at the center of the entire structure of the cylinder blocks), as both the cylinder blocks 11 and 12 are clamped together by the bolts 23. Because of the deformation of the cylinder blocks, the deformation of the cylinder bores 11a and 12a is also greater at the adjoining faces of both the cylinder blocks 11 and 12. For this reason, in the third embodiment, as shown in FIGS. 7 and 8, cavities 41 and 42 communicating with discharge chambers 27 and 28 are formed in the outer circumferences of the cylinder blocks 11 and 12 such that they are located in the vicinities of the portions of the cylinder bores that are deformed in the radially outward directions thereof. In addition, the portions of the cavities 41 and 42 facing the cylinder bores 11a and 12a are larger toward the adjoining ends of both cylinder blocks 11 and 12 (toward the center of the entire structure of the cylinder blocks) in the axial direction of the drive shaft 32.
With this structure, the inner peripheral surfaces of the cylinder bores 11a and 12a will be pressed in the radially inward directions (with respect to the bores) with larger forces nearer to the adjoining ends of both cylinder blocks 11 and 12, i.e., the end where the degree of deformation of the cylinder bores 11a and 12a is greater. The degree of radially inward deformation of the cylinder bores 11a and 12a caused by the pressing forces is greater at the adjoining ends of both cylinder blocks 11 and 12 as shown by two-dot chain lines in FIG. 7. Reduction in the deformations of the cylinder bores 11a and 12a is greater nearer to the adjoining ends of the both cylinder blocks 11 and 12. As a consequence, the clearance between the inner surface of each cylinder bore 11a or 12a and the outer surface of each piston 36 becomes nearly constant in the axial direction of the drive shaft 32.
Therefore, in the third embodiment, as in first and second embodiments, leakage of the refrigerant gas is suppressed and the compression efficiency of the refrigerant gas is enhanced. In addition, the wear on the piston 36 and the cylinder bores 11a and 12a is suppressed, they are prevented from being damaged, and the durability of the compressor is enhanced.
The present invention may be also embodied as follows:
(1) The structure of the compressor in the third embodiment is applicable nearly in the same way to the cavities 43 and 44 communicating with the suction chambers 25 and 26 in the second embodiment. That is, the cavities 43 and 44 may be formed such that the diameters of the inner peripheral surfaces thereof increase nearer to the adjoining ends of both cylinder blocks 11 and 12 in the axial direction of the drive shaft 32. If constructed like this, the degree of radially outward deformation of the cylinder bores 11a and 12a will increase toward the adjoining ends of both cylinder blocks 11 and 12, when the inner surfaces of the cylinder bores 11a and 12a are pressed with the high pressures of the compression chambers 29 and 30. Therefore, the deformation of the cylinder bores 11a and 12a is reduced more at the adjoining ends of the both cylinder blocks 11 and 12. As a consequence, the clearance between the inner peripheral surface of each cylinder bore 11a or 12a and the outer peripheral surface of each piston 36 becomes nearly constant in the axial direction of the drive shaft 32, and the advantages of the third embodiment are obtained.
(2) While the cavities 41 and 42 extend along the axial direction of the cylinder bores 11a and 12a in the first and third embodiments, the cavities 41 and 42 may be curved in the circumferential directions of the cylinder bores 11a and 12a in the range of the position where the radially outward deformations of the inner peripheral surfaces of the cylinder bores 11a and 12a are to be reduced.
(3) The present invention can be used with any type of piston compressors, such as a swash plate-type compressor of a single head piston type and a variable displacement-type compressor of the piston type where a discharge displacement can be adjusted by changing the angle of inclination of a swash plate.
(4) In the first and third embodiments, while the cavities 41 and 42 are formed in the cylinder blocks for reducing the deformation of the cylinder bores 11a and 12a, chambers may be formed in the front and rear housings 15 and 16 to communicate with the discharge chambers 27 and 28 instead of the cavities 41 and 42. In such case, when the high-pressure refrigerant gas in the discharge chambers 27 and 28 is introduced into the aforementioned chambers, wedge members are actuated through actuating members. The cylinder bores 11a and 12a are thus pressed in the radially inward direction of the bores using the wedge members, whereby the deformation of the bores 11a and 12a may be reduced.
(5) In the second embodiment and the embodiment stated in part (1) above, the cavities 43 and 44 need not always be in fluid communication with the suction chambers 25 and 26, and therefore the cavities 43 and 44 may be formed in the cylinder blocks 11 and 12 such that they do not communicate with the suction chambers 25 and 26.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | A compressor includes a housing body and a drive shaft rotatably supported in the housing body. A swash plate is mounted on the swash shaft. Cylinder bores are defined in the housing body. Pistons are operably coupled to the swash plate and are disposed in the cylinder bores. The swash plate converts a rotation of the swash shaft to a reciprocating movement of the pistons along an inner surface of the cylinder bores. Each piston compresses gas supplied from a suction chamber to the associated cylinder bore and discharges the compressed gas to a discharge chamber. Deformation of the inner surface of each cylinder bore is reduced by utilizing pressure of the gas compressed in the cylinder bore. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to exhaust mufflers for internal combustion engines of the kind comprising a closed chamber having an inlet pipe and an outlet pipe and containing means for absorbing noise in exhaust gases flowing into the chamber through the inlet pipe before the gases pass from the chamber through the outlet pipe.
As is well known, in mufflers of this type any improvement in the noise reducing properties of the muffler is usually accompanied by a reduction in the rate of flow of exhaust gases through the muffler, this reduction in rate of flow causing loss of power and efficiency of the engine and increase in fuel consumption.
International exhaust noise regulations are currently placing increasingly stringent limits on the noise output of motor vehicle exhausts, while at the same time there is an increasing demand for fuel economy. For the reason mentioned above, these requirements are to a certain extent conflicting and it is therefore an object of the invention to provide an exhaust muffler which effectively limits the noise output from the engine while at the same time maintaining a high flow rate of exhaust gases through the muffler.
Although it is desirable for the noise output from an engine exhaust to be kept low, there is also a requirement, particularly where the muffler is for use with engines in high performance vehicles, that the exhaust note which is produced should have a deep, powerful sound. It is therefore a further object of the invention to provide a muffler which may be constructed with a bias towards reducing noise in the high and midrange frequencies.
SUMMARY OF THE INVENTION
According to the invention there is provided an exhaust muffler comprising a closed chamber, an inlet pipe leading into the chamber, an outlet pipe leading from the chamber, at least one pipe length, having an open end, within the chamber, and means for reducing noise in exhaust gases flowing into the chamber through the inlet pipe before the gases pass from the chamber through the outlet pipe, said noise-reducing means including at least one noise reflector located opposite and spaced from the open end of said pipe length within the chamber in such manner as to reflect down the pipe length a proportion of the noise generated by gases flowing along the pipe length.
Said pipe length may comprise a continuation, within the chamber, of said inlet pipe or of said outlet pipe.
The noise reflector is preferably a parabolic reflector located on the central axis of said pipe length. The noise reflector may comprise two layers of material of different natural frequencies in frictional engagement with one another, so that vibrations induced in each layer tend to be damped by frictional engagement with the other layer. The layers may be of similar cross-sectional shape and nested one within the other. The noise reflector may be mounted on a bulkhead extending across the closed chamber, such as an end wall of the chamber.
The open end of said pipe length within the chamber is preferably outwardly flared to improve the rate of gas flow into or out of the pipe length.
In a preferred embodiment the muffler comprises a closed chamber, an inlet pipe leading into the chamber, an outlet pipe leading from the chamber, two spaced bulkheads dividing the chamber into first and second buffer compartments separated by an intermediate compartment, at least three pass tubes extending through the bulkheads and across the intermediate compartment, two of the pass tubes forming continuations of the inlet and outlet pipes respectively and having open ends in the buffer compartments respectively, the aforesaid noise reflector being located opposite the open end of at least one of the pass tubes in such manner as to reflect down the pass tube a proportion of the noise generated by gases flowing along the pass tube.
The pass tube forming a continuation of the inlet pipe is preferably of the same diameter as the inlet pipe, and the pass tube forming a continuation of the outlet pipe is preferably of the same diameter as the outlet pipe.
The intermediate compartment is preferably filled with a body of gas permeable material, such as glass fibre, at least one of the pass tubes having perforated walls whereby gases flowing along the pass tube may escape through the perforations into the gas permeable material.
Where two of the pass tubes have open ends in the same buffer compartment, they preferably have portions of different lengths projecting into that buffer compartment, whereby the open ends of the pass tubes lie in different planes. This reduces the extent to which gases flowing out of one tube and into the other must pass closely while moving at high speed in opposite directions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section through an exhaust muffler according to the invention,
FIG. 2 is a cross-section on the line 2--2 of FIG. 1,
FIG. 3 is a front view of one of the noise reflectors employed in the muffler of FIGS. 1 and 2, and
FIG. 4 is a section through the reflector along the line 4--4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the muffler comprises a main casing 10 formed from welded sheet metal. The casing, as seen in FIG. 2, is in the form of an elongate oval in cross-section and is closed by end plates 11, 12 at opposite ends of the casing.
The chamber within the casing 10 is divided by two parallel spaced bulkheads 13 into first and second buffer compartments 14 and 15 separated by an intermediate compartment 16 between the two bulkheads.
Three pass tubes 17, 18 and 19 extend through the bulkheads 13 and across the intermediate chamber 16. The wall of the centre pass tube 17 is formed with a high density array of perforations as indicated at 20, and low density arrays of perforations, as indicated at 21, are formed in the walls of the pass tubes 18 and 19. The intermediate chamber between the bulkheads 13 and around the pass tubes 17, 18 and 19 is filled with glass fibre packing.
The centre pass tube 17 forms a continuation of an inlet pipe 22 which extends through the end plate 11 of the casing. The major part of the inlet pipe 22 is of the same internal diameter as the centre pass tube 17 and the end of the inlet pipe 22 within the chamber 14 is swaged to a larger diameter so as tightly to embrace the projecting end of the pass tube 17 as indicated at 23.
The pass tube 18 forms a continuation of an outlet pipe 24 which pass through the end plate 12 and tightly embraces the end of the pass tube 18 which projects into the buffer compartment 15.
The open ends of the pass tubes 17, 18 and 19, within the buffer compartments, are flared outwardly as shown in FIG. 1. The centre pass tube 17 projects into the buffer compartment 15 to a greater extent than the pass tube 19 so that the open ends of the tubes 17 and 19 within the buffer compartment 15 lie in different planes.
A parabolic noise reflector 25 is mounted on the end plate 12 on the central axis of the pass tube 17 and faces, and is spaced from, the flared end of the pass tube. A similar parabolic reflector 26 is mounted on the end plate 11 opposite the flared end of the pass tube 18.
The two parabolic reflectors are of similar construction, and the reflector 25 is shown in greater detail in FIGS. 3 and 4. The reflector is generally circular and is formed from two similar nested layers 27 and 28. The nested layers are formed by pressing the reflector in a press tool from two sheets of steel together. Each layer comprises a central concave portion 29, a peripheral wall 30 and a radial outer flange 31. The outer flanges 31 of the two layers are spot-welded to the end plate of the muffler by at least four spot welds evenly distributed around the circumference of the reflector. The two layers of each reflector are secured together by the spot welds but are otherwise unconnected. As best seen in FIG. 3 a segment is removed from the flanges 31 at one side of the reflector so that the reflector clears the adjacent inlet or outlet pipe.
The central concave portion 29 of the reflector should preferably be parabolic to give the best results, but good results may also be achieved where the concave portion is part-spherical.
In operation of the muffler exhaust gases from the internal combustion engine pass into the muffler through the inlet pipe 22. As previously mentioned, the inlet pipe 22 is of generally the same internal diameter as the pass tube 17. In known mufflers it is conventional practice for the inlet pipe to be of greater internal diameter than the pipe which forms its continuation within the muffler and, as a result, there is an interference with the flow of exhaust gases into the muffler due to the edge effect of the junction between the inlet pipe and the pipe forming its continuation. By swaging out the inlet pipe to fit over a pass tube of the same diameter, this edge effect is eliminated and improved flow characteristics are achieved.
As the exhaust gases flow through the centre pass tube 17 the gases pass through the perforations 20 into the glass fibre pack within the intermediate compartment 16 where sound absorption takes place in known manner.
The glass fibre is a special toughened, high temperature glass which is resistant to heat far above normal muffler temperatures and is less prone to thermal shocks than ordinary glass. As sound pulses pass into the glass pack, they cause the glass to vibrate and this has the effect of turning the noise energy into heat energy which is then dissipated through the casing of the muffler. The selection of the type of glass is important as it determines the frequency spectrum in which the best sound absorption takes place. The glass is tuned to the absorption of the higher frequencies in the sound spectrum.
The high amplitude mid and lower frequency noise spectrum is reduced by virtue of gas friction through the strands of glass. Gases pass into the glass pack through the high density perforations of the centre pass tube 17 and the pulsations of flow are damped by the backward and forward motion of the mass of gas in the glass pack itself. It the pack is too densely packed, the slug of gas will tend to pass right through the pass tube without interacting with the glass pack in the intermediate compartment 16. If the pack is too lightly packed, insufficient damping will take place and the muffler will produce a more metallic ringing noise tone which is not generally accepted as a pleasant exhaust note.
As the exhaust gases emerge from the centre pass tube 17 into the buffer compartment 15, they impinge upon the parabolic reflector 25 mounted on the end plate 12. The purpose of the parabolic reflector 25 is to provide some measure of noise damping by reflecting a proportion of the high energy noise back down the pass tube 17 so that at some point a positive wave travelling down the pass tube or inlet tube will tend to cancel out a negative wave travelling in the opposite direction. A secondary function of the noise reflector 25 is to render the end plate 21 acoustically dead. As previously described, the reflector is pressed out of two sheets of material in one pass. This means that the natural vibration frequency of the two layers is different, in view of their slight difference in dimensions, and since they are in contact with each other any vibrations which tend to excite them will be damped out by friction between the two layers. The noise reflectors will also pick up vibrations from the end plates 12 and 11 and damp them out in similar fashion.
Gases pass through the pass tube 17 into the buffer compartment 15 then travel in the reverse direction along the pass tube 19 to the buffer compartment 14. The best flow properties in any system which have to pass gas are achieved when some uniform flow pattern can be established. One of the greatest losses in flow capability occurs when high speed gases pass each other closely, going in opposite directions, since this can cause disorientation of the flow. The arrangement shown in the drawings whereby the pass tube 17 projects into the buffer compartment 15 to a greater extent than the pass tube 19 minimises this effect by reducing the extent to which the gases pass each other closely while travelling in opposite directions within the buffer compartment. | An exhaust muffler comprises a closed chamber, an inlet pipe leading into the chamber, an outlet pipe leading from the chamber, two spaced bulkheads dividing the chamber into first and second buffer compartments separated by an intermediate compartment containing a glass fiber pack, three pass tubes extending through the bulkheads and across the intermediate compartment, two of the pass tubes forming continuations of the inlet and outlet pipes respectively and having flared open ends in the buffer compartments respectively, and a parabolic noise reflector located opposite the open end of said two pass tubes in such manner as to reflect down the pass tubes a proportion of the noise generated by gases flowing along the pass tubes. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a swimming pool cleaning method wherein an organosilane is immobilized as a coating on the pool walls in order to facilitate removal of algae and other microbial and nonmicrobial stains and soils.
Antimicrobial agents are chemical compositions that are used to prevent microbiological contamination and deterioration of products, materials, and systems. Particular areas of application of antimicrobial agents and compositions are, for example, cosmetics, disinfectants, sanitizers, wood preservation, food, animal feed, cooling water, metalworking fluids, hospital and medical uses, plastics and resins, petroleum, pulp and paper, textiles, latex, adhesives, leather and hides, and paint slurries. Of the diverse categories of antimicrobial agents and compositions, quaternary ammonium compounds represent one of the largest of the classes of antimicrobial agents in use At low concentrations, quaternary ammonium type antimicrobial agents are bacteriostatic, fungistatic, algistatic, sporostatic, and tuberculostatic. At medium concentrations they are bactericidal, fungicidal, algicidal, and viricidal against lipophilic viruses. Silicone quaternary ammonium salt compounds are well known as exemplified by U.S. Pat. No. 3,560,385, issued February 2, 1971, and the use of such compounds as antimicrobial agents is taught, for example, in a wide variety of patents such as U.S. Pat. Nos. 3,730,701, issued May 1, 1973, and 3,817,739, issued June 18, 1974, where the compounds are used to inhibit algae; 3,794,736, issued February 26, 1974, and 3,860,709, issued January 14, 1975, where they are employed for sterilizing or disinfecting a variety of surfaces and instruments; 3,865,728, issued February 11, 1975. where the compounds are used to treat aquarium filters; 4,259,103, issued March 31, 1981; and in British Pat. No. 1,386,876, of March 12, 1975. Published unexamined European Application No. 228464 of July 15, 1987, teaches that microorganisms on plants can be killed by the application thereto of an aqueous mixture of a surfactant and an organosilicon quaternary ammonium compound. U.S. Pat. No. 4,564,456, issued Jan. 14, 1986, discloses organosilanes as anti-scale agents in water systems. In a particular application of an antimicrobial silicone quaternary ammonium compound, a paper substrate is rendered resistant to the growth of microorganisms in U.S. Pat. No. 4,282,366, issued Aug. 4, 1981. In U.S. Pat. No 4,504,541, issued Mar. 12, 1985, an antimicrobial fabric is disclosed which is resistant to discoloration and yellowing by treatment of the fabric with a quaternary ammonium base containing an organosilicone. U.S. Pat. No. 4,615,937, issued Oct. 7, 1986, as well as its companion U. S. Pat. No. 4,692,374, issued Sept. 8, 1987, relate to wet wiper towelettes having an antimicrobial agent substantive to the fibers of the web and being an organosilicon quaternary ammonium compound. In a series of Burlington Industries, Inc. U.S. Pat. Nos. 4,408,996, issued Oct. 11, 1983, 4,414,268, issued Nov. 8, 1983, 4,425,372, issued Jan. 10, 1984, and 4,395,454, issued July 26, 1983, such compounds are disclosed to be useful in surgical drapes, dressings, and bandages. This same assignee also discloses these compounds as being employed in surgeons' gowns in U.S. Pat. Nos. 4,411,928, issued Oct. 25, 1983, and 4,467,013, issued Aug. 21, 1984. Organosilicon quaternary ammonium compounds have been employed in carpets, in U.S. Pat. No. 4,371,577, issued Feb. 1, 1983; applied to walls, added to paints, and sprayed into shoes, in U.S. Pat. No. 4,394,378, issued July 19, 1983; applied to polyethylene surfaces and used in pillow ticking in U.S. Pat. No. 4,721,511, issued Jan. 26, 1988, in flexible polyurethane foams of fine-celled, soft, resilient articles of manufacture in U.S. Pat. No. 4,631,297, issued Dec. 23, 1986; and mixed with a surfactant in Japanese Kokai Application No. 58-156809, filed Aug. 26, 1983, of Sanyo Chemical Industries, Ltd., for the purpose of achieving uniformity of distribution of the compounds to a surface. Thus, the versatility of such compositions is readily apparent.
However, it is not known in the prior art to utilize an immobilized organosilane for the purpose of providing a dead cell layer of algae, and employing the dead cell layer of algae as a release medium in order to facilitate cleaning of swimming pool surfaces, as is taught in accordance with the present invention. Organosilanes have been added to water systems as in U.S. Pat. No. 4,564,456, but the compounds function to inhibit the formation of scale. In U.S. Pat. No. 3,730,701, organosilanes function in water systems to flocculate algae which is subsequently removed by filtration or settling. Such compounds have also been bonded to surfaces such as fibrous filter media in order to kill algae in U.S. Pat. Nos. 3,817,739, and 3,865,728. None teach the concepts disclosed herein, nor the specific application of the concept to swimming pools.
SUMMARY OF THE INVENTION
This invention relates to a method of enhancing the cleanability and facilitating the removal of algae and other microorganisms and stains and soils from surfaces prone to biofouling and soiling by being exposed to and brought into contact with aqueous media containing algae, other microorganisms, and soiling elements, comprising immobilizing on said surfaces and bonding thereto a coating of an organosilane and organosilane copolymers, the organosilanes being compatible in the aqueous media under the following conditions:
______________________________________chlorine levels 0.5 to 20 ppmcyanurates 25 to 100 ppmcalcium hardness 50 to 2,000 ppmpH 4 to 8.5alkalinity 20 to 160 ppm______________________________________
forming on the coated surfaces a layer of dead cells of the algae and other microorganisms, utilizing the layer of dead cells as a release medium to facilitate removal of succeeding layers of algae and other microorganisms that accumulate thereon, and cleaning the surfaces by dislodging the accumulated layers from the release medium layer, the organosilane having the general formula selected from the consisting of: ##STR1## wherein, in each formula, Y is R or RO where R is an alkyl radical of 1 to 4 carbon atoms or hydrogen;
a has a value of 0, 1 or 2;
R' is a methyl or ethyl radical;
R'' is an alkylene group of 1 to 4 carbon atoms;
R''', R''' and R v are each independently selected from a group consisting of alkyl radicals of 1 to 18 carbon atoms, --CH 2 C 6 H 5 , --CH --CH 2 OH, and --(CH 2 ) x NHC(O)R vi , wherein x has a value of from 2 to 10 and R vi is a perfluoroalkyl radical having from 1 to 12 carbon atoms;
X is chloride, bromide, fluoride, iodide, acetate or tosylate.
In a particularly preferred embodiment of the present invention, the surfaces form the configuration of a swimming pool, and the organosilane or silane mixtures are added to water contained therein and migrates to the pool surfaces to form the coating. The organosilane is added to the pool water in an amount sufficient to provide a concentration in the pool water in excess of about fifteen parts per million of the organosilane. Alternatively, the surfaces may include a liner, and the organosilane is sprayed onto the liner in order to provide the coating. In this case, the level of the organosilane present as a coating on the liner is in excess of about five-hundred ug/g of liner.
It is therefore the object of the present invention to provide a method of facilitating the cleaning of swimming pool surfaces by employing a release layer of dead microbial cells to ease the removal of accumulated stains and microorganisms.
These and other features, objects, and advantages, of the present invention will be apparent when considered in light of the following detailed description thereof.
DETAILED DESCRIPTION OF THE INVENTION
Ammonium compounds in which all of the hydrogen atoms have been substituted by alkyl groups are called quaternary ammonium salts. These compounds may be represented in a general sense by the formula: ##STR2##
The nitrogen atom includes four covalently bonded substituents that provide a cationic charge. The R groups can be any organic substituent that provides for a carbon and nitrogen bond with similar and dissimilar R groups. The counterion X is typically halogen. Use of quaternary ammonium compounds is based on the lipophilic portion of the molecule which bears a positive charge. Since most surfaces are negatively charged, solutions of these cationic surface active agents are readily adsorbed to the negatively charged surface. This affinity for negatively charged surfaces is exhibited by 3-(trimethyoxysilyl)propyldimethyloctadecyl ammonium chloride (TMS) of the formula: ##STR3##
In the presence of moisture, this antimicrobial agent imparts a durable, wash resistant, broad spectrum biostatic surface antimicrobial finish to a substrate. The organosilicon quaternary ammonium compound is leach resistant, nonmigrating, and is not consumed by microorganisms. It is effective against gram positive and gram negative bacteria, fungi, algae, yeasts, mold, rot, and mildew. The silicone quaternary ammonium salt provides durable, bacteriostatic, fungistatic, and algistatic surfaces. It can be applied to organic or inorganic surfaces as a dilute aqueous or solvent solution of 0.1-1.5 percent by weight of active ingredient. After the alkoxysilane is applied to a surface, it is chemically bonded to the substrate by condensation of the silanol groups at the surface. The pure compound is crystalline whereas methanol solutions of the compound are low viscosity light to dark amber liquids, soluble in water, alcohols, ketones, esters, hydrocarbons, and chlorinated hydrocarbons. The compound has been used in applications such as, for example, socks, filtration media, bed sheets, blankets, bedspreads, carpet, draperies, fire hose fabric materials, humidifier belts, mattress pads, health care apparel, mattress ticking, underwear, nonwoven disposable diapers, nonwoven fabrics, outerwear fabrics, nylon hosiery, vinyl paper, wallpaper, polyurethane cushions, roofing materials, sand bags, tents, tarpaulins, sails, rope, blood pressure cuffs, athletic and casual shoes, shoe insoles, shower curtains, toilet tanks, toilet seat covers, throw rugs, towels, umbrellas, upholstery fiberfill, intimate apparel, wiping cloths, and medical devices such as blood pressure cuffs.
In the Examples as well as in the Tables, the composition identified as TMS refers to a product manufactured by the Dow Corning Corporation, Midland, Mich., as an antimicrobial agent. This compound is 3-(trimethoxysilyl)-propyloctadecyldimethyl ammonium chloride referred to above diluted to forty-two percent active ingredients by weight with methanol.
The silanes useful in this invention have the general formula ##STR4## It should be noted that generically, these materials are quaternary ammonium salts of silanes. Most of the silanes falling within the scope of this invention are known silanes and references disclosing such silanes are numerous. One such reference, U.S. Pat. No. 4,259,103, issued to James R. Malek and John L. Speier, on Mar. 31, 1981, discusses the use of such silanes to render the surfaces of certain substrates antimicrobial. British Pat. No. 1,433,303, issued to Charles A. Roth shows the use of fillers treated with certain silanes to be used in paints and the like to give antimicrobial effects.
Numerous other publications have disclosed such silanes, namely, A. J. Isquith, E. A. Abbott and P. A. Walters, Applied Microbiology, December, 1972, pages 859-863; P. A. Walters, E. A. Abbott and A. J. Isquith, Applied Microbiology, 25, No. 2, p. 253-256, February 1973 and E. A. Abbott and A. J. Isquith, U.S. Pat. No. 3,794,736 issued Feb. 26, 1974, U.S. Pat. No. 4,406,892, issued September 27, 1983, among others.
For purposes of this invention, the silanes can be used neat or they can be used in solvent or aqueous-solvent solutions. When the silanes are used neat, the inventive process is preferably carried out in a system in which some small amount of water is present. If it is not possible to have a system with some small amount of water present, then a water soluble or water-dispersable, low molecular weight hydrolyzate of the silane may be used. What is important is the fact that the durability of any effect produced by the silane as part of a product requires that the silane molecule react with a surface to a certain extent. The most reactive species, as far as the silanes are concerned, is the .tbd.SiOH that is formed by hydrolysis of the alkoxy groups present on the silane. The .tbd.SiOH groups tend to react with the surface and bind the silanes to the surface. It is believed by the inventor that even though the prime mode of coupling to the surface system is by the route described above, it is also believed by the inventor that the alkoxy groups on the silicon atom may also participate in their own right to bind to the surface.
Preferred for this invention is a reactive surface containing some small amount of water. By "reactive", it is meant that the surface must contain some groups which will react with some of the silanols generated by hydrolysis of the silanes of this invention.
R in the silanes of this invention are alkyl groups of 1 to 4 carbon atoms. Thus, useful as R in this invention are the methyl, ethyl, propyl and butyl radicals. In the above formulas RO can also be R. R can also be hydrogen thus indicating the silanol form, i.e. the hydrolyzate. The value of a is 0, 1 or 2 and R' is a methyl or ethyl radical.
R" for purposes of this invention is an alkylene group of 1 to 4 carbon atoms. Thus, R" can be alkylene groups such as methylene, ethylene, propylene, and butylene. R''', R'''', and R v are each independently selected from a group which consists of alkyl radicals of 1 to 18 carbons, --CH 2 C 6 H 5 , --CH 2 CH 2 OH, --CH 2 OH, and --(CH 2 ) x NHC(O)R vi . x has a value of from 2 to 10 and R vi is a perfluoroalkyl radical having from 1 to 12 carbon atoms. X is chloride, bromide, fluoride, iodide, acetate or tosylate.
Preferred for this invention are the silanes of the general formula ##STR5## R is methyl or ethyl; a has a value of zero; R" is propylene; R''' is methyl or ethyl; R'''' and R v are selected from alkyl groups containing 1 to 18 carbon atoms wherein at least one such group is larger than eight carbon 5 atoms and x is either chloride, acetate or tosylate. Most preferred for this invention are those silanes having the formula
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.⊕ (CH.sub.3).sub.2 C.sub.18 H.sub.37 Cl.sup.- and (CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 -N.sup.⊕ CH.sub.3 (C.sub.10 H.sub.21).sub.2 Cl.sup.- .
As indicated above, most of these silanes are known from the literature and methods for their preparation are known as well. See, for example, U.S. Pat. Nos. 4,282,366, issued Aug. 4, 1981; 4,394,378, issued July 19, 1983, and 3,661,963 issued May 9, 1972, among others.
Specific silanes within the scope of the invention resented by the formulae:
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.18 H.sub.37 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.18 H.sub.37 Br.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (C.sub.10 H.sub.21).sub.2 CH.sub.3 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (C.sub.10 H.sub.21).sub.2 CH.sub.3 Br.sup.+,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.3 CL.sup.-,
(CH.sub.3 O).sub.3 SiCH.sub.2 CH.sub.2 CH.sub.2 P.sup.+ (C.sub.6 H.sub.5).sub.3 Cl.sup.-,
(CH.sub.3 O).sub.3 SiCH.sub.2 CH.sub.2 CH.sub.2 P.sup.+ (C.sub.6 H.sub.5).sub.3 Br.sup.-,
(CH.sub.3 O).sub.3 SiCH.sub.2 CH.sub.2 CH.sub.2 P.sup.+ (CH.sub.3).sub.3 Cl.sup.-,
(CH.sub.3 O).sub.3 SiCH.sub.2 CH.sub.2 CH.sub.2 P.sup.+ (C.sub.6 H.sub.13).sub.3 Cl.sup.-,
(CH.sub.3).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.-,
(CH.sub.3).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (C.sub.10 H.sub.21).sub.2 CH.sub.3 Cl.sup.-,
(CH.sub.3).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.18 H.sub.37 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.4 H.sub.9 Cl.sup.-,
(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 C.sub.18 h.sub.37 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 CH.sub.2 C.sub.6 H.sub.5 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 CH.sub.2 CH.sub.2 OHCl.sup.-, ##STR6##
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (CH.sub.3).sub.2 (CH.sub.2).sub.3 NHC(O)(CF.sub.2).sub.6 CF.sub.3 Cl.sup.-,
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+ (C.sub.2 H.sub.5).sub.3 Cl.sup.-.
Swimming pools include recirculation equipment, and because the water is continuously treated by mechanical filtration and by the addition of various categories of chemicals, the same water is recycled rather than being changed. Chemicals must be added to the water in order to kill and control disease causing and fouling microorganisms introduced into the water by swimmers and dirt entering the pool. It is also necessary to destroy or control algae whose spores are carried into the pool water by the wind and rain. Excessive algae accumulation results in discolored water, unsightly growths on the walls and pool bottoms, clogging of filtration equipment, and is a breeding ground for bacteria. Algae causes slipperiness, develops malodors, clouds water, increases the chlorine demand in the pool as well as bacterial growth, and results in stains on surfaces. Algae growth is promoted by high temperatures, nutrient build up, and sunlight, common to swimming pools and other recirculating water systems. Three forms of algae most often found in swimming pools are green algae, blue-green algae referred to as black algae, and mustard or yellow algae. Green algae remain suspended in the water, while the black and yellow algal types attach to pool surfaces where they become firmly fixed by penetrating cracks, crevices, and the grouting of the pool surface construction. While in the following Examples reference is made to swimming pools, the concept is applicable to spas and hot tubs, and other recirculating water systems.
EXAMPLE I
In order to determine if the compound TMS exhibits any adverse reactions characteristic of incompatibility such as clouding, precipitation, and foaming, in systems typical of swimming pool, spa environments, or other recirculating water systems, a series of tests were conducted employing TMS at three different concentration levels of two, four, and eight parts per million, in a container of water at extreme concentrations of chlorine, cyanurates, hardness, alkalinity, and pH. A blank control was used for comparative purposes. Observations were recorded over a period of forty-eight hours. At the end of forty-eight hours, a shock treatment was performed, in which a concentrated two percent solution of TMS was added to each system at the most extreme levels. The shock treatment was intended to simulate the initial addition of TMS into pool water. The results of these tests are tabulated in Tables I to VII. No adverse reaction was noted in any of the systems or conditions.
TABLE I______________________________________COMPATIBILITY TESTING - CHLORINE AND TMSDEIONIZED WATER- Time 0.5 ppm 1 ppm 5 ppm 10 ppm 20 ppmTMS Observed Cl Cl Cl Cl Cl______________________________________0 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear2 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear4 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear8 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clearShock -- clear clear clear clear clear______________________________________
TABLE II______________________________________COMPATIBILITY TESTING - CYANURATE AND TMSDEIONIZED WATER- Time Cyanurate Cyanurate CyanurateTMS Observed 25 ppm 50 ppm 100 ppm______________________________________0 0 hours clear clear clear 4 hours clear clear clear 24 hours clear clear clear 48 hours clear clear clear2 ppm 0 hours clear clear clear 4 hours clear clear clear 24 hours clear clear clear 48 hours clear clear clear4 ppm 0 hours clear clear clear 4 hours clear clear clear 24 hours clear clear clear 48 hours clear clear clear8 ppm 0 hours clear clear clear 4 hours clear clear clear 24 hours clear clear clear 48 hours clear clear clearShock -- clear clear clear______________________________________
TABLE III__________________________________________________________________________COMPATIBILITY TESTING - CHLORINE AND CYANURATE AND TMSDEIONIZED WATER- 0.5 ppm Cl 1 ppm Cl 5 ppm Cl 10 ppm Cl 20 ppm Cl Time 2.5 ppm 5 ppm 25 ppm 50 ppm 100 ppmTMS Observed Cyanurate Cyanurate Cyanurate Cyanurate Cyanurate__________________________________________________________________________0 0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear2 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear4 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear8 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clearShock -- clear clear clear clear clear__________________________________________________________________________
TABLE IV__________________________________________________________________________COMPATIBILITY TESTING - CHLORINE AND CYANURATE AND TMSTAP WATER- 0.5 ppm Cl 1 ppm Cl 5 ppm Cl 10 ppm Cl 20 ppm Cl Time 2.5 ppm 5 ppm 25 ppm 50 ppm 100 ppmTMS Observed Cyanurate Cyanurate Cyanurate Cyanurate Cyanurate__________________________________________________________________________0 0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear2 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear4 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear8 ppm0 hours clear clear clear clear clear4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clearShock -- clear clear clear clear clear__________________________________________________________________________
TABLE V__________________________________________________________________________COMPATIBILITY TESTING - CALCIUM HARDNESS AND CHLORINE AND TMSDEIONIZED WATER- 0.5 ppm Cl 1.25 ppm Cl 2.5 ppm Cl 5 ppm Cl 10 ppm Cl 20 ppm Cl Time 50 ppm 125 ppm 250 ppm 500 ppm 1000 ppm 2000 ppmTMS Observed Calcium Calcium Calcium Calcium Calcium Calcium__________________________________________________________________________0 0 hours clear clear clear clear clear clear4 hours clear clear clear clear clear clear 24 hours clear clear clear clear clear clear 48 hours clear clear clear clear clear clear2 ppm0 hours clear clear clear clear clear clear4 hours clear clear clear clear clear clear 24 hours clear clear clear clear clear clear 48 hours clear clear clear clear clear clear4 ppm0 hours clear clear clear clear clear clear4 hours clear clear clear clear clear clear 24 hours clear clear clear clear clear clear 48 hours clear clear clear clear clear clear8 ppm0 hours clear clear clear clear clear clear4 hours clear clear clear clear clear clear 24 hours clear clear clear clear clear clear 48 hours clear clear clear clear clear clearShock -- clear clear clear clear clear clear__________________________________________________________________________
TABLE VI______________________________________COMPATIBILITY TESTING - pH AND TMSTAP WATER WITH 5 PPM Cl AND 25 PPM CYANURATE- TimeTMS Observed pH 4 pH 5 pH 6 pH 7 pH 8.5______________________________________0 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear2 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear4 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clear8 ppm 0 hours clear clear clear clear clear 4 hours clear clear clear clear clear 24 hours clear clear clear clear clear 48 hours clear clear clear clear clearShock -- clear clear clear clear clear______________________________________
TABLE VII______________________________________COMPATIBILITY TESTING - TOTAL ALKALINITYAND TMS -TAP WATER WITH 5 PPM ClAND 25 PPM CYANURATE- 20 ppm Time Alka- 40 ppm 80 ppm 160 ppmTMS Observed linity Alkalinity Alkalinity Alkalinity______________________________________0 0 hours clear clear clear clear 4 hours clear clear clear clear 24 hours clear clear clear clear 48 hours clear clear clear clear2 ppm 0 hours clear clear clear clear 4 hours clear clear clear clear 24 hours clear clear clear clear 48 hours clear clear clear clear4 ppm 0 hours clear clear clear clear 4 hours clear clear clear clear 24 hours clear clear clear clear 48 hours clear clear clear clear8 ppm 0 hours clear clear clear clear 4 hours clear clear clear clear 24 hours clear clear clear clear 48 hours clear clear clear clearShock -- clear clear clear clear______________________________________
The anion of an aqueous sodium salt of bromphenol blue can be complexed with the cation of polymerized silanes of this invention while on a substrate. The blue colored complex, substantive to a water rinse, is qualitatively indicative of the presence of the cation on the substrate thus indicating the extent of antimicrobial agent on a given substrate. A comparison of the intensity of retained blue color to a color standard is used as a check to determine if the treatment has been applied properly.
The method consists of preparing a 0.02 to 0.04 weight percent solution of bromphenol blue in distilled water. This solution is made alkaline using a few drops of saturated Na 2 CO 3 solution per 100 milliliters of the solution. Two to three drops of this solution are placed on the treated substrate and allowed to stand for two minutes. The substrate is then rinsed with copious amounts of tap water and the substrate is observed for a blue stain and it is compared to a color standard.
For a spectrophotometric determination, the following test is used.
The sodium salt of bromphenol blue is depleted from a standard solution by complexing with the cations on a treated substrate. The change in bromphenol blue concentration is determined spectrophotometrically or by comparison with color standards whereby the level of substrate treatment by the cationic silane is determinable.
The method consists of preparing a 0.02 weight percent standard solution of bromphenol blue in distilled water. It is made alkaline with a few drops of saturated Na 2 CO 3 solution per 100 milliliters of bromphenol blue solution. The color of this solution is purple.
The blank solution is adjusted to yield a 10 to 12% transmittance reading when measured in 1 cm cells using a spectrophotometer set at 589 nm by the following method.
Fill a container 3/4 full of distilled water and add Z ml of the 0.02% standard bromphenol blue solution for every 50 ml of distilled water. Add 0.5 ml of a 1% Triton® X-100 surfactant (manufactured by Rohm and Haas, Philadelphia, Pa., U.S.A.) aqueous solution for every 50 ml of water. Mix, and using the spectrophotometer, determine the maximum absorbance. Adjust the upper zero to 100% transmittance with distilled water. Check the percent transmittance of the working bromphenol blue solution at the maximum absorbance setting. Adjust the blank solution to 10 to 12% transmittance with either water or bromphenol blue standard solution as necessary.
The samples of treated substrate are tested by placing 0.5 gram samples of the substrate standards in a flask large enough for substantial agitation of the sample and the test solution. Add 50 ml of the working solution. Agitate for 20 minutes on a wrist-action shaker. Fill the test curvette with the test solution. Centrifuge if particulate matter is present. Measure the % transmittance at the wavelength set forth above. The transmittance is compared against a standard curve prepared by preparing several substrate samples of known concentration of the cationic silane. For example, samples containing a known amount of cationic silane at, for example, 0%, 0.25%, 0.50%, 0.75% and 1% are read spectrophotometrically and a curve is plotted.
EXAMPLE 11
A swimming pool constructed to scale was built in an aquarium which included polyvinyl chloride walls and painted gunite walls. Water in the pool was conditioned to contain twenty parts per million chlorine and one-hundred parts per million cyanuric acid. Two rayon strips about three centimeters in width were located in the pool extending over its length and width. The TMS compound was added to the pool water in order to provide a concentration therein of four parts per million, or 1.7 parts per million based on active ingredients. At the end of forty-eight hours, the rayon strips were removed and stained with bromophenol blue in accordance with the foregoing procedure. A definite blue color was exhibited indicating an even deposition of TMS on the strips. Polyvinyl chloride and plaster strips representative of pool liner materials were also tested at concentration levels of TMS of eight, twelve, and sixteen, parts per million. At the end of forty-eight hours, the strips were removed, rinsed with tap water, dried, and analyzed in accordance with the above mentioned bromophenol blue test. In all cases, the blue color indicative of deposition was evidenced. At levels of eight, twelve, and sixteen, parts per million TMS, the level of TMS detected on the liner strips was found to be, respectively, one hundred ug/g of liner, one hundred-fifty ug/g of liner, and six hundred-fifty ug/g of liner. The level of TMS detectable in the pool water at the end of forty-eight hours was one ug/milliliter. Deposition of TMS on the strips was also evidenced at concentration levels in excess of sixteen parts per million, for example, at levels of from eighty to one hundred sixty parts per million TMS in the pool water. however, the preferred maximum was found to be about sixty parts per million TMS in any treatment.
EXAMPLE III
In order to demonstrate the effectiveness of the compound TMS in enhancing the cleanability and facilitating the removal of algae from surfaces prone to biofouling, the following tests were conducted employing coupon samples of polyvinyl chloride and plaster. A ten gallon glass tank was arranged having the coupons suspended therein. The tank was equipped with an upflow filter designed to push water through a filter media with an overflow return to the tank. A second tank was also used but equipped with a downflow filter which sucks water through a filter media and including a power return. Four foot fluorescent grow lights were installed behind each tank and in the tank covers. Room lights were left burning twenty-four hours per day. A tank heater was used to control the water temperature at eighty-five degrees Fahrenheit. Each tank was filled with nine gallons of water conditioned to a pH of 7.4, a total alkalinity of one hundred parts per million expressed as calcium carbonate, a calcium hardness of two hundred-fifty parts per million expressed as calcium carbonate, and a cyanuric acid concentration of one hundred parts per million. The additive materials for the tanks included HTH®, a trademark for a calcium hypochlorite material containing seventy percent available chlorine and manufactured by Olin Chemicals, Stamford, Conn. The algae insult was a mixture of green, yellow, and black algae. A plant food was employed having ten percent urea nitrogen, eight percent phosphorous expressed as P 2 O 5 , seven percent potash expressed as K 2 O, one tenth of one percent iron, five hundreds of one percent manganese, and five hundreds of one percent zinc. The plant food was added to each tank at the rate of five milliliters every other day. Each tank was used to conduct experiments under the following conditions:
1. Control: no treatment
2. TMS: eight parts per million
3. TMS: sixteen parts per million
______________________________________4. Chlorine three parts per million5. TMS eight parts per million Chlorine three parts per million6. TMS sixteen parts per million Chlorine three parts per million______________________________________
The procedure followed in each instance was to insert the pool liner coupons. The tank was charged with conditioned water. The filter was activated and allowed to circulate water twenty-four hours per day. The tank was then dosed as noted above, with the chlorine in the form of HTH®, the HTH® being added to the pool water before the addition of TMS. The materials were allowed to disburse, and determinations were made on initial turbidity, pH. chlorine, and TMS levels, in the tank. The filter system was then inactivated for forty- eight hours in order to allow the TMS compound to migrate in order to cover the coupon surfaces. The filter system was then reactivated and the addition of the algae insult and plant food initiated. Monitoring was conducted daily on temperature, turbidity, pH, chlorine, and TMS levels. The coupons were also visually inspected for algae growth. The pH was controlled at levels between 7.2 and 7.6 by the addition, when necessary, of hydrochloric acid and sodium carbonate. The chlorine level was maintained at three parts per million in those instances where the tank contained chlorine as a treatment condition. Five milliliters of plant food was added daily, and after determining the pool water balance, the algae insult was added daily in a dosage of thirty milliliters until the algae was either visible in the water or on the coupon surfaces, at which time the algae insult was added every other day. Pool water was added when required in order to maintain a constant volume. For purposes of comparison, a second set of conditions was imposed on each tank, similar to conditions 1-6 set forth above, as follows:
______________________________________ 7. Control no treatment 8. TMS eight parts per million 9. TMS sixteen parts per million10. Chlorine one and one-half parts per million11. Calcium sixteen parts per million Citrate12. HTH ® sixteen parts per million______________________________________
The procedure set forth above with regard to conditions 1-6 was followed in the case of conditions 7-12. Calcium citrate was used as a representative algicide, and the composition HTH® in instance No. 12 was a composition containing eighty-nine percent available chlorine which functioned as another representative algicide. The results of the extensive tests conducted in accordance with this Example III indicated that the only coupon which was easier to clean was the coupon treated with sixteen parts per million of the compound TMS of the present invention.
The antimicrobial effectiveness of the compound TMS is generally known as evidenced by U.S. Pat. Nos. 3,730,701; 3,817,739; and 3,865,728; although the function of TMS in enhancing cleanability is not known. The mechanism can be explained by the fact that dead cells adjacent the surface form a release layer, which when disturbed by mechanical cleaning or flushing, free any accumulated algae and other microorganisms therefrom. The compound may be added into the pool water directly and allowed to migrate to the surfaces of the pool, or the compound may be sprayed on the pool surfaces during manufacture of the pool or when the pool is being reconditioned. The preferred level of the treatment is between 1.71 to 3.42 parts per million based on the active ingredients. In order to be effective, it is important that the compound employed and the concentration levels of the compound provide compatibility in the system in which the treatment is to be conducted, especially as in the case of a swimming pool, cloudiness or turbidity which persisted would not be acceptable for aesthetic reasons, in most instances. In environments where cloudiness, turbidity, and aesthetics, were not an issue, compatibility would not be a critical factor, such as in the treatment with the compounds of the present invention of filters, cooling towers, humidifier systems, heat exchangers, drainage systems, ponds, pipe lines, storage tanks, cisterns, sumps, boats, and other surfaces prone to microbiological soiling and fouling.
The treating can be carried out with the quaternary ammonium compounds of this invention per se. Often, however, it is desirable to extend the compounds of this invention by incorporating therein hydrocarbon or halohydrocarbon substituted siloxanes of the formula ##EQU1## in which R is a hydrocarbon or halohydrocarbon radical and a varies from 0 to 3. The incorporation of such siloxanes in no way effects the property of the quaternary ammonium compound so that the claims of this invention are construed to cover both the use of the quaternary ammonium siloxane per se and mixtures or copolymers of such siloxanes with said hydrocarbon substituted siloxanes or halohydrocarbon substituted siloxanes.
For example, surfaces can be treated with an aqueous solution of a mixture of 10 mols of monomethyl trimethoxysilane and 1 mol of
Cl.sup.- C.sub.18 H.sub.37 Me.sub.2 N.sup.+ (CH.sub.2).sub.3 Si(OMe).sub.3.
It has also been found that combinations of 1 mol
Cl.sup.- C.sub.18 H.sub.37 Me.sub.2 N.sup.+ (CH.sub.2).sub.3 Si(OMe).sub.3
and 0.5 mol of 3-chloropropyltrimethoxysilane give effective siloxane coatings. The use of hydrocarbon and halohydrocarbon siloxane extenders often give cheaper treatment than the pure quaternary siloxane.
It will be apparent from the foregoing that many other variations and modifications may be made in the compounds, compositions, and methods described herein without departing substantially from the essential features and concepts of the present invention. Accordingly, it should be clearly understood that the forms of the invention described herein are exemplary only and are not intended as limitations on the scope of the present invention. | A method of enchancing the cleanability and facilitating the removal of algae and other microorganisms from surfaces prone to biofouling by immobilizing on said surfaces and bonding thereto a coating of organosilanes, forming on the coated surfaces a layer of dead cells of the algae and other microorganisms, utilizing the layer of dead cells and inherent release characteristics of silicone surface as a release medium to facilitate removal of succeeding layers of algae and other microorganisms that accumulate thereon, and cleaning the surfaces by dislodging the accumulated layers from the release medium layer. | 2 |
This application claims the benefit of Provisional Application No. 60/130,475, filed Apr. 22, 1999.
ORIGIN OF THE INVENTION
The invention described herein was made by employee of the United States Government. The invention may be manufactured and used by or for the governmental purposes without the payment of royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The present invention relates generally to image processing, and particularly to image enhancement following JPEG image compression and decompression. Prior methods for enhancing compressed images are beset with disadvantages or limitations. To achieve acceptable compression rates, the JPEG standard adopted a lossy compression technique. Furthermore, the JPEG, MPEG, H.261 and HDITV image and video coding algorithms are severely impaired by blocking artifacts when operating at low bit rates. A compressed image becomes distorted when compressed by lossy methods. Distortion in the image can be confined to hidden areas of the image by carefully implementing the JPEG standard and several enhancement methods for reducing the distortion have been attempted. However, in some regions of the image these prior methods may further degrade the image. Prior methods for reducing distortion introduced by the JPEG compression algorithm can introduce a high-frequency artifact around high contrast edges. Algorithms for removing artifacts exist, but can mistakenly remove thin lines and smooth over important texture. Errors also arise between adjacent 8×8 pixel image blocks created by opposite-signed round-off errors in the two blocks. One way to remove these errors is to filter the image using a low-pass filter. However, other image regions that contain important high frequency information may suffer a loss in fidelity. Likewise, many other post-processing algorithms are most effective when they are selectively applied only to certain regions of an image. Previous techniques are mainly non-linear filtering methods based on local pixel statistics rather than on local frequency content. Prior efforts include; JPEG Cross Block Smoothing (CBS), Projection Onto Complex Sets (POCS), and a variety of nonlinear filters. These offer lower peak signal to noise ratio (PSNR) and lower subjective quality than the improved algorithms proposed in the present invention, however. Additional background information may be found in the following literature references:
IJG JPEG Software 0 1990-95, Tom G. Lane.
Canny Edge Detector from “X-based Image Processing Tools and Environment (XITE)”, S. Boe, 1994.
JPEG image-adaptive DCT coefficient quantization software “adaptQ( )” as described and made available by M. Crouse and K. Ramchandran, “Joint Thresholding and Quantizer Selection for Transform Image Coding: Entropy-Constrained Analysis and Applications to Baseline JPEG,” IEEE Transactions on Image Processing, vol. 6, No. 2. pp. 205-297, February 1997.
“Theory and Applications of the Estimated Spectrum Adaptive Post-filter”, Ph.D. thesis, Georgia Institute of Technology . © 1998 Irving Linares , Pages 1-113 May, 1998.
SUMMARY OF THE INVENTION
ESAP and IPF algorithms of the present invention significantly reduce the blocking artifacts resulting from high compression by reusing the DCT coefficient local frequency characteristics to control a pixel-adaptive non-linear post-filter or a pre-post filtering system. This allows more compression and better quality compression when compared with the default JPEG compression parameters. These algorithms provide a new frequency-based pixel-adaptive filtering algorithm which may be used to enhance de-compressed JPEG images and to enhance MPEG sequences for Internet or HDTV video applications.
One object of the present invention is to reduce blocking artifacts in low-bit-rate JPEG images, particularly in systems wherein image pixels are coded using bit to pixel ratios less than or equal to 0.25 bits per pixel.
Another object is to improve PSNR and perceptual quality of coded images simultaneously and to demonstrate the feasibility of extending still image pre- and post-processing concepts to MPEG and HDTV standards.
A further object is to suggest use of ESAP/IPF algorithms to improve very low rate MPEG video sequences such as those processed by popular 28.8 k-56 k modems generally used with web browser streaming video viewers such as RealPlayer™ or Streamworks, for example.
ESAP relies on DFT analysis of the DCT and is compliant with the coded stream syntax of the Independent JPEG Group (IJG) Version 5b Software. At the decoder, ESAP estimates the 2-D pixel-adaptive bandwidths directly from the dequantized DCT coefficient. These coefficients are used to control a 2-D spatially adaptive non-linear post-filter. The algorithm optionally performs directional filtering parallel to the edges with no filtering across the edges. Post-filtering images show minimal blurring of their true edges while blocking is significantly removed.
IPF is based on the concepts of dbx audio noise reduction. IPF is a pre-post filtering system that uses inverse pair 2D filters for high frequency pre-emphasis before encoding and high frequency de-emphasis after decoding. Convergence to a unique minimum mean square error (MMSE) is possible for fixed quantization matrices. However, convergence can not be guaranteed when image-adaptive DCT quantization is jointly optimized under pre-post filtering.
The ESAP methods of the present invention have been successfully applied to JPEG color images, synthetic aperture radar (SAR) images, and image sequences. Typical PSNR improvement depends on the image, the encoding method, and the bit rate. For 512×512 8-BPP gray-scale images improvement in the range between 0.5-3.2 dB over baseline JPEG has been observed. Adaptive quantization has been observed to improve 5.6 dB for 1008×1008 8-BPS SAR images at 4-BPP over baseline JPEG. A comparison of all the treated techniques is presented at the conclusion of thesis document ( Irving Linares, Theory and Applications of the Estimated Spectrum Adaptive Post - filter, Georgia Institute of Technology . © 1998 Irving Linares , Pages 1-113 May, 1998) incorporated herein by reference. ESAP and IPF algorithms of the present invention significantly reduce blocking artifacts resulting from high compression by reusing the DCT coefficient local frequency characteristics to control a pixel-adaptive non-linear post-filter or a pre-post filtering system. This allows more compression and/or better quality compression when compared with the default JPEG compression parameters alone. The subjective quality of image improvement is more clearly shown by means of foregoing software-simulated results—including several image samples. The ESAP and IPF algorithms may also improve the visual quality of DCT coded images, such as JPEG images and may be extended to MPEG video sequences, since MPEG is largely a DOT coder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block representation of the ESAP algorithm—which includes or employs a JPEG digital image compression-decompression system.
FIG. 2 is a Table comparing waveforms: DCT basis functions ƒ j [n], Fourier transforms |F j (ω)|, & ideal Low-Pass Filter forms LPF j , respectively.
FIG. 3 ( a ) is a non-interpolated vertical frequency (NIVF) image.
FIG. 3 ( b ) is an interpolated vertical frequency (IVF) image.
FIG. 3 ( c ) is the non-interpolated horizontal frequency (NIHF) image.
FIG. 3 ( d ) is an interpolated vertical frequency (IVF) image.
FIG. 4 describes a typical block with substantial diagonal frequencies for the determination of rotated bandwidths ω θ [m].
FIG. 5 ( a ) shows a baseline JPEG image of Lena at 0.25 BPP.
FIG. 5 ( b ) is Lena showing her corresponding adaptive quantization (AQ-ESAP) image at 33.01 dB PSNR.
FIG. 5 ( c ) is a baseline JPEG Barbara image at 0.5 BPP, 28.27 dB PSNR.
FIG. 5 ( d ) is Barbara showing jointly optimized (JO-ESAP) version at 31.23 dB PSNR.
FIG. 6 shows the IPF JPEG blocking noise reduction algorithm—which is based on dbx noise reduction.
FIG. 7 ( a ) shows an original 8-BPP Lena image x at IPF encoder.
FIG. 7 ( b ) is a preemphasized 8-BPP Lena image x e at IPF encoder.
FIG. 7 ( c ) is a DRC 8-BPP Lena image x r at IPF encoder.
FIG. 7 ( d ) is a decoded DRC 8-BPP Lena image x r at IPF encoder.
FIG. 7 ( e ) is a DRE 8-BPP Lena image x e at IPF encoder.
FIG. 7 ( f ) is a Deemphasized 8-BPP Lena image x at IPF encoder.
FIG. 7 ( g ) is a JPEG-IPF-ESAP 8-BPP Lena image x at IPF encoder.
Tables 2( a ), ( b ), ( c ), and ( d ) summarize the decibel (dB) PSNR comparative results.
Tables 3( a ) and ( b ) show the IPF results for the 512×512 8-BPP Lena image.
Tables 3( c ) and ( d ) show the results for the 512×512 Barbara image.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, ESAP Encoder is an acronym for Estimated Spectrum Adaptive Post-filter (ESAP) Encoder. The main components of the ESAP algorithm are shown including a JPEG Encoder and a JPEG Decoder. Each of these coders includes standard Independent JPEG Group (IJG) Version 5b Software. From the JPEG decoder, we obtain the decoded DCT coefficients used to estimate each pixel's local bandwidth. This process uses 1:8 spatial interpolation as will be more fully explained in sections that follow. The ESAP algorithm iteratively searches for the minimum mean square error (MMSE) of the error signal e(m, σ,t,f,w), where m are the 2-D pixel coordinates. The m coordinates are omitted for clarity in the foregoing discussion. Local pixel bandwidth is used to adaptively post-filter the decoded image. The MMSE search algorithm searches a 4-D error surface e(σ,t,f,w) to obtain an optimal 4-tuple with parameters σ,t,f and w as shown in FIG. 1 .
The parameters are:
σ=Canny edge detector's Gaussian standard deviation sigma parameter (usually in the range [0.5 . . . 2.5]). This controls the region of support of the edge detector.
t=Canny edge detector's edge strength threshold, [0 . . . 255] range.
f=Magnitude of ESAP's DCT frequency bandwidth, [0.0 . . . 2π] range. In conjunction with t, this classifies pixels into the three categories: EDGE, NON-EDGE, or TEXTURE.
w=directional filter region of support (w×w) in pixels,
w=[2 . . . 16]. Non-directional filters have a fixed order of 17×17 pixels to cover four contiguous 8×8 DCT blocks.
Each iteration requires compression, decompression and bandwidth estimation.
Estimated Spectrum Adaptive Post-filter
FIG. 1 shows the ESAP algorithm extension to the baseline JPEG coder. In the block diagram of FIG. 1, x[n] is the gray-scale input image, X{circumflex over ( )} i (k) are the DCT coefficients of the transformed image, x{circumflex over ( )}[n] is the decoded JPEG image and x{tilde over ( )}[n], is the post-filtered image.
The meaning of error signal e(σ,f,t,w) was explained earlier [as e(σ,t,f,w)] and will not be repeated here.
To obtain better visual quality and a lower MSE, ESAP uses image-adaptive DCT quantization tables or Q-tables. This is not strictly necessary, but can improve PSNR about 1-2 dB without increasing the bit rate. In post-processing, ESAP estimates 2-D pixel adaptive bandwidths directly from the dequantized DCT coefficients—without incurring any additional side information. Post-processing usually provides an additional 1 dB improvement. The ESAP algorithm combines pixel-adaptive bandwidths with directional Canny edge detectors to control a 2-D spatially-adaptive non-linear post-filter h m [n] to significantly reduce DCT blocking artifacts. Overhead required to transmit the MMSE post-filter parameters amounts to only two to four bytes. Results of our experiments outlined in the pages, tables and image samples ahead show ESAP improved PSNR up to 3.23 dB over baseline JPEG while yielding subjective improvement as well.
ESAP takes into consideration the Human Visual System (HVS) spatial frequency masking characteristics. Based on the HVS tolerance to quantization errors in the high-frequency regions, ESAP performs directional filtering parallel to edges with little or no filtering across edges. Low-frequency non-edge regions are post-filtered with separable non-directional adaptive low-pass filters to minimize blocking and restore some of the image's natural smoothness. The edges are post-filtered with non-separable directional low-pass filters. The filter's directionality helps to reduce blocking along the local edge without significantly reducing perceived fidelity across the edge, where high-frequency quantization discontinuity errors are otherwise masked by the HVS perception of the edge itself.
Fourier Transform Analysis of the DCT Basis Functions
Each DCT basis function has a Fourier transform whose waveform can be explained by the modulation theorem. In the 1-D case, this takes the form x [ n ] w [ n ] ⇔ F 1 / ( 2 π ) X ( ω ) * W ( ω ) Equation ( 7 )
Referring to FIG. 2, note that multiplication of a cosine function ƒ j [n] by an eight-point rectangular window w[n] in the time domain is equivalent to the circular convolution ‘*’ of a sine-shaped rectangular window transform W(ω) with an ideal pair of impulses πδ(ω±ω j ) resulting in the |F j (ω)| waveforms shown. Analysis of the discrete-time Fourier transform of each of the DCT basis functions, in conjunction with FIG. 2, indicates that the ripples or side lobes of the spectrum of each DCT basis function, shown as dashed lines, are the frequency representation of the DCT blocking at any particular spatial frequency. The window's width determines the main lobe frequency resolution and simultaneously introduces ripples.
The ripples represent the out-of-band DCT blocking, while the main lobes contain the dominant in-band signal. If we neglect aliasing, then reduction of the DCT blocking is obtained by low-pass filtering the out-of-band side-lobes starting at a cutoff frequency W, determined by the highest-frequency nonzero DCT coefficient. This analysis is readily extensible to the 2-D case using a separable DCT. FIG. 2 further shows the ideal low-pass filters LPF j associated with each DCT basis function. Table 1 below lists their cutoff frequencies.
TABLE 1
Coefficient-block bandwidth relationship
Highest DCT Coeff. Present
Normalized I-D Bandwidth ω c
C 0
0.125π
C 1
0.250π
C 2
0.375π
C 3
0.500π
C 4
0.625π
C 5
0.750π
C 6
0.875π
C 7
1.0π
Using Table 1, each block's bandwidth is found by inspecting the highest 2-D nonzero coefficient. Intermediate zero coefficients are neglected since they do not determine the block's bandwidth. For example, if the block's highest coefficient is C 25 , then the vertical bandwidth is 0.375 π and the horizontal bandwidth is 0.750 π. The 2-D local bandwidth is centered in the middle of the block for interpolation purposes. This analysis generates two images each having a 64×64 pixel bandwidth from a 512×512 pixel image. These are the non-interpolated vertical frequency (NIVF) image [FIG. 3 ( a )] and the non-interpolated horizontal frequency (NIHF) image [FIG. 3 ( c )]. In each of these, the gray level is proportional to the local horizontal or vertical bandwidth. Each NIF is subsequently 1:8 interpolated to obtain two 512×512 interpolated frequency (IF) images. FIGS. 3 ( b ) and ( d ) show the interpolated vertical frequency (IVF) and the interpolated horizontal frequency (IHF), respectively. To properly filter the image boundaries, we symmetrically extend or replicate the IF images ω(m) and the decoded image x{circumflex over ( )}[n]. This extends the decoded image by one 8×8 block on each side. For example, a 512×512 pixel image increases to 528×528 pixels and the NIF images increase from 64×64 to 66×66 pixels. After the adaptive convolution is performed, the symmetrically extended blocks and NIF images serve no additional purpose and are cleared.
Non-directional Filtering
ESAP smoothes the current pixel of the decoded image x{circumflex over ( )}[m 1 ,m 2 ] with a 2-D adaptive cutoff low-pass FIR Hamming filter h m1,m2 [n 1 ,n 2 ] which may be directional or non-directional. The filter's directionality is determined from the output of a Canny edge detector applied to the decoded image. Horizontal and vertical bandwidths are obtained from the IHF and IVF images, respectively. EDGE and NON-EDGE pixels are found by the following rule:
/* Classify EDGE & NON-EDGE pixels */
for (n 1 =0; n 1 <N; n 1 ++)
for (n 2 =0; n 2 <N; n 2 ++)
if (canny_mag[n 1 ][n 2 ]>T &&
sqrt(Bw 1 [n 1 ][n 2 ]*Bw 1 [n 1 ][n 21 +Bw 2 [n 1 ][n 21 *Bw 2 [n 1 ][n 2 ])>F)
edge[n 1 ][n 21 =TRUE;
else
edge[n 1 ][n 2 =FALSE;
wherein:
T is a Canny edge magnitude threshold, F is a normalized 2-D frequency magnitude threshold, and Bw are IFs. In other words, if a pixel is an EDGE pixel in both the spatial domain and the frequency domain, then the pixel is declared a true image EDGE pixel and it is directionally post-filtered. If a pixel's Canny magnitude is <T but its 2-D bandwidth magnitude is >F, then it is declared a TEXTURE pixel and filtered with an impulse δ[n 1 ,n 2 ].
Otherwise, the pixel is declared a NON-EDGE pixel and is subsequently post-filtered non-directionally.
In FIG. 1, we use the equivalent notation t,f, and ω[m] for T,F, and Bw respectively.
Parameters σ and w were explained earlier.
Directional Filtering
Once the angular orientation θ of an edge passing through a pixel x{circumflex over ( )}[m] are determined using the Canny edge detector, we compute a rotated bandwidth ω θ [m] from the original rectangular bandwidth estimation ω[m]. FIG. 4, describes a typical block with a substantial quantity of diagonal frequencies. The magnitude of the highest 2-D frequency in the frequency plane corresponds to the perpendicular cutoff frequency across the edge and is given by
ω c perp ≅min(1.0, sqrt(ω c1 2 +ω c2 2 ))π Equation (2)
To exploit the HVS high-frequency masking characteristics, we fix ω c perp =π. The cutoff frequency parallel to the edge is approximately the lower of the vertical ω c1 or horizontal ω c2 DCT bandwidths:
ω c par ≅min(ω c1 ,ω c2 )π Equation (3)
Now, a non-causal 2-D rotated Hamming filter can be expressed as
h θ [ω c par , ω c perp , n 1 n 2 ]=
h ωc par [sqrt( n 1 2 +n 2 )sin(θ+tan −1 ( n 1 / n 2 ))] *
h ωc par [sqrt( n 1 2 +n 2 )cos(θ+tan −1 ( n 1 / n 2 ))] Equation (4)
where θ is measured counterclockwise with respect to the horizontal axis n 2 (or (ω 2 ) and the 1-D Hamming window LPF is given by:
h ωc [n ]=[sin(ω c n )/(π n )][0.54−0.46 cos(2 πn/M )], 0 ≦n≦M. Equation (5)
For NON-EDGE pixels, the above expression simplifies to separable filter
h [(ω c1 , ω c2 , n 1 ,n 2 ]=h ωc1 [n 1 ]h ωc2 [n 2 ]. Equation (6)
Non-directional 1-D filters of Equation (6) are pre-computed at program initialization and accessed as a lookup table during execution. ESAP's computational complexity is approximately 0((MN) 2 ) multiplications and additions for the estimated frequency interpolation and 0((MN) 2 ) additions, 0((NM 2 /4) multiplications for the adaptive convolution of each image (wherein N×N is the image size and M×M is the filter size). Equations (2) and (3) and the model of FIG. 4, are based on actual separable bandwidth measurements obtained from the quantized DCT coefficients of rotated images using MATLAB. Note that for both directional and non-directional filtering, the pixel-adaptive nature of the IF images forces us to use spatially-adaptive convolution or equivalently, a linear combiner. In other words, the actual implementation cannot use frequency-domain filtering. Nevertheless, the analysis presented in Section entitled “Fourier Transform Analysis of the DCT Basis Functions” is useful in determining the adaptive filter's 2-D bandwidth, although the filtering operation is actually performed in the spatial domain.
Referring to FIG. 6, original image x at the encoder is pre-emphasized with filter P(ω,G), where ω is the HPF cutoff frequency corresponding to separable DCT bandwidth ƒ of FIG. 1 . Note that (ω≈ƒ) and G is the pre-emphasis gain in dB. The dynamic range of the resulting pre-emphasized signal x e is compressed into an 8-BPP range of 0-255 using the dynamic range compression (DRC) function.
Then, the range-compressed signal X r of FIG. 7 ( c ) is used to compute MMSE optimally quantized Q-table using the Lagrange multiplier minimization function adaptQw( ).
The image is then JPEG compressed using the standard IJG cjpeg( ) function. The 2-D pre-post filters P(ω,G) and D(ω,G) are made of separable 1-D filters, where the dB gain G applies to both dimensions, P(ω,G) is the pre-emphasis filter and D(ω,G) is the de-emphasis filter. P(ω,G) is designed to obey the pre-emphasis characteristic p [ n ] = δ [ n ] + gh [ n ] ⇔ F P ( ω ) = 1 + gH ( ω ) . Equation ( 7 )
From Equation (7) above, the dB gain is given by
G dB =10 log 10 (1 +g ) Equation (8)
since p[n] is a non-causal even-symmetric real sequence. The 2-D separable pre-post filter inverse pair is given by
P (ω 1 ,ω 2 ,G ) D (ω 1 ,ω 2 ,G )= P 1 (ω 1 ,G ) P 2 (ω 2 ,G ) D 1 (ω 1 ,G ) D 2 (ω 2 ,G )=1. Equation (9)
Finally, companding obeys the following equations. For dynamic range compression
x r =C ( x e −x emin ), Equation (10)
and for dynamic range expansion
x{circumflex over ( )} e =( l/C ) x{circumflex over ( )} r +x emin , Equation (11)
where
C =255/( x emin −x emax ). Equation (12)
At the decoder, JPEG file X i (k) is de-compressed into the x{circumflex over ( )} r image. Then, it is dynamic range expanded (DRE) into the file x{circumflex over ( )} e image. Next, the image is de-emphasized with the filter D(ω,G) to create the x{circumflex over ( )} image. Finally, the image is ESAP post-filtered into the x{tilde over ( )} image to obtain further block smoothing. The ESAP filter can be inserted in any of three possible positions: pos 1 , pos 2 , or pos 3 . Depending on which position is selected, we could create the intermediate process images x{tilde over ( )} r , x{tilde over ( )} e or x{tilde over ( )}.
Along with the JPEG coded image X i (k), four overhead bytes are passed to the decoder: two dynamic range compression parameters (x emin , x emax ) and two pre-post filter parameters (ω, G). This overhead only amounts to about 0.0001 BPP for a 512×512 8-BPP gray-scale image at a 32:1 compression ratio (0.25 BPP). Please note that the encoder contains an internal decoder.
Results for ESAP Enhancement of Baseline JPEG, AQ and JO Images
To compare the objective performance of several versions of the JPEG-ESAP algorithm, we use two PSNR references: JPEG and the embedded zerotree wavelet (EZW). We also show subjective improvement, including edge preservation with blocking reduction for the Lena and Barbara images.
FIG. 5 ( a ) shows a baseline JPEG image of Lena at 0.25 BPP, 31.68 dB PSNR and FIG. 5 ( b ) shows its corresponding adaptive quantization (AQ-ESAP) image at 33.01 dB PSNR.
Similarly, FIG. 5 ( c ) is a baseline JPEG Barbara image at 0.5 BPP, 28.27. dB PSNR and FIG. 5 ( d ) is its jointly optimized (JO-ESAP) version at 31.23 dB PSNR.
Tables 2( a ), ( b ), ( c ), and ( d ) summarize the decibel (dB) PSNR comparative results.
Consider, for example, the 512×512 Lena image at 0.25 BPP. Referring to the first two lines of Tables 2( a ) and ( b ), observe that the JPEG's cross-block smoothing (CBS) reduces the PSNR by 0.04 dB. After applying ESAP to the default quantized JPEG image we obtain a 1.08 dB improvement. When we pre-process the image to obtain an image-adaptive Q-table and post-process it with ESAP we observe post-filtering improvement as shown under Δ AQ-ESAP . For this case it is 1.33 dB.
TABLE 2(a)
PSNRs for 512 × 512 Lena image.
AQ-
BPP
JPEG
CBS
ESAP
AQ
ESAP
JO
JO-ESAP
EZW
0.25
31.68
31.64
32.76
31.88
33.01
32.34
33.02
33.17
0.50
34.90
34.87
35.59
35.48
36.23
35.96
36.34
36.28
1.00
37.96
37.95
38.20
38.88
39.23
39.58
39.61
39.55
TABLE 2(b)
PSNR improvement over baseline JPEG for
the 512 × 512 Lena image.
BPP
Δ CBS
Δ JPEG-ESAP
Δ AQ
Δ AQ-ESAP
Δ JO
Δ JO-ESAP
Δ EZW
0.25
−0.04
1.08
0.20
1.33
0.66
1.34
1.49
0.50
−0.03
0.69
0.58
1.33
1.06
1.44
1.38
1.00
−0.01
0.24
0.92
1.27
1.62
1.65
1.59
TABLE 2(c)
PSNRs for 512 × 512 Barbara image.
AQ-
BPP
JPEG
CBS
ESAP
AQ
ESAP
JO
JO-ESAP
EZW
0.25
25.02
25.01
25.73
26.02
26.96
26.66
27.05
26.77
0.50
28.27
28.25
29.44
29.99
31.03
30.63
31.23
30.53
1.00
33.10
33.09
34.01
35.22
35.84
35.94
36.33
35.14
TABLE 2(d)
PSNR improvement over baseline JPEG for
the 512 × 512 Barbara image.
BPP
Δ CBS
Δ JPEG-ESAP
Δ AQ
Δ AQ-ESAP
Δ JO
Δ JO-ESAP
Δ EZW
0.25
−0.01
0.71
1.00
1.94
1.64
2.03
1.75
0.50
−0.02
1.17
1.72
2.76
2.36
2.96
2.26
1.00
−0.01
0.91
2.12
2.74
2.84
3.23
2.04
TABLE 3(a)
JPEG, IPF, EZW and SPIHT comparison 512 × 512 Lena image.
IPF Parameters
(ω cq , G q )
(χ emin , χ emax )
Image/PSNR
BPP
N, G r
JPEG
IPF
EZW
SPIHT
0.25
(0.0469, 8.9609)
lena.25.jpg
lena.25.ipf
N/A
lena.25.sp
(−94, 1106)
31.68
33.15
33.17
34.14
13, 9.25
0.50
(0.0312, 7.8047)
lena.5.jpg
lena.5.ipf
N/A
lena.5.sp
(−14, 976)
34.90
36.34
36.28
37.25
13, 9.25
1.00
(0.0469, 8.4375)
lena1.0.jpg
lena1.0.ipf
N/A
lena1.0.sp
(−20, 1019)
37.96
39.28
39.55
40.46
11, 10
TABLE 3(b)
IPF PSNR dB improvement for 512 × 512 Lena image.
BPP
Δ IPF
Δ EZW
Δ SPIHT
0.25
1.47
1.49
2.46
0.50
1.44
1.38
2.35
1.00
1.32
1.59
2.50
TABLE 3(c)
JPEG, IPF, EZW and SPIHT comparison
for 512 × 512 Barbara image.
IPF Parameters
(ω cq , G q )
(χ emin , χ emax )
Image/PSNR
BPP
N, G r
JPEG
IPF
EZW
SPIHT
0.25
(0.0469, 7.5938)
barb.25.jpg
barb.25.ipf
N/A
barb.25.sp
(−195, 1021)
25.02
27.23
26.77
27.40
9, 9
0.50
(0.0312, 4.3125)
barb.5.jpg
barb.5.ipf
N/A
barb.5.sp
(−33, 562)
28.27
31.09
30.53
31.25
7, 6
1.00
(0.0469, 3.5938
barb1.0.jpg
barb1.0.ipf
N/A
barb1.0.sp
(−50, 451)
33.10
35.87
35.14
36.22
9, 5
TABLE 3(d)
IPF PSNR dB improvement for 512 × 512 Barbara image.
BPP
Δ IPF
Δ EZW
Δ SPIHT
0.25
2.21
1.75
2.38
0.50
2.82
2.26
2.98
1.00
2.77
2.04
3.12
To conclude this example, preprocessing the image to obtain a joint-optimized Q-table followed by ESAP post-processing generates an improvement Δ AO-ESAP of 1.34 dB. For comparison, the last column shows the EZW Δ EZW improvement. For this case it is 1.49 dB.
IPF Results
This section compares IPF with baseline JPEG, EZW, and SPIHT algorithms. Tables 3( a ) and ( b ) show the IPF results for the 512×512 8-BPP Lena image and Tables 3( c ) and ( d ) show the results for the 512×512 Barbara image. All the images are .gif formatted. The IPF images were obtained with the algorithm described in FIG. 6 .
For comparison, the PSNR values obtained with baseline JPEG, Shapiro's embedded zerotree wavelet coder, and experimental results obtained with Said and Pearlman's set partitioning in hierarchical trees (SPIHT) subband coder are shown in the third and the two rightmost columns, respectively. The EZW PSNR values are taken from the literature and their corresponding images are not available. The values (ω cq , G q ) are the quantized cutoff frequencies and gains for the pre-post filters, respectively. The expanded dynamic range is bounded by (x emin ,x emax ) which can normally be represented by two 12-bit signed integers. “N” is the 2-D pre-post filters' order N×N, and finally, “G r ” is the pre-post filters' dB gain range (−G r . . . 0 . . . G r ).
Alternate Embodiments
FIG. 6 shows the IPF JPEG blocking noise reduction algorithm based on the dbx noise reduction system. In this case, the MMSE search looks for four parameters: the minimum and maximum pixel amplitudes (x e min , x e max ) and the (ω,G) cutoff and gain parameters, respectively.
In its simplest (sub-optimal) form, without MMSE searching, these algorithms do not require any additional overhead. These algorithms may be implemented in firmware or a fast processor capable of real-time video sequence enhancement may be used to process these algorithms to accommodate improved performance over low bit rate connections.
Variants of the disclosed ESAP system may be extended to include non-DCT coders; Including for example:
Vector Quantization (VQ);
Projection Onto Convex Sets (POCS), and;
Set Partitioning In Hierarchical Trees (SPIHT) octave-band subband coders.
The ESAP and IPF algorithms of the present invention may be implemented in firmware to obtain fast real-time response; Either one may significantly enhance the visual quality of low bit rate Internet video or MPEG video sequences.
This software has Potential applicability for video enhancement of very low rate MPEG video sequences in the range of 28.8 kbps-56 kbps generally used in popular web browser streaming video viewers such as RealPlayer or Streamworks© and for H.261 ISDN coders from PictureTel® and Compression Labs.
Other possible applications include use for moderate rate (4-8 Mbps) HDTV broadcasts. | The invention presents The Estimated Spectrum Adaptive Postfilter (ESAP) and the Iterative Prepost Filter (IPF) algorithms. These algorithms model a number of image-adaptive post-filtering and pre-post filtering methods. They are designed to minimize Discrete Cosine Transform (DCT) blocking distortion caused when images are highly compressed with the Joint Photographic Expert Group (JPEG) standard. The ESAP and the IPF techniques of the present invention minimize the mean square error (MSE) to improve the objective and subjective quality of low-bit-rate JPEG gray-scale images while simultaneously enhancing perceptual visual quality with respect to baseline JPEG images. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefit of U.S. Provisional Applications No. 61/074,899, 61/074,906, 61/074,910 and 61/074,914, all filed Jun. 23, 2008, the entire disclosure of each which is hereby incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
The subject matter of this application relates to a method of identifying speakers in a home theater system.
A typical home theater system comprises a display unit, a DVD player or other signal source, an audio video control receiver, and multiple speakers. A so-called 7.1 channel system uses eight speakers, namely a center speaker, a subwoofer and six surround speakers (right and left front, right and left fill and right and left rear). The home theater system includes a home theater decoder which creates eight digital audio signals, which are assigned to the eight speakers respectively, from data that the DVD player reads from the disk. We will assume for the purpose of this discussion that the home theater decoder is integrated in the DVD player but it could be elsewhere in the system.
The home theater decoder combines the digital audio signals in four pairs, each pair running on an I2S serial bus. The I2S serial bus signal is composed of a succession of frames, each of which contains 32 left channel bits followed by 32 right channel bits. The labeling of the two groups of 32 bits as left channel and right channel is conventional but arbitrary, in that there is no industry standard that requires the left channel component of a two-channel audio signal to be encoded in the first group of bits of the I2S frame and the corresponding right channel component to be encoded in the second group of bits of the I2S frame. In a 7.1 channel home theater decoder having four I2S buses, I2S bus 0 might convey the signals created for the right front and left front speakers, bus 1 might convey the signals for right fill and left fill, bus 2 the signals for right rear and left rear, and bus 3 the signals for center and subwoofer. However, there is no industry standard for mapping speaker position to I2S bus channel. The DVD player transmits the four I2S serial bus signals over a digital communication medium to the receiver, which separates the four two-channel signals to generate eight digital audio signals and converts the digital audio signals to analog form for driving the eight speakers respectively. The system may employ wired speaker connections, in which case the receiver has at least eight pairs of speaker terminals from which wires run to the eight speakers respectively.
The subwoofer conveys low frequency information and the placement of the subwoofer and the timing of the audio signal for driving the subwoofer are not critical to satisfactory operation of the home theater system. However, optimum performance of the home theater system requires that the acoustic signals received from the other seven speakers at a listening location have the proper timing relationships, and consequently the receiver includes a facility for selectively delaying the audio signals supplied to the speakers to achieve the proper timing relationships among the acoustic signals.
The procedures for proper adjustment of the audio signal delays are so challenging to many would-be users of home theater systems that a large proportion of the receivers and multi-channel speaker systems that are purchased are returned to the stores without ever being properly installed.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the disclosed subject matter there is provided a method of identifying speakers in an array comprising a center speaker, a left speaker, and a right speaker, the method comprising providing the center speaker with left and right ultrasonic electro-acoustic transducers, providing the left speaker and the right speaker each with an ultrasonic electro-acoustic transducer, and either (a) energizing one transducer of the center speaker to emit an acoustic ping signal, utilizing the transducers of the left and right speakers to detect the ping signal, measuring lapse of time between emission of the ping signal by said one transducer and detection of the ping signal by the transducers of the left and right speakers, energizing the other transducer of the center speaker to emit an acoustic ping signal, utilizing the transducers of the left and right speakers to detect the ping signal, and measuring lapse of time between emission of the ping signal by said other transducer and detection of the ping signal by the transducers of the left and right speakers, or (b) energizing the transducer of the left speaker to emit an acoustic ping signal, utilizing the transducers of the center speaker to detect the ping signal, measuring lapse of time between emission of the ping signal by the transducer of the left speaker and detection of the ping signal by the transducers of the center speaker, energizing the transducer of the right speaker to emit an acoustic ping signal, utilizing the transducers of the center speaker to detect the ping signal, and measuring lapse of time between emission of the ping signal by the transducer of the right speaker and detection of the ping signal by the transducers of the center speakers, and employing the measured values of lapse of time to assign a location to each of the left and right speakers relative to the center speaker.
In accordance with a second aspect of the disclosed subject matter there is provided a method of identifying speakers in an array comprising a center speaker, multiple A speakers, and multiple B speakers, where one of A and B is left and the other of A and B is right, wherein the A speakers include a front A speaker that is the closest of the A speakers to the center speaker, the center speaker includes A and B ultrasonic electro-acoustic transducers and each of the A speakers and each of the B speakers includes an ultrasonic electro-acoustic transducer, wherein the A transducer of the center speaker is closer than the B transducer to at least one of the A speakers and the B transducer of the center speaker is closer than the A transducer to at least one of the B speakers, and the method includes energizing the A transducer of the center speaker to emit an acoustic ping signal, utilizing the transducers of the A speakers to detect the ping signal, and measuring lapse of time between emission of the ping signal by the A transducer and detection of the ping signal by the transducers of the A and B speakers and energizing the B transducer of the center speaker to emit an acoustic ping signal, utilizing the transducers of the A speakers to detect the ping signal, and measuring lapse of time between emission of the ping signal by the B transducer and detection of the ping signal by the transducers of the A and B speakers.
In accordance with a third aspect of the disclosed subject matter there is provided a home theater system comprising a control unit including a radio transceiver for emitting and receiving wireless control signals and wireless left and right audio signals, a center speaker provided with left and right ultrasonic electro-acoustic transducers and with a center speaker control means for controlling the left and right electro-acoustic transducers in response to wireless control signals received from the radio transceiver, a first surround speaker provided with an ultrasonic electro-acoustic transducer and with a first speaker control means for controlling the electro-acoustic transducer of the first surround speaker in response to wireless control signals received from the radio transceiver, and a second surround speaker provided with an ultrasonic electro-acoustic transducer and with a second speaker control means for controlling the electro-acoustic transducer of the second surround speaker in response to wireless control signals received from the radio transceiver, and wherein the control unit, the center speaker control means, the first speaker control means and the second speaker control means are programmed so that when one of the surround speakers is in a right surround location relative to the center speaker and the other surround speaker is in a left surround location relative to the center speaker, the control unit cooperates with the center speaker control means, the first speaker control means and the second speaker control means to identify which of the first and second surround speakers is in the right surround location and which surround speaker is in the left surround location, and the control unit transmits the wireless left and right audio signals to the surround speakers in the left and right surround locations respectively.
In accordance with a fourth aspect of the disclosed subject matter there is provided a home theater system comprising a control unit including a radio transceiver for emitting and receiving wireless control signals and wireless left and right audio signals, a first speaker provided with an ultrasonic electro-acoustic transducer and with a first speaker control means for controlling the electro-acoustic transducer of the first speaker in response to wireless control signals received from the radio transceiver, and a second speaker provided with an ultrasonic electro-acoustic transducer and with a second speaker control means for controlling the electro-acoustic transducer of the second speaker in response to wireless control signals received from the radio transceiver, and wherein the control unit, the first speaker control means and the second speaker control means are programmed so that when one of the speakers is in a right location relative to a listening location and the other speaker is in a left location relative to the listening location, the control unit cooperates with the first speaker control means and the second speaker control means to determine distance between the first and second speakers, and the control unit transmits the wireless left and right audio signals to the left and right speakers respectively.
In accordance with a fifth aspect of the disclosed subject matter there is provided speaker that is suitable for use as a center speaker in an array of speakers that also includes multiple left speakers and multiple right speakers, wherein the speaker includes left and right ultrasonic electro-acoustic transducers for emitting an ultrasonic ping signal, wherein the left and right transducers are positioned so that when the speaker is utilized as a center speaker in an array that also includes a front left speaker and a front right speaker, the left transducer is closer than the right transducer to the front left speaker and the right transducer is closer than the left transducer to the right front speaker.
In accordance with a sixth aspect of the disclosed subject matter there is provided a method of optimizing a speaker system that includes a center speaker, multiple left speakers and multiple right speakers for a listener at a selectively variable location, wherein each speaker includes an ultrasonic electro-acoustic transducer, the method comprising positioning a portable location measurement device including an ultrasonic electro-acoustic transducer at a selected location and using the portable location measurement device to initiate a measurement procedure by which the transducers of at least two speakers emit ultrasonic ping signals, the transducer of the location measurement device detects the ultrasonic ping signals, and lapse of time between emission of the ping signal and detection of the ping signal by the transducer of the location measurement device is measured, allowing calculation of the position of the measurement location device relative to the speakers, whereby relative signal delays to the speakers may be adjusted to account for the position of the location measurement device.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of a 7.1 channel home theater audio system embodying the subject matter disclosed in this application,
FIG. 2 is a plan view of a room in which the home theater system may be installed,
FIG. 3 is a more detailed block diagram illustrating parts of the decoder unit of the system shown in FIG. 1 ,
FIG. 4A and FIG. 4B (collectively referred to as FIG. 4 ) are, respectively, a horizontal sectional view and a front elevation of one form of speaker used in the system shown in FIG. 1 ,
FIG. 5 is a schematic block diagram illustrating an electronics package included in the speaker shown in FIG. 4 ,
FIG. 6A and FIG. 6B (collectively referred to as FIG. 6 ) are, respectively, a horizontal sectional view and a front elevation of a second form of speaker used in the home theater system shown in FIG. 1 , and
FIG. 7 is a schematic block diagram of an electronics package included in the speaker shown in FIG. 6 .
DETAILED DESCRIPTION
As used in this detailed description and in the appended claims, the term “audio” as applied to a signal means a signal having a frequency within the accepted standard range of audible frequencies, i.e. from 20 Hz to 20,000 Hz, whereas “ultrasonic” as applied to a signal means a signal having a frequency higher than 20 kHz. As applied to an electro-acoustic transducer, the term “ultrasonic” as used herein means that the transducer is able to emit and receive ultrasonic acoustic signals.
The 7.1 channel home theater system shown in FIG. 1 comprises a signal source 2 , which may, for example, be a satellite receiver, a cable TV decoder or a DVD player, eight speakers 61 - 68 (a center speaker 61 , six surround speakers 62 - 67 and a subwoofer 68 ) and a display unit 8 . The home theater system also includes a home theater decoder 14 ( FIG. 3 ), which receives audio data from the signal source and generates four I2S serial bus signals, as described above. The home theater decoder may be installed in, for example, the display unit, the DVD player or an audio video control receiver (AVR), or it may be a stand-alone unit. We will refer to the component in which the home theater decoder is installed as the decoder unit.
The decoder unit has a main processor 12 , which controls the functions performed by the decoder unit, be it a display unit or an AVR, for example, in the home theater system. The main processor communicates with the home theater decoder 14 and a master module 4 .
The home theater system is installed in a room having front, rear, left and right walls, with the display unit 8 against the front wall and the speakers 61 - 68 positioned as shown in FIG. 2 relative to the walls and a listening location 10 . Generally, the user will interact with the home theater system using a hand-held remote control unit 11 that transmits user commands to an infrared receiver installed in the decoder unit. The IR receiver in the decoder unit passes the user commands to the main processor 12 and the main processor responds to the commands transmitted by the remote control unit. The main processor 12 communicates certain user commands to the master module 4 .
Referring to FIG. 3 , the master module 4 also includes an antenna 24 for wireless transmission and reception of signals, a radio transceiver 28 that is able to transmit and receive on any selected one of several channels, a controller 32 that receives signals from the main processor and controls operation of the radio transceiver, and a non-volatile memory 40 .
As discussed in detail below, the master module employs the radio transceiver 28 and antenna 24 for wireless transmission of audio signals provided by the home theater decoder 14 to the speakers. Accordingly, there is no need to run individual speaker wires to the speakers.
The center speaker and the six surround speakers are sometimes referred to herein as the main speakers. The six surround speakers are essentially identical to each other. The installer places the six surround speakers (in the 7.1 channel system under discussion) at selected positions in the room. Since the six surround speakers are identical, they are interchangeable and the installer can place the speakers without regard to whether a particular speaker is at a given location. In this specification, the term “location,” as applied to a speaker, refers to the general location of the speaker relative to the listening location, e.g. front right, left rear, whereas the term “position” refers to the spatial position of the speaker expressed in units of linear (and possibly angular) displacement in a coordinate system having at least two axes.
We will discuss the six surround speakers by reference to the speaker 62 , which is placed in the front right location, i.e. in front of and to the right of the listening location 10 . Referring to FIG. 4 , the speaker 62 comprises a housing 70 and an audio driver 72 . The housing is substantially symmetrical about a vertical plane 73 . Typically, the speaker will be oriented so that the plane 73 extends towards the listening location 10 . The driver 72 includes a diaphragm and a voice coil for displacing the diaphragm in response to an audio signal, thereby causing the driver to emit an audio frequency acoustic signal in a pattern that is substantially symmetrical about a horizontal axis that lies in the vertical plane 73 and is considered to be the central axis of the speaker. The speaker also comprises an electro-acoustic ultrasonic transducer 74 distinct from the audio driver 72 . The transducer 74 is designed to emit and receive acoustic signals at ultrasonic frequencies, e.g. about 40 kHz, and has a relatively wide angle of sensitivity. For example, a typical inexpensive transducer, although rated as having an angle of sensitivity of 90°, may in fact be able to emit and receive over an angular range of 180° or more. The transducer is mounted in the housing so that the line defining the center of its angular range of sensitivity is parallel to, and vertically above, the central axis of the speaker.
Referring to FIG. 5 , the speaker 62 also includes an antenna 76 and an electronics package connected to a source of operating current. The electronics package includes a radio transceiver 78 connected to the antenna for receiving signals transmitted by the master module and transmitting signals to the master module, and a switch 80 . The switch communicates a signal received from the radio transceiver 78 either to an audio processor 82 or to a controller 84 via a message filter 85 . The electronics package also includes an ultrasonic transceiver 86 , which is connected to the ultrasonic transducer.
The ultrasonic transceiver 86 responds to a command from the controller 84 by driving the ultrasonic transducer 74 to emit a brief ultrasonic signal at a frequency of about 40 kHz for about 250 μs (a ping). The signal power level may be quite high (over 100 dB) but because the signal is very brief it contains very little energy. When operating as a receiver, the ultrasonic transceiver provides a signal to the controller 84 when the transducer detects ultrasonic energy above a threshold level.
The controller 84 includes a counter that continuously counts clock pulses. The counter can be reset selectively to zero in response to a signal provided by the radio transceiver 78 and will store its count in response to a signal provided by the ultrasonic transceiver 86 .
Referring to FIGS. 6 and 7 , the center speaker 61 is similar to the speaker 62 except that the center speaker 61 includes two electro-acoustic transducers 74 L, 74 R positioned to left and right respectively of the central axis of the speaker. The lines defining the centers of the respective angular ranges of sensitivity are equidistant horizontally from the central axis of the speaker. The transducers 74 L, 74 R are spaced apart horizontally by at least 10 cm, and preferably at least 15 cm.
The topology of the electronics package in the center speaker is similar to that shown in FIG. 5 except that there are two ultrasonic transceivers connected to the two ultrasonic transducers 74 L, 74 R respectively and the controller 84 includes two counters (L, R) that count clock pulses in similar fashion to the counter of the speaker 62 and store their respective counts in response to signals provided by the transceivers 86 L and 86 R respectively.
The subwoofer 68 is similar to the speaker 62 . The topology of the electronics package in the subwoofer is similar to that shown in FIG. 5 except that, for a reason mentioned below, it is not necessary for the controller to include a counter.
Each speaker has a unique access control address, similar in function to the MAC address assigned to a network adapter, and also has a hardware type. The three hardware types are center, surround and subwoofer. The access control address and hardware type are hard-wired into the controller 84 at time of manufacture. The center speaker also has a unique speaker ID, which is both hard-wired into the controller and recorded on a plate attached to the center speaker. The horizontal spacing of the transducers 74 L, 74 R is also hard-wired into the controller 84 , for example as supplementary field to the hardware type. Other items of speaker-specific information may also be stored in the controller at time of manufacture.
The speakers are slave modules relative to the master module 4 . When the home theater system is first installed and connected to a source of operating current, and before the decoder unit is switched on for the first time, the master module contains no information regarding the speakers. When the home theater system is connected to a source of operating current, and before the decoder unit is switched on, the master module operates in a low power condition in which its radio transceiver 28 periodically monitors each of its communication channels to determine whether the channel is clear for transmission. The master module maintains a list of the channels that are clear and updates that list as necessary. Similarly, the electronics packages of the speakers operate in a low power condition in which the audio processor and ultrasonic transceiver are off and at intervals of 500 ms the controller 84 turns the radio transceiver 78 on and scans all possible channels in an attempt to detect a signal from a master module that is organizing or running a network. If the speaker does not detect a master module organizing or running a network, the controller turns the transceiver 78 off.
The system remains in this low power condition until a user switches the home theater system on, for example by pressing the power button on the remote control unit. In this event, the main processor 12 detects the POWER ON signal emitted by the remote control unit and issues a command to the internal components of the decoder unit to initiate a POWER ON routine. The master module 4 also receives this command from the main processor and selects, at random, a clear communication channel and transmits a beacon for about one second. The speakers that are within range (and are scanning all possible channels at intervals of 500 ms) are thereby informed that the master module is organizing a network and respond to the beacon by turning on their ultrasonic transceivers 86 . The audio processor 82 of the speaker remains off.
During this initial phase of operation, the switch 80 directs signals received from the transceiver 78 to the message filter 85 . The message filter 85 , when operational, passes control messages that include the access control address of the speaker to the controller 84 and blocks other control messages from reaching the controller 84 . However, at this point in operation, the message filter is not operational and all control messages transmitted by the master module are communicated to the controller 84 .
After transmitting the beacon, the master module transmits a discovery command and then switches its radio transceiver to the receive mode for a brief interval of, for example, 64 ms. Each speaker selects at random a hold off time less than 64 ms and transmits a response to the discovery command at the end of the selected hold off time. The response contains the access control address of the speaker and the hardware type of the speaker. The master module stores a table containing the access control addresses and hardware types of the responding speakers in its non-volatile memory 40 . For speakers other than the subwoofer, the table is also able to store one or more distance values, a left or right indicator, a front, fill or rear indicator, and at least one set of coordinates specifying speaker position. For the center speaker, the table stores a value for the distance between the left and right transducers.
Since the speakers select the hold off time at random, there is a possibility that two or more speakers will select the same hold off time. In order to guard against this possibility, the master module repeats the discovery process and if it detects a response from one or more slave units that did not respond to the first execution of the discovery process, the master module adds the access control address and hardware type of each additional speaker to the table stored in its memory.
After responding to the discovery command, the message filter 85 becomes operational so that only messages that include the proper access control address are communicated to the controller 84 .
If there is a similar home theater system in a neighboring room, it is possible that the discovery command transmitted by the master module will elicit a response from two or more center speakers, in which case the table of speakers stored by the master module in response to the discovery command will contain entries for two or more center speakers. If this is the case, the master module must exclude from the network that it is organizing every center speaker that is not in the same room as the master module. In order to identify a center speaker that is not in the master module's room, the controller 32 causes the transceiver 28 to transmit a reduced power probe signal addressed to each center speaker listed in the table. Each center speaker that receives the probe signal transmits a response message. If the master module still receives multiple response messages, it reduces its transmission power again and issues a further probe signal. The master module continues in this manner until it receives a response from only one center speaker, and the master module identifies this center speaker as a member of its network and deletes the entries for other center speakers from its table.
In the event that this procedure is unable to resolve ambiguity in the identification of the center speaker that should be included in the network that is being organized by the master module, the user may employ the decoder unit's user interface to select the center speaker by reference to the speaker ID.
The surround speakers that received the discovery command may include speakers other than the six speakers 62 - 67 . Likewise, the discovery command may be received by one or more subwoofers outside the room containing the center speaker. The master module transmits a command message to the center speaker and all the surround speakers and subwoofers in its table. The center speaker responds to the message by issuing a ping from each of its ultrasonic transducers and the surround speakers and subwoofer(s) respond by enabling their ultrasonic transducers to receive the pings. The master module then issues a request message to which the surround speakers and subwoofer(s) respond by reporting whether they detected at least one of the pings.
Because the ping issued by the center speaker 61 contains very little energy, it is not detected by surround speakers or subwoofers outside the room containing the center speaker and therefore the only speakers that report having detected at least one ping are speakers in the same room as the master module. The master module updates its table by deleting any entries for speakers that did not respond to the ping.
It will be appreciated that checks might be desirable before deleting a speaker from the table, for example to ensure that a speaker that is temporarily hidden from the center speaker by a person moving about the room, is detected. Such checks are not necessary to an understanding of the subject matter disclosed in this application and will not be described further.
In this manner, the master module is able to determine the access control addresses of all eight speakers in its network and exclude from the network any speakers that are outside the room in which the master module is located, associate a hardware type with each speaker, and learn the distance between the left and right ultrasonic transducers of the center speaker. The master module must then determine the location (left or right and front, fill or rear) of each of the surround speakers. For proper operation of the home theater system, it is sufficient for the master module to determine that a subwoofer is in the same room as the center speaker. It is not necessary to determine the location of the subwoofer.
There are several ways in which the locations of the surround speakers can be determined.
In accordance with one approach, the master module executes an algorithm based on certain assumptions regarding the layout of the home theater system. In accordance with these assumptions, the central axes of the left and right fill speakers are perpendicular to the central axis of the center speaker and the listening position is located on the central axis of the center speaker and midway between the central axes of the left and right fill speakers. Referring to FIG. 2 , the listening area is divided into four quadrants relative to a polar coordinate system centered at the default listening position and having the 0° vector aligned with the central axis of the center speaker. The front left quadrant is from 0° to 90°, rear left is from 90° to 180°, rear right is from 180° to 270° and front right is from 270° to 0°.
In order to facilitate discussion, it is convenient to specify an (X,Y) coordinate system in which the default listening position is at the origin (0,0), the right speakers are at positive X positions, the left speakers are at negative X positions, the front speakers are at positive Y positions and the rear speakers are at negative Y positions. See FIG. 2 .
The master module selects one of the surround speakers and transmits a command message to which the selected surround speaker responds by issuing a ping and the center speaker responds by resetting its counters to zero. Each transducer of the center speaker detects the ping and the controller 84 stores the counts attained by the two counters. The master module interrogates the center speaker and the center speaker reports the stored count values. The master module repeats this operation for each of the other surround speakers in turn and thereby acquires a dataset that relates the access control address of the selected speaker (which issued the ping) and the two count values reported by the center speaker. As mentioned previously, the angle of sensitivity of the transducers typically exceeds 180° and accordingly the transducers of the center speaker 61 and the transducers of the speakers 62 and 67 are mutually acoustically visible in the layout shown in FIG. 2 . If, in an alternative layout, the center speaker 61 is significantly closer to the listening position along the Y axis than the front speakers, an alternative triangulation technique may be used to determine the positions of the front speakers, for example utilizing the transducers of the rear speakers.
The master module is able to calculate the respective distances of the left and right transducers of the center speaker from each surround speaker. Since the distance between the transducers of the center speaker is known, it is then a routine matter for the master module to calculate the position of each surround speaker in the (X,Y) coordinate system.
Using the calculated (X,Y) positions of the speakers, the master module assigns each speaker to a speaker location (front left, right rear, etc.), by identifying the quadrants within which the speakers are located. It will be appreciated that this may result in some ambiguity. For example, both speakers 62 and 63 are located in the front right quadrant. This ambiguity can be resolved later, e.g. by use of triangulation to measure the Y locations of the speakers 62 , 63 and 64 and inferring that the speaker 63 , being between the speakers 62 and 64 , must be the right fill speaker. It will also be appreciated that a greater error is associated with calculation of the Y positions of the front speakers than with calculation of the Y positions of the rear speakers, and it may therefore be desirable to recalculate the positions of the front speakers utilizing pings transmitted by the transducers of the rear speakers.
In this manner, the master module associates each speaker's access control address with a speaker location. The master module then transmits a message that associates the speaker's access control address with the I2S bus channel assigned to that speaker location, as discussed in greater detail below.
When the master module has associated each speaker with a speaker location and has calculated the distance of each speaker from the center speaker, the master module is able to calculate the position of each speaker in the (X,Y) coordinate system by triangulation, i.e. by using a ping emitted by the transducer of the right fill speaker to measure the distance between the right fill speaker and the front left and rear left speakers. By iteratively calculating speaker positions, the master module can calculate the positions of the surround speakers with substantial precision and accuracy.
Current 7.1 channel home theater decoders create the seven main speaker signals based on the locations of the main speakers in a polar coordinate system (r,θ) in which listening location is at the origin. By default, the right fill and left fill speakers are at 90° and 270° respectively and the center speaker is at 0°. The front and rear speakers also have default angular positions. The master module transforms the positions of the surround speakers in the (X,Y) coordinate system to the polar coordinate system (r,θ). The master module supplies the (r,θ) values for the main speakers to the home theater decoder 14 via the main processor 12 .
The home theater decoder uses the r values and the calculated (or default) angular positions in processing the audio data received from the signal source to produce the seven surround signals, so that the center signal and the six surround signals received at the default listening location are in the proper phase relationship.
Set up of the home theater system is now almost complete. Referring again to FIG. 3 , the main processor communicates certain user commands to the home theater decoder 14 , which receives digital audio data from the signal source 2 . The home theater decoder 14 creates eight audio signals assigned to the eight speaker positions respectively from the digital audio data and the (r,θ) information for the main speakers and combines the eight signals in four pairs, as described above, and outputs four I2S serial data streams, each conveying the digital audio signals for two speakers. Although the I2S bus frame provides 32 bits for each channel, in a practical implementation, 24 of the 32 bits are used for each channel and the remaining 8 bits are null. The four serial data streams are received by the master module 4 .
The master module includes a deserializer 18 that separates each of the I2S signals into its two components and a matrix 20 that assigns each of the resulting eight digital audio signals to respective slots (slots 0-7) in a transmission multiplex.
Different home theater decoders employ different mappings between speaker position and the channels of the I2S buses. The matrix 20 maps the I2S bus channels to the slots to provide a fixed relationship between speaker position and slot. For example, regardless of the mappings of speaker positions to I2S bus channels, the matrix may be configured to assign the right front speaker signal to slot 0. Thus, the message that associates each speaker's access control address with an I2S channel informs the speaker whose access control address is associated with the right front speaker position that it should capture the digital audio signal transmitted in slot 0.
At this point, the home theater system is operative. The controller 32 enables the radio transceiver 28 to transmit the digital audio signal provided by the matrix 20 . The matrix 20 supplies a signal block, containing the data bits of eight consecutive slots, to the radio transceiver 28 , which transmits the eight digital audio signals. The digital audio signal is organized as a succession of blocks, each of which contains the data for eight slots representing one sample value for each speaker. The radio transceiver 28 employs the digital audio signal to encode a carrier at the frequency of the selected communication channel and transmits the modulated signal via the antenna 24 . In each speaker, the controller 84 sets the switch 80 to direct the signal received from the radio transceiver to the audio processor 82 . The controller also provides the audio processor with the appropriate slot ID. The audio processor 82 receives the audio data blocks from the radio transceiver 78 , captures the audio data for the appropriate slot, converts the digital audio signal to analog form, amplifies the audio signal and supplies the audio signal to the audio driver.
Each slot of the signal transmitted by the matrix contains 24 bits. A noise event may impair the receipt of several consecutive bits. In order to reduce the impact of such a noise event on the signal provided to any one speaker, the output signal block transmitted by the matrix may be scrambled so that, for example, no two consecutive bits of the transmitted signal are of the same slot and higher order bits are interleaved with lower order bits.
Since it is possible that the actual listening location will in fact be different from the default listening location, it is desirable that the master module be able to calculate the (r,θ) positions of the center speaker and surround speakers relative to the actual listening location. In order to support this autofind (AF) functionality, the remote control unit 11 includes an ultrasonic transducer and an ultrasonic transceiver.
In order to execute the listening location AF calculation, the user, seated at the listening location, presses an AF button on the remote control unit and the infrared transmitter of the remote control unit issues an IR command that is received by the main processor. The main processor 12 decodes the IR message and determines it to be an AF command, and responds by sending an AF command to the master module 4 . The master module transmits an AF command over the radio. The AF command contains the access control address of the center speaker and instructs the center speaker to transmit a ping signal by each of its transducers. The center speaker and the left and right fill speakers restart their counters and the left and right fill speakers listen for the pings transmitted by the left and right transducers of the center speaker. When the left or right fill speaker receives a ping from the center speaker, it saves the count value and restarts its counter. The remote control unit also listens for a ping from the center speaker. Upon receiving a ping, the remote control unit waits a set period that is sufficient for all echoes of the center speaker's pings to have decayed so that they are no longer detectable, say 100 ms, and then transmits a ping. The center speaker and the left and right fill speakers receive the second ping. The left and right fill speakers add the count value (since the restart) to the count value saved for the ping transmitted by the center speaker. The center speaker saves the two left and right count values. The master module then reads all these values and uses them (and the set wait period of the remote control unit) to triangulate the position of the remote control unit in the (X,Y) coordinate system. Knowing the (X,Y) position of the listening location relative to the center speaker, the master module can transform the (X,Y) locations of the main speakers to (r,θ) locations relative to the listening location.
In the case of the embodiment described above, delaying the audio signals to take account of distance of the main speakers from the listening location is performed by the home theater decoder when it creates the digital audio signals. In other embodiments, the audio signals may be delayed elsewhere, for example in the main module or in the individual speakers. Amplification of the audio signals in response to adjustment of a volume control on the remote control unit is accomplished by the home theater decoder but in other embodiments, the amplification may be performed in the individual speakers either in the digital domain or in the analog domain by supplying suitable control messages to the speakers.
A less sophisticated home theater decoder may create the seven main speaker signals based only on the distance of each of the main speakers from a default listening location that is between the two fill speakers and directly in front of the center speaker (and based on default angular positions of the speakers). Since the locations of the main speakers in the (X,Y) coordinate system are known, it is straightforward to calculate the distance of each main speaker from the default listening location.
In the case of a home theater system including such a less sophisticated home theater decoder, the master module supplies the distance values to the home theater decoder and the home theater decoder uses the distance values to calculate an appropriate set of delay times. The home theater decoder delays the individual audio signals for the seven main speakers based on the respective delay times.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, as interpreted in accordance with principles of prevailing law, including the doctrine of equivalents or any other principle that enlarges the enforceable scope of a claim beyond its literal scope. For example, the subject matter disclosed in this application has been described with reference to a home theater system having eight speakers but it will be appreciated by those skilled in the art that equivalent subject matter may be applied to a system having as few as two speakers and to systems having more than eight speakers. In addition, although the method of identifying speakers, in a system having a center speaker, a left speaker, and a right speaker, has been described in terms of the ping signals being emitted by the transducers of the surround speakers and detected by the transducers of the center speaker, it would alternatively be possible for the ping signals to be emitted by the transducers of the center speaker and received by the transducers of the surround speakers.
In the case of the described embodiment of the disclosed subject matter, the system is able to distinguish between the left and right sides of the listening area by virtue of the two transducers of the center speaker preferring the left and right sides respectively, in the sense that the left transducer, for example, receives a ping from a surround speaker on the left of the listening area before the right transducer does so, and a surround speaker on the left side of the listening area receives a ping from the left transducer of the center speaker with a shorter delay than that with which it receives a ping from the right transducer. However, there are other mechanisms by which the system may be able to distinguish between the left and right sides of the listening area. For example, the two transducers of the center speaker may prefer the left and right sides of the listening area by virtue of their being angularly oriented so that one transducer transmits and receives preferentially to and from the right of the central axis of center speaker and the other transducer transmits and receives preferentially to and from the left of the central axis of the center speaker.
Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or more than one instance, requires at least the stated number of instances of the element but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated. The word “comprise” or a derivative thereof, when used in a claim, is used in a nonexclusive sense that is not intended to exclude the presence of other elements or steps in a claimed structure or method. | With an array of speakers including a center speaker provided with left and right ultrasonic electro-acoustic transducers and left and right speakers provided with respective ultrasonic electro-acoustic transducers, it is possible to identify the left and right speakers. One approach includes energizing the left transducer of the center speaker to emit an acoustic ping signal, utilizing the transducers of the left and right speakers to detect the ping signal, measuring lapse of time between emission of the ping signal by said the left transducer and detection of the ping signal by the transducers of the left and right speakers. Then, the right transducer of the center speaker is energized to emit an acoustic ping signal, the transducers of the left and right speakers are utilized to detect the ping signal, and lapse of time between emission of the ping signal by the right transducer and detection of the ping signal by the transducers of the left and right speakers is measured. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 11/841,967, filed Aug. 20, 2007, which is a continuation application of U.S. patent application Ser. No. 10/395,631, filed Mar. 21, 2003, now U.S. Pat. No. 7,297,130 B2, issued Nov. 20, 2007, which is a continuation application of U.S. patent application Ser. No. 09/549,350, filed Apr. 14, 2000, now U.S. Pat. No. 6,638,239 B1, issued Oct. 28, 2003, the contents of which are incorporated in their entirety by reference herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to improved medical devices and methods for the reduction of elevated pressure in organs of the human body. More particularly, the present invention relates to the treatment of glaucoma by trabecular bypass surgery, which is a means for using an implant or seton, such as a micro stent, shunt or the like, to bypass diseased trabecular meshwork at the level of trabecular meshwork and use/restore existing outflow pathways.
BACKGROUND OF THE INVENTION
[0003] About two percent of people in the United States have glaucoma. Glaucoma is a group of eye diseases that causes pathological changes in the optic disk and corresponding visual field loss resulting in blindness if untreated. Intraocular pressure elevation is the major etiologic factor in all glaucomas.
[0004] In glaucomas associated with an elevation in eye pressure the source of resistance to outflow is in the trabecular meshwork. The tissue of the trabecular meshwork allows the “aqueous” to enter Schlemm's canal, which then empties into aqueous collector channels in the posterior wall of Schlemm' s canal and then into aqueous veins. The aqueous or aqueous humor is a transparent liquid that fills the region between the cornea at the front of the eye and the lens. The aqueous humor is constantly secreted by the ciliary body around the lens, so there is a continuous flow of the aqueous humor from the ciliary body to the eye's front chamber. The eye's pressure is determined by a balance between the production of aqueous and its exit through the trabecular meshwork (major route) or via uveal scleral outflow (minor route). The trabecular meshwork is located between the outer rim of the iris and the internal periphery of the cornea. The portion of the trabecular meshwork adjacent to Schlemm' s canal causes most of the resistance to aqueous outflow (juxtacanilicular meshwork).
[0005] Glaucoma is grossly classified into two categories: closed-angle glaucoma and open-angle glaucoma. The closed-angle glaucoma is caused by closure of the anterior angle by contact between the iris and the inner surface of the trabecular meshwork. Closure of this anatomical angle prevents normal drainage of aqueous humor from the anterior chamber of the eye. Open-angle glaucoma is any glaucoma in which the angle of the anterior chamber remains open, but the exit of aqueous through the trabecular meshwork is diminished. The exact cause for diminished filtration is unknown for most cases of open-angle glaucoma. However, there are secondary open-angle glaucomas which may include edema or swelling of the trabecular spaces (from steroid use), abnormal pigment dispersion, or diseases such as hyperthyroidism that produce vascular congestion.
[0006] All current therapies for glaucoma are directed at decreasing intraocular pressure. This is initially by medical therapy with drops or pills that reduce the production of aqueous humor or increase the outflow of aqueous. However, these various drug therapies for glaucoma are sometimes associated with significant side effects, such as headache, blurred vision, allergic reactions, death from cardiopulmonary complications and potential interactions with other drugs. When the drug therapy fails, surgical therapy is used. Surgical therapy for open-angle glaucoma consists of laser (trabeculoplasty), trabeculectomy and aqueous shunting implants after failure of trabeculectomy or if trabeculectomy is unlikely to succeed. Trabeculectomy is a major surgery which is most widely used and is augmented with topically applied anticancer drugs such as 5-flurouracil or mitomycin-c to decrease scarring and increase surgical success.
[0007] Approximately 100,000 trabeculectomies are performed on Medicare age patients per year in the United States. This number would increase if the morbidity associated with trabeculectomy could be decreased. The current morbidity associated with trabeculectomy consists of failure (10-15%), infection (a life long risk about 2-5%), choroidal hemorrhage (1%, a severe internal hemorrhage from pressure too low resulting in visual loss), cataract formation, and hypotony maculopathy (potentially reversible visual loss from pressure too low).
[0008] If it were possible to bypass the local resistance to outflow of aqueous at the point of the resistance and use existing outflow mechanisms, surgical morbidity would greatly decrease. The reason for this is that the episcleral aqueous veins have a backpressure that would prevent the eye pressure from going too low. This would virtually eliminate the risk of hypotony maculopathy and choroidal hemorrhage. Furthermore, visual recovery would be very rapid and risk of infection would be very small (a reduction from 2-5% to 0.05%). Because of these reasons surgeons have tried for decades to develop a workable surgery for the trabecular meshwork.
[0009] The previous techniques, which have been tried, are goniotomy/trabeculotomy, and other mechanical disruption of the trabecular meshwork, such as trabeculopuncture, goniophotoablation, laser trabecular ablation and goniocurretage. They are briefly described below.
[0010] Goniotomy/Traabeculotomy: Goniotomy and trabeculotomy are simple and directed techniques of microsurgical dissection with mechanical disruption of the trabecular meshwork. These initially had early favorable responses in the treatment of open-angle glaucoma. However, long-term review of surgical results showed only limited success in adults. In retrospect, these procedures probably failed secondary to repair mechanisms and a process of “filling in”. The filling in is the result of a healing process which has the detrimental effect of collapsing and closing in of the created opening throughout the trabecular meshwork. Once the created openings close, the pressure builds back up and the surgery fails.
[0011] Trabeculopuncture: Q-switched Neodymium (Nd):YAG lasers also have been investigated as an optically invasive technique for creating full-thickness holes in trabecular meshwork. However, the relatively small hole created by this trabeculopuncture technique exhibits a filling in effect and fails.
[0012] Goniophotoablation/Laser Trabecular Ablation: Goniophotoablation is disclosed by Berlin in U.S. Pat. No. 4,846,172, and describes the use of an excimer laser to treat glaucoma by ablating the trabecular meshwork. This was not demonstrated by clinical trial to succeed. Hill et al. used an Erbium:YAG laser to create full thickness holes through trabecular meshwork (Hill et al., Lasers in Surgery and Medicine 11:341-346, 1991). This technique was investigated in a primate model and a limited human clinical trial at the University of California, Irvine. Although morbidity was zero in both trials, success rates did not warrant further human trials. Failure again was from filling in of created defects in trabecular meshwork by repair mechanisms. Neither of these is a valid surgical technique for the treatment of glaucoma.
[0013] Goniocurretage: This is an ab-interno (from the inside) mechanical disruptive technique. This uses an instrument similar to a cyclodialysis spatula with a microcurrette at the tip. Initial results are similar to trabeculotomy that fails secondary to repair mechanisms and a process of filling in.
[0014] Although trabeculectomy is the most commonly performed filtering surgery, Viscocanulostomy (VC) and non-penetrating trabecilectomy (NPT) are two new variations of filtering surgery. These are ab-externo (from the outside), major ocular procedures in which Schlemm's canal is surgically exposed by making a large and very deep scleral flap. In the VC procedure, Schlemm's canal is cannulated and viscoelastic substance injected (which dilates Schlemm's canal and the aqueous collector channels). In the NPT procedure, the inner wall of Schlemm's canal is stripped off after surgically exposing the canal.
[0015] Trabeculectomy, VC, and NPT are performed under a conjunctival and scleral flap, such that the aqueous humor is drained onto the surface of the eye or into the tissues located within the lateral wall of the eye. Normal physiological outflows are not used. These surgical operations are major procedures with significant ocular morbidity. When Trabeculectomy, VC, and NPT are thought to have a low chance for success, a number of implantable drainage devices have been used to ensure that the desired filtration and outflow of aqueous humor through the surgical opening will continue. The risk of placing a glaucoma drainage implant also includes hemorrhage, infection and postoperative double vision that is a complication unique to drainage implants.
[0016] Examples of implantable shunts or devices for maintaining an opening for the release of aqueous humor from the anterior chamber of the eye to the sclera or space underneath conjunctiva have been disclosed in U.S. Pat. Nos. 6,007,511 (Prywes), 6,007,510 (Nigam), 5,893,837 (Eagles et al.), 5,882,327 (Jacob), 5,879,319 (Pynson et al.), 5,807,302(Wandel), 5,752,928 (de Roulhac et al.), 5,743,868 (Brown et al.), 5,704,907 (Nordquist et al.), 5,626,559 (Solomon), 5,626,558 (Suson), 5,601,094 (Reiss), RE. 35,390 (Smith), 5,558,630 (Fisher), 5,558,629 (Baerveldt et al.), 5,520,631 (Nordquist et al.), 5,476,445 (Baerveldt et al.), 5,454,796 (Krupin), 5,433,701 (Rubinstein), 5,397,300 (Baerveldt et al.), 5,372,577 (Ungerleider), 5,370,607 (Memmen), 5,338,291 (Speckman et al.), 5,300,020 (L'Esperance, Jr.), 5,178,604 (Baerveldt et al.), 5,171,213 (Price, Jr.), 5,041,081 (Odrich), 4,968,296 (Ritch et al.), 4,936,825 (Ungerleider), 4,886,488 (White), 4,750,901 (Molteno), 4,634,418 (Binder), 4,604,087 (Joseph), 4,554,918 (White), 4,521,210 (Wong), 4,428,746 (Mendez), 4,402,681 (Haas et al.), 4,175,563 (Arenberg et al.), and 4,037,604 (Newkirk).
[0017] All of the above embodiments and variations thereof have numerous disadvantages and moderate success rates. They involve substantial trauma to the eye and require great surgical skill by creating a hole over the full thickness of the sclera/cornea into the subconjunctival space. Furthermore, normal physiological outflow pathways are not used. The procedures are mostly performed in an operating room generating a facility fee, anesthesiologist's professional fee and have a prolonged recovery time for vision. The complications of filtration surgery have inspired ophthalmic surgeons to look at other approaches to lowering intraocular pressure.
[0018] The trabecular meshwork and juxtacanilicular tissue together provide the majority of resistance to the outflow of aqueous and, as such, are logical targets for surgical removal in the treatment of open-angle glaucoma. In addition, minimal amounts of tissue are altered and existing physiologic outflow pathways are utilized. Trabecular bypass surgery has the potential for much lower risks of choroidal hemorrhage, infection and uses existing physiologic outflow mechanisms. This surgery could be performed under topical anesthesia in a physician's office with rapid visual recovery.
[0019] Therefore, there is a great clinical need for the treatment of glaucoma by a method that would be faster, safer and less expensive than currently available modalities. Trabecular bypass surgery is an innovative surgery which uses a micro stent, shunt, or other implant to bypass diseased trabecular meshwork alone at the level of trabecular meshwork and use or restore existing outflow pathways. The object of the present invention is to provide a means and methods for treating elevated intraocular pressure in a manner which is simple, effective, disease site specific and can be performed on an outpatient basis.
SUMMARY OF THE INVENTION
[0020] In some preferred embodiments, the seton has an inlet portion configured to extend through a portion of the trabecular meshwork of an eye, and an outlet portion configured to extend into Schlemm's canal of the eye, wherein the inlet portion is disposed at an angle relative to the outlet portion. In some embodiments, the outlet portion has a lumen with an oval cross-section having a long axis.
[0021] The outlet portion in certain embodiments has a longitudinal axis, such that the long axis of the oval cross-section and the longitudinal axis of the outlet portion define a plane, the inlet portion having a longitudinal axis which lies outside the plane at an angle θ (theta) thereto.
[0022] In some preferred arrangements, the seton comprises an inlet portion, configured to extend through a portion of the trabecular meshwork; an outlet portion, configured to extend into Schlemm's canal; and at least one protrusion on the outlet portion, configured to exert traction against an inner surface of Schlemm' s canal. This protrusion can comprise at least one barb or ridge.
[0023] Some preferred embodiments comprise an inlet portion configured to extend through a portion of the trabecular meshwork, an outlet portion configured to extend into Schlemm' s canal, and a one-way valve within the inlet and/or outlet portions.
[0024] A method for delivering a seton within an eye is disclosed, comprising providing an elongate guide member, advancing a distal end of the guide member through at least a portion of the trabecular meshwork of the eye, advancing the seton along the guide member toward the distal end, and positioning the seton to conduct aqueous humor between the anterior chamber of the eye and Schlemm's canal.
[0025] In certain embodiments, the advancing of the guide member comprises advancing it from the anterior chamber into the trabecular meshwork. In further embodiments, the positioning comprises positioning an end of the seton within Schlemm's canal adjacent to an aqueous collection channel.
[0026] Certain preferred embodiments include an apparatus for delivering a seton to the anterior chamber of an eye comprising an elongate tube having a lumen, an outer surface, and a distal end; a removable, elongate guide member within the lumen, configured to permit the seton to be advanced and to be positioned in the trabecular meshwork of the eye. This apparatus can further comprise a cutting member positioned at the distal end of the tube. The cutting member can be selected from the group consisting of a knife, a laser probe, a pointed guide member, a sharpened distal end of said tube, and an ultrasonic cutter. The apparatus can also further comprise an opening in the outer surface of the tube, configured to allow fluid infusion into the eye.
[0027] In further preferred embodiments, an apparatus for delivering a seton in an eye, comprises an elongate member adapted for insertion into an anterior chamber of the eye, the elongate member having a distal end portion configured to retain the seton therein, the distal end portion comprising a cutting member configured to form an opening in the trabecular meshwork of the eye for receipt of the seton, such that one end of the seton is in Schlemm's canal. The elongate member can further comprise a lumen which conducts fluid toward said distal end portion.
[0028] The preferred embodiment provides further surgical treatment of glaucoma (trabecular bypass surgery) at the level of trabecular meshwork and restores existing physiological outflow pathways. An implant bypasses diseased trabecular meshwork at the level of trabecular meshwork and which restores existing physiological outflow pathways. The implant has an inlet end, an outlet end and a lumen therebetween. The inlet is positioned in the anterior chamber at the level of the internal trabecular meshwork and the outlet end is positioned at about the exterior surface of the diseased trabecular meshwork and/or into fluid collection channels of the existing outflow pathways.
[0029] In accordance with a preferred method, trabecular bypass surgery creates an opening or a hole through the diseased trabecular meshwork through minor microsurgery. To prevent “filling in” of the hole, a biocompatible elongated implant is placed within the hole as a seton, which may include, for example, a solid rod or hollow tube. In one exemplary embodiment, the seton implant may be positioned across the diseased trabecular meshwork alone and it does not extend into the eye wall or sclera. In another embodiment, the inlet end of the implant is exposed to the anterior chamber of the eye while the outlet end is positioned at the exterior surface of the trabecular meshwork. In another exemplary embodiment, the outlet end is positioned at and over the exterior surface of the trabecular meshwork and into the fluid collection channels of the existing outflow pathways. In still another embodiment, the outlet end is positioned in the Schlemm's canal. In an alternative embodiment, the outlet end enters into fluid collection channels up to the level of the aqueous veins with the seton inserted in a retrograde or antegrade fashion.
[0030] According to the preferred embodiment, the seton implant is made of biocompatible material, which is either hollow to allow the flow of aqueous humor or solid biocompatible material that imbibes aqueous. The material for the seton may be selected from the group consisting of porous material, semi-rigid material, soft material, hydrophilic material, hydrophobic material, hydrogel, elastic material, and the like.
[0031] In further accordance with the preferred embodiment, the seton implant may be rigid or it may be made of relatively soft material and is somewhat curved at its distal section to fit into the existing physiological outflow pathways, such as Schlemm's canal. The distal section inside the outflow pathways may have an oval shape to stabilize the seton in place without undue suturing. Stabilization or retention of the seton may be further strengthened by a taper end and/or by at least one ridge or rib on the exterior surface of the distal section of the seton, or other surface alterations designed to retain the seton.
[0032] In one embodiment, the seton may include a micropump, one way valve, or semi-permeable membrane if reflux of red blood cells or serum protein becomes a clinical problem. It may also be useful to use a biocompatible material that hydrates and expands after implantation so that the seton is locked into position around the trabecular meshwork opening or around the distal section of the seton.
[0033] One of the advantages of trabecular bypass surgery, as disclosed herein, and the use of a seton implant to bypass diseased trabecular meshwork at the level of trabecular meshwork and thereby use existing outflow pathways is that the treatment of glaucoma is substantially simpler than in existing therapies. A further advantage of the invention is the utilization of simple microsurgery that may be performed on an outpatient basis with rapid visual recovery and greatly decreased morbidity. Finally, a distinctly different approach is used than is found in existing implants. Physiological outflow mechanisms are used or re-established by the implant of the present invention, in contradistinction with previously disclosed methodologies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Additional objects and features of the present invention will become more apparent and the invention itself will be best understood from the following Detailed Description of Exemplary Embodiments, when read with reference to the accompanying drawings.
[0035] FIG. 1 is a sectional view of an eye for illustration purposes.
[0036] FIG. 2 is a close-up sectional view, showing the anatomical diagram of trabecular meshwork and the anterior chamber of the eye.
[0037] FIG. 3 is an embodiment of the seton implant constructed according to the principles of the invention.
[0038] FIG. 4 is a top cross-sectional view of section 4 - 4 of FIG. 3 .
[0039] FIG. 5 is another embodiment of the seton implant constructed in accordance with the principles of the invention.
[0040] FIG. 6 is a perspective view illustrating the seton implant of the present invention positioned within the tissue of an eye.
[0041] FIG. 7 is an alternate exemplary method for placing a seton implant at the implant site.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Referring to FIGS. 1 to 7 , what is shown is a method for the treatment of glaucoma by trabecular bypass surgery. In particular, a seton implant is used to bypass diseased trabecular meshwork at the level of trabecular meshwork to use or restore existing outflow pathways and methods thereof
[0043] For background illustration purposes, FIG. 1 shows a sectional view of an eye 10 , while FIG. 2 shows a close-up view, showing the relative anatomical locations of the trabecular meshwork, the anterior chamber, and Schlemm's canal. Thick collagenous tissue known as sclera 11 covers the entire eye 10 except that portion covered by the cornea 12 . The cornea 12 is a thin transparent tissue that focuses and transmits light into the eye and the pupil 14 which is the circular hole in the center of the iris 13 (colored portion of the eye). The cornea 12 merges into the sclera 11 at a juncture referred to as the limbus 15 . The ciliary body 16 begins internally in the eye and extends along the interior of the sclera 11 and becomes the choroid 17 . The choroid 17 is a vascular layer of the eye underlying retina 18 . The optic nerve 19 transmits visual information to the brain and is sequentially destroyed by glaucoma.
[0044] The anterior chamber 20 of the eye 10 , which is bound anteriorly by the cornea 12 and posteriorly by the iris 13 and lens 26 , is filled with aqueous. Aqueous is produced primarily by the ciliary body 16 and reaches the anterior chamber angle 25 formed between the iris 13 and the cornea 12 through the pupil 14 . In a normal eye, the aqueous is removed through the trabecular meshwork 21 . Aqueous passes through trabecular meshwork 21 into Schlemm's canal 22 and through the aqueous veins 23 which merge with blood-carrying veins and into venous circulation. Intraocular pressure of the eye 10 is maintained by the intricate balance of secretion and outflow of the aqueous in the manner described above. Glaucoma is characterized by the excessive buildup of aqueous fluid in the anterior chamber 20 which produces an increase in intraocular pressure (fluids are relatively incompressible and pressure is directed equally to all areas of the eye).
[0045] As shown in FIG. 2 , the trabecular meshwork 21 constitutes a small portion of the sclera 11 . It is understandable that creating a hole or opening for implanting a device through the tissues of the conjunctiva 24 and sclera 11 is relatively a major surgery as compared to a surgery for implanting a device through the trabecular meshwork 21 only. A seton implant 31 of the present invention for either using or restoring existing outflow pathways positioned through the trabecular meshwork 21 is illustrated in FIG. 5 .
[0046] In a first embodiment, a method for increasing aqueous humor outflow in an eye of a patient to reduce the intraocular pressure therein. The method comprises bypassing diseased trabecular meshwork at the level of the trabecular meshwork and thereby restoring existing outflow pathways. Alternately, a method for increasing aqueous humor outflow in an eye of a patient to reduce an intraocular pressure therein is disclosed. The method comprises bypassing diseased trabecular meshwork at a level of said trabecular meshwork with a seton implant and using existing outflow pathways. The seton implant 31 may be an elongated seton or other appropriate shape, size or configuration. In one embodiment of an elongated seton implant, the seton has an inlet end, an outlet end and a lumen therebetween, wherein the inlet end is positioned at an anterior chamber of the eye and the outlet end is positioned at about an exterior surface of said diseased trabecular meshwork. Furthermore, the outlet end may be positioned into fluid collection channels of the existing outflow pathways. Optionally, the existing outflow pathways may comprise Schlemm's canal 22 . The outlet end may be further positioned into fluid collection channels up to the level of the aqueous veins with the seton inserted either in a retrograde or antegrade fashion with respect to the existing outflow pathways.
[0047] In a further alternate embodiment, a method is disclosed for increasing aqueous humor outflow in an eye of a patient to reduce an intraocular pressure therein. The method comprises (a) creating an opening in trabecular meshwork, wherein the trabecular meshwork comprises an interior side and exterior side; (b) inserting a seton implant into the opening; and (c) transporting the aqueous humor by said seton implant to bypass the trabecular meshwork at the level of said trabecular meshwork from the interior side to the exterior side of the trabecular meshwork.
[0048] FIG. 3 shows an embodiment of the seton implant 31 constructed according to the principles of the invention. The seton implant may comprise a biocompatible material, such as a medical grade silicone, for example, the material sold under the trademark Silastic™, which is available from Dow Corning Corporation of Midland, Mich., or polyurethane, which is sold under the trademark Pellethane™, which is also available from Dow Corning Corporation. In an alternate embodiment, other biocompatible materials (biomaterials) may be used, such as polyvinyl alcohol, polyvinyl pyrolidone, collagen, heparinized collagen, tetrafluoroethylene, fluorinated polymer, fluorinated elastomer, flexible fused silica, polyolefin, polyester, polysilison, mixture of biocompatible materials, and the like. In a further alternate embodiment, a composite biocompatible material by surface coating the above-mentioned biomaterial may be used, wherein the coating material may be selected from the group consisting of polytetrafluoroethlyene (PTFE), polyimide, hydrogel, heparin, therapeutic drugs, and the like.
[0049] The main purpose of the seton implant is to assist in facilitating the outflow of aqueous in an outward direction 40 into the Schlemm's canal and subsequently into the aqueous collectors and the aqueous veins so that the intraocular pressure is balanced. In one embodiment, the seton implant 31 comprises an elongated tubular element having a distal section 32 and an inlet section 44 . A rigid or flexible distal section 32 is positioned inside one of the existing outflow pathways. The distal section may have either a tapered outlet end 33 or have at least one ridge 37 or other retention device protruding radially outwardly for stabilizing the seton implant inside said existing outflow pathways after implantation. For stabilization purposes, the outer surface of the distal section 32 may comprise a stubbed surface, a ribbed surface, a surface with pillars, a textured surface, or the like. The outer surface 36 , including the outer region 35 and inner region 34 at the outlet end 33 , of the seton implant is biocompatible and tissue compatible so that the interaction/irritation between the outer surface and the surrounding tissue is minimized. The seton implant may comprise at least one opening at a location proximal the distal section 32 , away from the outlet end 33 , to allow flow of aqueous in more than one direction. The at least one opening may be located on the distal section 32 at about opposite of the outlet end 33 .
[0050] In another exemplary embodiment, the seton implant 31 may have a one-way flow controlling means 39 for allowing one-way aqueous flow 40 . The one-way flow controlling means 39 may be selected from the group consisting of a check valve, a slit valve, a micropump, a semi-permeable membrane, or the like. To enhance the outflow efficiency, at least one optional opening 41 in the proximal portion of the distal section 32 , at a location away from the outlet end 33 , and in an exemplary embodiment at the opposite end of the outlet end 33 , is provided.
[0051] FIG. 4 shows a top cross-sectional view of FIG. 3 . The shape of the opening of the outlet end 33 and the remaining body of the distal section 32 may be oval, round or some other shape adapted to conform to the shape of the existing outflow pathways. This configuration will match the contour of Schlemm's canal to stabilize the inlet section with respect to the iris and cornea by preventing rotation.
[0052] As shown in FIG. 3 , the seton implant of the present invention may have a length between about 0.5 mm to over a meter, depending on the body cavity the seton implant applies to. The outside diameter of the seton implant may range from about 30 μm to about 500 μm. The lumen diameter is preferably in the range between about 20 μm to about 150 μm. The seton implant may have a plurality of lumens to facilitate multiple flow transportation. The distal section may be curved at an angle between about 30 degrees to about 150 degrees, in an exemplary embodiment at around 70-110 degrees, with reference to the inlet section 44 .
[0053] FIG. 5 shows another embodiment of the seton implant 45 constructed in accordance with the principles of the invention. In an exemplary embodiment, the seton implant 45 may comprise at least two sections: an inlet section 47 and an outlet section 46 . The outlet section has an outlet opening 48 that is at the outlet end of the seton implant 45 . The shape of the outlet opening 48 is preferably an oval shape to conform to the contour of the existing outflow pathways. A portion of the inlet section 47 adjacent the joint region to the outlet section 46 will be positioned essentially through the diseased trabecular meshwork while the remainder of the inlet section 47 and the outlet section 46 are outside the trabecular meshwork. As shown in FIG. 5 , the long axis of the oval shape opening 48 lies in a first plane formed by an X-axis and a Y-axis. To better conform to the anatomical contour of the anterior chamber 20 , the trabecular meshwork 21 and the existing outflow pathways, the inlet section 47 may preferably lie at an elevated second plane, at an angle θ, from the first plane formed by an imaginary inlet section 47 A and the outlet section 46 . The angle θ may be between about 30 degrees and about 150 degrees.
[0054] FIG. 6 shows a perspective view illustrating the seton implant 31 , 45 of the present invention positioned within the tissue of an eye 10 . A hole/opening is created through the diseased trabecular meshwork 21 . The distal section 32 of the seton implant 31 is inserted into the hole, wherein the inlet end 38 is exposed to the anterior chamber 20 while the outlet end 33 is positioned at about an exterior surface 43 of said diseased trabecular meshwork 21 . In a further embodiment, the outlet end 33 may further enter into fluid collection channels of the existing outflow pathways.
[0055] In one embodiment, the means for forming a hole/opening in the trabecular mesh 21 may comprise an incision with a microknife, an incision by a pointed guidewire, a sharpened applicator, a screw shaped applicator, an irrigating applicator, or a barbed applicator. Alternatively, the trabecular meshwork may be dissected off with an instrument similar to a retinal pick or microcurrette. The opening may alternately be created by retrograde fiberoptic laser ablation.
[0056] FIG. 7 shows an illustrative method for placing a seton implant at the implant site. An irrigating knife or applicator 51 comprises a syringe portion 54 and a cannula portion 55 . The distal section of the cannula portion 55 has at least one irrigating hole 53 and a distal space 56 for holding a seton implant 31 . The proximal end 57 of the lumen of the distal space 56 is sealed from the remaining lumen of the cannula portion 55 .
[0057] For positioning the seton 31 in the hole or opening through the trabecular meshwork, the seton may be advanced over the guidewire or a fiberoptic (retrograde). In another embodiment, the seton is directly placed on the delivery applicator and advanced to the implant site, wherein the delivery applicator holds the seton securely during the delivery stage and releases it during the deployment stage.
[0058] In an exemplary embodiment of the trabecular meshwork surgery, the patient is placed in the supine position, prepped, draped and anesthesia obtained. In one embodiment, a small (less than 1 mm) self sealing incision is made. Through the cornea opposite the seton placement site, an incision is made in trabecular meshwork with an irrigating knife. The seton 31 is then advanced through the cornea incision 52 across the anterior chamber 20 held in an irrigating applicator 51 under gonioscopic (lens) or endoscopic guidance. The applicator is withdrawn and the surgery concluded. The irrigating knife may be within a size range of 20 to 40 gauges, preferably about 30 gauge.
[0059] From the foregoing description, it should now be appreciated that a novel approach for the surgical treatment of glaucoma has been disclosed for releasing excessive intraocular pressure. While the invention has been described with reference to a specific embodiment, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the true spirit and scope of the invention, as described by the appended claims. | Implants and methods for treating ocular disorders are disclosed. One implant has an inlet portion configured to extend through a portion of a tissue of an eye and an outlet portion configured to extend into and along a physiologic outflow pathway of the eye. The implant provides a flow path between an anterior chamber of the eye and the physiologic outflow pathway. One implant includes a body having adjacent regions of differing cross-sectional dimensions configured to anchor the implant and/or stabilize at least a portion of the flow path through the implant. One method involves inserting a fiber optic in an eye, locating a distal end of the fiber optic at a physiologic outflow pathway through which aqueous humor drains from an anterior chamber of the eye, and delivering a material comprising a therapeutic agent along the fiber optic and into the physiologic outflow pathway. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to polymorphic forms of Rifaximin and to methods for their preparation.
BACKGROUND
[0002] Rifaximin (1) is a non-aminoglycoside semi-synthetic, nonsystemic antibiotic derived from Rifamycin, useful for the treatment of traveler's diarrhea in adults and in children 12 years of age and older caused by Escherichia coli bacteria. Rifaximin has also been evaluated for the treatment of irritable bowel syndrome, diverticular disease, hepatic encephalopathy, pyogenic skin infections, and as an antibacterial prophylactic prior to colon surgery. Chemically, Rifaximin is (2S, 16Z, 18E, 20S, 21S, 22R, 23R, 24R, 25S, 26S, 27S, 28E)-5,6,21,23,25-pentahydroxy-27-methoxy-2,4,11,16,20,22,24,26-octamethyl-2,7-(epoxypentadeca-[1,11,13]trienimino)-benzofuro[4,5-e]-pyrido[1,2-(alpha)]-benzimidazole-1, 15(2H)dione, 25-acetate.
[0000]
[0003] Rifaximin is currently sold in the US under the brand name Xifaxan™ by Salix Pharmaceuticals. It is also sold in Europe under the names Spiraxin™ Zaxine™, Normix™ and Rifacol™ and in India under the name Rifagut™.
[0004] U.S. Pat. No. 4,557,866 describes a new process for the synthesis of pyrido-imidazo-rifamycins of formula I. The process comprises reacting the rifamycin O with 4-methyl-2-aminopyridine.
[0005] U.S. Pat. No. 7,045,620, U.S. Pat. No. 7,612,199, US 20080262220 and US 20080262232 disclose crystalline polymorphous forms of Rifaximin (INN) antibiotic named Rifaximin alpha and Rifaximin beta, and a poorly crystalline form named Rifaximin gamma. These forms can be obtained by means of a crystallization process carried out by hot-dissolving the raw Rifaximin in ethyl alcohol and by causing the crystallization of the product by the addition of water at a determinate temperature and for a determinate time period. The crystallization is followed by drying carried out under controlled conditions until specific water content is reached in the end product in order to consistently obtain the above mentioned homogeneous polymorphic forms of Rifaximin.
[0006] US20080262024 describes forms of Rifaximin (INN) antibiotic, such as the poorly crystalline form named Rifaximin gamma, along with the production of medicinal preparations containing Rifaximin for oral and topical use.
[0007] US 20050272754 relates to Rifaximin polymorphic forms alpha, beta and gamma, the processes for their preparation and the use thereof in the manufacture of medicinal preparations for the oral or topical route.
[0008] WO 2008155728 describes a process which enables Rifaximin in a completely amorphous form to be obtained. Said process comprises the steps of dissolving crude Rifaximin in absolute ethanol while hot and then collecting after precipitation by cooling the title compound in amorphous form.
[0009] US 20090312357 discloses amorphous Rifaximin, methods of making it, and pharmaceutical compositions containing it. Also described are methods of converting amorphous Rifaximin to crystalline Rifaximin and vice versa.
[0010] WO 2009108730 relates to Rifaximin polymorphic, salt, hydrate, and amorphous forms, to their use in medicinal preparations and to therapeutic methods using them. Form zeta, Form eta, Form alpha-dry, Form i, Form beta-1, Form beta-2, Form epsilon-dry, and amorphous forms of Rifaximin as wells a mesylate salt are described.
[0011] US 20090082558 describes a stable amorphous form of Rifaximin. This form is chemically and polymorphic stable on storage and can be prepared by dissolving Rifaximin in a solvent to form a solution which is precipitated by adding an anti-solvent and isolating of the precipitated amorphous Rifaximin as an end product.
[0012] US 20090130201 describes crystalline polymorphous forms of Rifaximin (INN) antibiotic named Rifaximin delta and Rifaximin epsilon useful in the production of medicinal preparations containing Rifaximin for oral and topical use and obtained by means of a crystallization process carried out by hot-dissolving the raw Rifaximin in ethyl alcohol and by causing the crystallization of the product by addition of water at a determinate temperature and for a determinate time period, followed by drying carried out under controlled conditions until reaching a settled water content in the end product.
[0013] US 20100010028 describes polyols which stabilize polymorphous forms of Rifaximin, in particular the beta form. When polyols having at least two hydroxyl groups are added to Rifaximin powder, polymorph beta is stable and remains stable in time independently from the environment humidity. A method to prepare formulations constituted by pure and stable polymorphous forms able to give a pharmaceutical product is also described.
SUMMARY
[0014] The present invention relates to crystalline forms of Rifaximin, namely polymorphic forms of Rifaximin termed herein as APO-I and APO-II and to processes for preparing APO-I and APO-II in substantially pure form.
[0015] Illustrative embodiments of the present invention provide substantially pure polymorphic form APO-I of Rifaximin.
[0016] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a PXRD diffractogram comprising peaks, in terms of degrees 2-theta, at approximately 6.32, 6.70, 8.36, 9.57, 12.67 and 18.73
[0017] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a PXRD diffractogram comprising peaks, in terms of degrees 2-theta, at approximately 6.32, 6.52, 6.54, 6.70, 8.36, 8.38, 9.57, 12.67, 12.68, 18.73 and 24.94.
[0018] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a PXRD diffractogram substantially similar to the PXRD diffractogram as depicted in FIG. 1 .
[0019] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a PXRD diffractogram as depicted in FIG. 1 .
[0020] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a 1% KBr FTIR spectrum comprising peaks, in terms of cm −1 , at approximately 3427.9, 2968.1, 2934.1, 1714.2 1647.7, 1587.3, 1507.1, 1373.7, 1338.1, 1226.4, 1157.0, and 1124.1.
[0021] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a 1% KBr FTIR spectrum comprising peaks, in terms of cm −1 , at approximately 2968.1, 2934.1, 1714.2, 1507.1, and 1124.1.
[0022] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a FTIR spectrum substantially similar to the FTIR spectrum as depicted in FIG. 2 .
[0023] Illustrative embodiments of the present invention provide the polymorphic form APO-I of Rifaximin described herein having a FTIR spectrum as depicted in FIG. 2 .
[0024] Illustrative embodiments of the present invention provide a pharmaceutical formulation comprising the polymorphic form APO-I of Rifaximin described herein and a pharmaceutically acceptable excipient.
[0025] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin comprising: dissolving Rifaximin in a first organic solvent thereby forming a Rifaximin solution; adding the Rifaximin solution to a second organic solvent thereby forming a mixture; stirring the mixture; heating the mixture to a temperature of about 40° C. to about 50° C.; isolating the polymorphic form APO-I of Rifaximin; and drying the polymorphic form APO-I of Rifaximin in a vacuum oven at a temperature of about 5° C. to about 90° C.
[0026] Illustrative embodiments of the present invention provide a process for preparation of a substantially pure polymorphic form APO-I of Rifaximin described herein wherein the stirring occurs for a time period of from about 8 hours to about 12 hours.
[0027] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin described herein wherein the first organic solvent is a C 3 to C 7 alkyl acetate.
[0028] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin described herein wherein the first organic solvent is ethyl acetate.
[0029] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin described herein wherein the temperature for drying temperature is from about 40° C. to about 60° C.
[0030] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin described herein wherein the second organic solvent is a C 6 to C 9 hydrocarbon.
[0031] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-I of Rifaximin described herein wherein the second organic solvent is heptanes.
[0032] Illustrative embodiments of the present invention provide a substantially pure polymorphic form APO-II of Rifaximin.
[0033] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a PXRD diffractogram comprising peaks, in terms of degrees 2theta, at approximately 6.18, 6.33, 6.93, 8.90, 14.34, 19.42, 20.63, and 26.49.
[0034] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a PXRD diffractogram comprising peaks, in terms of degrees 2theta, at approximately 6.18, 6.19, 6.33, 6.34, 6.93, 6.94, 8.90, 8.92, 14.34, 17.07, 19.42, 19.85, 20.63, 21.33, 26.26, and 26.49.
[0035] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a PXRD diffractogram substantially similar to the PXRD diffractogram as depicted in FIG. 3 .
[0036] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a PXRD diffractogram as depicted in FIG. 3 .
[0037] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a 1% KBr FTIR spectrum comprising peaks, in terms of cm −1 , at approximately 3428.3, 2971.8, 2934.0, 1720.7, 1646.2, 1588.2, 1504.9, 1374.0, 1320.8, 1226.7, and 1120.2.
[0038] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a 1% KBr FTIR spectrum comprising peaks, in terms of cm −1 , at approximately 2971.8, 1720.7, 1504.9, and 1120.2.
[0039] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a FTIR spectrum substantially similar to the FTIR spectrum as depicted in FIG. 4 .
[0040] Illustrative embodiments of the present invention provide the polymorphic form APO-II of Rifaximin described herein having a FTIR spectrum as depicted in FIG. 4 .
[0041] Illustrative embodiments of the present invention provide a pharmaceutical formulation comprising the polymorphic form APO-II of Rifaximin described herein and pharmaceutically acceptable excipients.
[0042] Illustrative embodiments of the present invention provide a process for preparation of a substantially pure polymorphic form APO-II of Rifaximin comprising: dissolving Rifaximin in a third organic solvent thereby forming a Rifaximin solution; adding the Rifaximin solution to a fourth organic solvent thereby forming a mixture; stirring the mixture; heating the mixture to a temperature of from about 40° C. to about 50° C.; isolating the polymorphic form APO-II of Rifaximin; and drying the polymorphic form APO-II of Rifaximin in a vacuum oven at a temperature of about 5° C. to about 90° C.
[0043] Illustrative embodiments of the present invention provide a process for preparation of a polymorphic form APO-II of Rifaximin described herein wherein the third organic solvent is ethyl acetate.
[0044] APO-I and APO-II polymorphic forms may have properties suitable for commercial use. These may include properties such as chemical stability, polymorphic stability, and/or varying solubilities relative to other forms of Rifaximin.
[0045] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Drawings which illustrate embodiments of the invention are:
[0047] FIG. 1 : is a powder X-ray diffraction (PXRD) diffractogram of APO-I
[0048] FIG. 2 : is a Fourier Transform Infrared (FTIR) spectrum of APO-I.
[0049] FIG. 3 : is a powder X-ray diffraction (PXRD) diffractogram of APO-II
[0050] FIG. 4 : is a Fourier Transform Infrared (FTIR) spectrum of APO-II
DETAILED DESCRIPTION
[0051] As used herein, the term “substantially pure”, when used in reference to a polymorphic form, means that the polymorphic form has a polymorphic purity of 90% or more. Often the polymorphic purity will be 95% or more. Often the polymorphic purity will be 99% or more.
[0052] When used in reference to a diffractogram, a spectrum and/or data presented in a graph, the term “substantially similar” means that the subject diffractogram, spectrum and/or data presented in a graph encompasses all diffractograms, spectra and/or data presented in graphs that vary within acceptable boundaries of experimentation that are known to a person of skill in the art. Such boundaries of experimentation will vary depending on the type of the subject diffractogram, spectrum and/or data presented in a graph, but will nevertheless be known to a person of skill in the art.
[0053] When used in reference to a peak in a PXRD diffractogram, the term “approximately” means that the peak may vary by ±0.2 degrees 2-theta of the subject value.
[0054] When used in reference to a peak in a FTIR spectrum, the term “approximately” means that the peak may vary by ±5 cm −1 of the subject value.
[0055] As used herein when referring to a diffractogram, spectrum and/or to data presented in a graph, the term “peak” refers to a feature that one skilled in the art would recognize as not attributing to background noise.
[0056] Depending on the nature of the methodology applied and the scale selected to display results obtained from an X-ray diffraction analysis, an intensity of a peak obtained may vary quite dramatically. For example, it is possible to obtain a relative peak intensity of 0.001% when analyzing one sample of a substance, but another sample of the same substance may show a much different relative intensity for a peak at the same position. This may be due, in part, to the preferred orientation of the sample and its deviation from the ideal random sample orientation, sample preparation and the methodology applied. Such variations are known and understood by a person of skill in the art.
[0057] Processes for the preparation of Rifaximin often provide a polymorphic form that has unsuitable bioavailability and/or a mixture of polymorphic forms.
[0058] The transformation of particular polymorphic forms of Rifaximin to other polymorphic forms is known (for instance, G. C. Viscomi et al., CrystEngComm, 2008, 10, 1074-1081). The present invention provides stable polymorphic forms and methods that may be used to consistently prepare these polymorphic forms in a pure form.
[0059] In an illustrative embodiment, the present invention comprises a crystalline form of Rifaximin which is referred to herein as APO-I. APO-I may be characterized by an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at approximately 6.32±0.2, 6.52±0.2, 6.54±0.2, 6.70±0.2, 8.36±0.2, 8.38±0.2, 9.57±0.2, 12.67±0.2, 12.68±0.2, 18.73±0.2 and 24.94±0.2. An illustrative PXRD diffractogram of APO-I is given in FIG. 1 .
[0060] Illustrative relative peak intensities of the aforementioned peaks appearing in a typical PXRD for APO-I, expressed in terms of percent, are illustrated below in Table 1.
[0000]
TABLE 1
Relative peak intensities for APO-I
Angle 2-
theta
Relative intensity %
6.32
19.41
6.52
44.07
6.54
22.04
6.70
100.00
8.36
59.42
8.38
29.71
9.57
25.22
12.67
26.41
12.68
25.91
18.73
30.48
24.94
21.46
[0061] An illustrative FTIR spectrum of APO-I according to the conditions given Example 1 is shown in FIG. 2 . APO-I Rifaximin may have an absorption band (“peak”) at any one or more of the values expressed in cm −1 given in Table 2. Some illustrative and non limiting possible observations regarding peak intensity (% transmission) of the peaks are also set out in Table 2.
[0000]
TABLE 2
Form APO-I Rifaximin
Peak (cm −1 )
Intensity (% Transmission)
3427.9
18.1
2968.1
21.2
2934.1
23.1
1714.2
24.9
1647.7
4.9
1587.3
3.2
1507.1
6.0
1373.7
15.2
1338.1
18.4
1226.4
3.3
1157.0
18.5
1124.1
36.8
[0062] In another illustrative embodiment, the present invention provides a process of preparing APO-I comprising:
[0063] a. dissolving Rifaximin in a first organic solvent thereby forming a Rifaximin solution;
[0064] b. adding the Rifaximin solution to a second organic solvent thereby forming a mixture;
[0065] c. stirring the mixture;
[0066] d. heating the mixture to a temperature of from about 40° C. to 50° C.;
[0067] e. stirring the mixture for a time period of from about 2 hours to about 6 hours;
[0068] f. isolating the APO-I; and
[0069] g. drying the APO-I in vacuum at a temperature of about 5° C. to about 90° C.
[0070] The first organic solvent may be a C 3 to C 7 alkyl acetate, for example ethyl acetate. The second organic solvent may be a C 6 to C 9 cyclic alkyl hydrocarbon or a C 6 to C g acyclic alkyl hydrocarbon, for example heptanes. The stirring may occur for a time period of from about 8 hours to about 12 hours.
[0071] In an illustrative embodiment, the present invention comprises a form of Rifaximin which is referred to herein as APO-II. APO-II may be characterized by an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at approximately 6.18±0.2, 6.19±0.2, 6.33±0.2, 6.34±0.2, 6.93±0.2, 6.94±0.2, 8.90±0.2, 8.92±0.2, 14.34±0.2, 17.07±0.2, 19.42±0.2, 19.85±0.2, 20.63±0.2, 21.33±0.2, 26.26±0.2, and 26.49±0.2. An illustrative PXRD diffractogram of APO-II is given in FIG. 3 .
[0072] Illustrative relative peak intensities of the aforementioned peaks appearing in a typical PXRD for APO-II, expressed in terms of percent, are illustrated below in Table 3.
[0000]
TABLE 3
Relative peak intensities for APO-II
Angle 2θ
Relative intensity %
6.18
44.91
6.19
22.46
6.33
100.00
6.34
50.00
6.93
54.39
6.94
27.19
8.90
36.16
8.92
18.08
14.34
21.86
17.07
15.77
19.42
20.58
19.85
12.05
20.63
15.77
21.33
12.97
26.26
13.15
26.49
15.35
[0073] An illustrative FTIR spectrum of Form APO-II according to the conditions given Example 2 is shown in FIG. 4 . APO-II Rifaximin may have an absorption band (“peak”) at any one or more of the values expressed in cm −1 given in Table 4. Some illustrative and non limiting possible observations regarding peak intensity (% transmission) of the peaks are also set out in Table 4.
[0000]
TABLE 4
Form APO-II Rifaximin
Peak (cm −1 )
Intensity (% Transmission)
3428.3
9.4
2971.8
13.2
2934.0
15.8
1720.7
16.2
1646.2
3.6
1588.2
3.2
1504.9
4.9
1374.0
10.3
1320.8
11.2
1226.7
3.8
1120.2
27.9
[0074] In another illustrative embodiment, the present invention provides a process of preparing APO-II comprising:
[0075] A. dissolving Rifaximin in a third organic solvent thereby forming a Rifaximin solution;
[0076] B. adding the Rifaximin solution to a fourth organic solvent thereby forming a mixture;
[0077] C. stirring the mixture;
[0078] D. heating the mixture to a temperature of from about 40° C. to about 50° C.;
[0079] E. isolating APO-II by filtration; and
[0080] F. drying the APO-II in vacuum at a temperature of from about 5° C. to about 90° C.
[0081] APO-I and APO-II may be formulated into pharmaceutical formulations, typically by adding at least one pharmaceutically acceptable excipient and by using techniques well understood by a person of skill in the art. Many techniques known to one of skill in the art and many pharmaceutically acceptable excipients known to one of skill in the art are described in Remington: the Science & Practice of Pharmacy by Alfonso Gennaro , 20 th ed., Lippencott Williams & Wilkins, (2000).
[0082] The following examples are illustrative of some of the embodiments of the invention described herein. These examples do not limit the spirit or scope of the invention in any way
EXAMPLES
[0083] Powder X-Ray Diffraction Analysis: The data were acquired on a PANanalytical X-Pert Pro MPD diffractometer with fixed divergence slits and an X-Celerator RTMS detector. The diffractometer was configured in Bragg-Brentano geometry; data was collected over a 2-theta range of 3 to 40 using CuKα radiation at a power of 40 mA and 45 kV. CuKβ radiation was removed using a divergent beam nickel filter. A step size of 0.017 degrees was used. A step time of 50 seconds was used. Samples were rotated at 1 Hz to reduce preferred orientation effects. The samples were prepared by the back-loading technique.
[0084] Fourier Transform Infrared (FTIR) Analysis: The FTIR spectrum was collected at 4 cm −1 resolution using a Perkin Elmer Paragon 1100 single beam FTIR instrument. The samples were intimately mixed in an approximately 1:100 ratio (w/w) with potassium bromide using an agate mortar and pestle to a fine consistency; the mixture was compressed in a pellet die at a pressure of 4 to 6 tonnes for a time period between 2 and 5 minutes. The resulting disk was scanned 4 times versus a collected background. Data was baseline corrected and normalized
Example 1
Preparation of Form APO-I Rifaximin
[0085] Rifaximin (130 g) was dissolved in ethyl acetate (390 mL) followed by adding this solution to heptanes (650 mL). After stirring at room temperature for 12 hrs, the resulting suspension was heated to 45° C. and stirred for 4 hrs to obtain a uniform mixture. The suspension was filtered, washed with water (260 mL) and dried in a vacuum oven at 50° C. to provide Form APO-I Rifaximin (127 g).
Example 2
Preparation of Form APO-II Rifaximin
[0086] Rifaximin (50 g) was dissolved in ethyl acetate (150 mL) followed by adding this solution to heptanes (250 mL) at room temperature. After stirring at room temperature for 21 hrs, the resulting suspension was heated to 45° C. and stirred for 6 hrs to obtain a uniform mixture. The suspension was filtered, and dried in a vacuum oven at 60° C. to provide Form APO-II Rifaximin (44 g). | Provided for in the instant application are two additional polymorphic forms of rifaximin; namely substantially pure APO-I and APO-II. Also provided are processes for preparing substantially pure APO-I and APO-II. Rifaximin is a non-aminoglycoside antibiotic that has previously been found to be useful for the treatment of traveller's diarrhea caused by Escherichia coli bacteria, as well as in the treatment of irritable bowel syndrome, diverticular disease, hepatic encephalopathy, pyogenic skin infections and as an antibacterial prophylactic prior to colon surgery. | 2 |
BACKGROUND OF THE DISCLOSURE
The present disclosure is directed to a process for treating a producing well and particularly one for treating a well where production has fallen over a period of time. The normal completion process involved in producing a well after drilling includes cementing casing in the well and then making perforations by means of shaped charges which perforate through the casing and any surrounding cement which holds the casing in place. The perforations penetrate into producing formations. Assuming that fluid production is obtained, the production fluids flow from the formation into the cased well. The production fluids are removed to the surface normally by installing a production tubing string in the cased well. For instance, the production tubing string typically measures 23/8 inches, or perhaps 27/8 inches. This defines an annular spaced around the production tubing string within the cased well borehole. The zone of fluid production is normally isolated with packers or plugs. A plug is normally placed in the casing just below the perforations. This enables a column of production fluid to accumulate above the plug. For production, there is also a plug or packer positioned above the perforations, and the production tubing string extends through this packer. Thus, the produced fluids from the formations are removed upwardly through the production tubing string usually by pumping or by gas lift apparatus.
Normally, after the passage of time, there is some loss of formation pressure in the localized formation region immediately adjacent to the well borehole near the perforations into the formation. This loss of production is occasioned also by a loss of fluid flow velocity. As the velocity decreases, the small cracks and fissures in the vicinity of the perforations may become clogged or plugged with silt, clay or other formation debris which is generally referred to as "fines". As well be understood, a higher pressure drive will tend to move the production fluids more rapidly through the perforations and into the cased well borehole. That however declines as sediment or fines in the produced fluid collects in the cracks and fissures connecting with the perforations. In other words, as the pressure drive decreases, it is decreased even further by sediment or fines in the flowing production fluids which falls out in the immediate region of the perforations. While this is a localized effect, it is nevertheless detrimental to production of fluids even where the formation or reservoir has ample fluids for production. The decline in production requires remedial treatment. There are multiple ways to treat such a well including further stimulation of the well by means of high pressure fracture, an injection of acid, etc. The present disclosure is directed to a particular well stimulation process which can materially ehance the production. Thus, it is a wireline conveyed tool which can be lowered on a wireline through the production tubing. It can be lowered to a location adjacent to the perforations without shutting in the well. Acoustic or sonic energy is generated by the tool and the acoustic vibrations are coupled from the tool through the incompressible liquids which make up the formation fluids to impinge on the formation to change the nature of the formation and to interact on both the formation materials including any fines or sediments which may settle in the perforations, in addition, the acoustic energy interacts with the formation fluids. This interaction serves to reduce formation fluid viscosity thereby enhancing volume fluid flow at a given pressure.
The materials which are found immediately outside the perforations are often multi-phase materials involving some, perhaps much water, and different weights of petroleum fluids, some of which might be natural gas and some which might be so heavy as to be tar like in nature. All of this material can be found in a producing sand formation which may be described generally as a supportive matrix with some given range of permeability to permit fluid flow from the formation into the well. The intersticial spaces in the formation normally provide sufficient connected pore space to enable fluid flow. The well fluid can carry fines which are sufficiently small that they can lodge or settle in the interstices of the formation and thereby tend to clog or plug the small connected pores of the formation. While there is no simple model to describe this, it is sufficient to note that there is a relatively complex interplay between the various solid, liquid and gas phase components as described above which can plug or impede flow in this region.
The present procedure contemplates the irradiation of the formation with acoustic energy at a selected power distribution and frequency. This irradiation agitates the fines so that they go back into fluidic suspension and can be removed with formation fluid flow. In addition, the irradiation appears to reduce the viscosity of the well fluids, thereby enabling enhanced fluid flow. Repetitive irradiation appears to clear or clean the pores or passage ways at and surrounding the perforations into the formations, thereby enhancing well fluid production.
The present apparatus is described very generally as a sonde which is adapted to be lowered in a well borehole on a wireline which supports the device at specified depths for remedial treatment of perforations and the immediate regions just beyond the perforations. The sonde houses one or more acoustic transducers which are operated at selected frequencies. Frequencies up to perhaps 20 or 30 kilohertz are generated to provide the appropriate irradiation. Acoustic power of a few hundred to a few thousand watts is delivered to the formation. The power density ranges anywhere from about 1 watt/cm 2 to values less than this. This power level is sufficient to break free coagulated fines, and to also reduce the viscosity of the well fluid so that the fluid may flow more readily. In summary, well stimulation can be accomplished by selectively and repetitively irradiating the region of the perforations to obtain this improved production flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
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.
FIG. 1 shows an irradiation tool in accordance with the present invention lowered on a wireline in a production casing string and positioned opposite perforations through the cased well into the adjacent producing formations;
FIG. 2 is a sectional view through an acoustic pulse generating device;
FIG. 3 shows a schematic of a second embodiment of an acoustic irradiation tool according to the concepts of the present invention;
FIG. 3A in a cross section of the tool of FIG. 3 along the line A--A Of FIG. 3;
FIG. 4 is a schematic illustration of the connection of seven conductor cable connectors to an acoustic transducer; and
FIG. 5, 6, and 7 are diagrams illustrating the power distribution from an acoustic irradiation tool like that of FIG. 3 for different spacings of the acoustic transducer elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Attention is now directed of FIG. 1 of the drawings which schematically shows a cased well having perforations 14 extending into a producing formation 12. In FIG. 1, the casing is identified by the numeral 10, and is normally cemented to the formations which are penetrated by the well borehole. The cement layer has been omitted for sake of clarity. The cased well supports a string of production tubing 11 which is coaxially positioned within te cased well. The production tubing string provides a flow path for the production fluid from the formation 12. The formation 12 is a producing formation having appropriate permeability so that production fluids from the formation flow through perforations 14 into the cased well. The production is accomplished through a set of perforations at 14. The perforations form aproximately circular holes 13 in the casing and form a puncture pathway 14 into the formation 12. Typically, there are several perforations and they extend radially outwardly from the cased well. They are spaced at even locations along the length of the casing where it passes through the formation 12. Ideally, the perforations are located only in the producing formation 12, and hence the number of formation perforations varies dependent on the thickness of the formation 12. It is not uncommon to have as many as 9 to 12 perforations per meter of formation thickness. Moreover, perforations extend in all longitudinal directions, thus, there are perforations which might extend radially at 0° azimuth, and additional perforations arranged every 90° to thereby define four sets of perforations around the azimuth.
Formation fluid flows through the perforations 14 to enter the cased well. Preferably, the well is plugged with some type of plugging mechanism such as a packer or bridge plug below the perforations. In addition to that, a packer 15 is positioned above the formation 12. The packer 15 connects with the production tubing 11 to define a chamber 16 where production fluid flows from the formation 12 into the chamber and tends to fill the chamber. The chamber can have a height which is determined by the spacing between the plug below and the packer 15 above the formation 12. The fluid capacity of the chambers varies depending upon the height of the chamber. The production fluid flows out of the formation and into the chamber 16 and accumulates in the chamber to some height, perhaps even filling the chamber. Production fluid is shown accumulated to the fluid level 17 in the chamber 16. The accumulated fluid flow from the formation may also be accompanied by the production of variable quantities of natural gas. In summary, the casing chamber 16 will accumulate some water, perhaps oil, perhaps natural gas and also sand or solid debris. The sand will normally settle to the bottom of the chamber 16. The fluid produced from the formation may change phase in the event of pressure reduction from formation pressure which permits some of the lighter molecules to vaporize. On the other hand, the well may also produce very heavy tar molecules. This variety of fluid weights is readily accommodated by the apparatus of the present invention.
Over a period of time, the perforation pathways 14 extending into the formation 12 can clog with fines or debris. As will be understood, these pathways 14 are represented in the drawings as neatly defined conics but this is not always the case. In fact, passageways 14 are typically defined around the edges by numerous cracks, fissures, and surface irregularities which extend into the formation 12. This defines a fluid connected pore space within the formation to enable fluids to flow from the formation through cracks or fissures or connected pores and flowing through the interstical spaces into the chamber 16 for collection. During this flow, very small solid particles of the formation known as fines can flow, but they tend to settle. While the fines might be held in a dispersed state for a while, they may drop out and thereby plug or clog the pore spaces and reduce the fluid production flow rate. When this occurs, the well will slowly lose production. This may become a problem which feeds on itself, namely as the production flow rate drops, more and more fines can settle in the perforations and block these perforations, tending to prevent even a minimal rate of flow.
Apparatus according to concepts of the present invention is identified by the numeral 20 and comprises an elongate housing 21 known as a sonde which is lowered into the well on an armored cable or wireline 22. One or more electrical conductors are provided in the cable 22. These provide power and communications to the equipment as will be described in more detail.
Attention is now directed to FIG. 2 of the drawings where a downhole well tool according to the present invention is identified in greater detail. The tool 20 is shown in schematic sectional view through the apparatus. More specifically, it includes a closed cylindrical housing 23 which is formed of a material which will transmit acoustic vibrations. Moreover, it is connected to a cylindrical extension 24 of equal diameter having an internal cavity 25. The cavity 25 is connected with the exterior by means of small holes 26. Fluid may flow through the small holes 26 into the cavity 25. This delivers borehole fluid at ambient well bore pressure into the equipment. The fluid acts on an expandable set of bellows 27. The bellows 27 permit some expansion of the fluid in the housing 23. That housing is filled with a fluid 28 which completely fills the chamber 19. In the chamber, a magnetostrictive acoustic transducer 30 is centrally supported. It is wrapped with a coil of wire 31. The coil 31 connects with suitable electrical conductors extending to a transformer 32 in a separate chamber within the tool. The transformer 32 provides coupling between the magnetostrictive coil 31 and the driving source connected with the equipment. The transformer 32 provides an impedance match for operation. In turn, a pulsed oscillator 33 drives the transformer 32. That is provided with power for operation from a power supply 34 which is provided with power from the surface by conductors in the logging cable connected to the acoustic signal transducer equipment 20.
The power supply 34 is provided with power to form an output power pulse. The output power pulse is delivered to the oscillator 33. The oscillator is operated at a selected frequency. The oscillator's frequency output is a continuous wave (CW) output signal which is pulsed on and off. As an example, the operating frequency is typically in the area of about 20 kilohertz (khz), but operation in the range of about 2 to30 khz is permissible. The oscillator 33 is pulsed on and off at a rate where pulses are formed every few milliseconds, for instances with pulses formed every 10 to 100 milliseconds. The power output is transmitted in pulse form in an omnidirectional propagation mode. Ideally, 1000 to perhaps 2000 watts of power is delivered by the magnetostrictive transducers 30. The acoustic radiation is transmitted radially outwardly to pass through the wall of the housing 23. It is coupled through the liquid 28 in the chamber which is at borehole pressure, through the wall, through the well fluid that surrounds the tool and into the casing 10 and perforations 14 to impinge on the formation 12. The transmission of the acoustic pulses provides mechanical vibratory coupling into the formation 12. Assume for purposes of illustration that the transducer 30 has a height of 25 cm. At a radial distance of 25 cm, the acoustic energy transmitted into the formation impinges on an equivalent surface area of about 4000 cm 2 at a radial spacing of 25 cm from the axis of the equipment. If the equipment is operated with a power of about 2000 watts, this energy distribution on such a surface is approximately 0.5 watts per cm 2 . This power level has been found to be sufficient to agitate sedimentary fines in the pore spaces of the formation 12. The device can be pulsed at a pulse repetition rate ranging from perhaps 10 pulses per second to about 1000 pulses per second. The duty cycle can range anywhere from 30% to 70%. When the transducers 30 are on, it generates this second CW acoustic pulse which impinges on the formation, routinely passing through the perforations 14 and into the formation at the interface beyond the perforations so that fluid flow is enhanced. The treatment of a particular set of perforations can be repeated in this manner for several hours. The sonde apparatus may be moved to different depth levesl in the borehole, and thus the treatment is applied to several locations or sets of perforations as desired. All of this, of course, may be done while the well is under production conditions.
It has been discovered that the present apparatus enhances production by changing the viscosity of the fluid. To be sure, fluid flow is also changed by altering the sedimentation rate of the small fines. That is, prior accumulations of sediment in the pores of the formation are broken up. When this occurs, there is a tendency to flush out the pores so that the sedimentary fines are carried by fluid flow away from that region. That enhances the production of the well. This particularly provides a long term effect in that the fine agitation which occurs during irradiation tends to clear the perforations and thereby remove the clogging sediment which otherwise impedes fluid production. As a consequence, production is improved long after the acoustic irradiation tool 20 has been removed.
A typical procedure is to provide acoustic irradiation to a specific depth region of the well for a selected interval such as 5 to 50 minutes. After irradiation, the tool is lowered or moved to another horizon in the well for irradiation at that level. The magnetostrictive transducer has a specified length along the well so that it can irradiate a specified length of the well such as 25 cm, or perhaps one meter in a longer embodiment. Each separate irradiation operation is achieved by raising or lowering the tool as needed to the necessary depth in the well whereby the entire formation 12 is successfully irradiated. As a generalization, it is desirable to irradiate the entire set of perforations in the formation 12, thereafter removing the tool 20, and returning several months later to repeat the process. When the sedimentary fines are dislodged and carried by fluid flow out of the perforations into the cased chamber within the well, they collect either at the bottom of the chamber 16 or they are produced by the upwardly production flow through the production tubing string. This helps remove them from the immediate region of the perforation so that the agitated fines are removed and those fines need not pose any further problem.
The agitation achieved by the present apparatus is curative in that it does not have any detrimental impact on the well whatsoever. Further, repeated treatment of the well is permitted. It is particularly noteworthy that during the actual process of irradiation that the viscosity of the flowing fluids is reduced while the sedimentary fines are carried with the fluid flow. An example of the reduction of fluid viscosity by the acoustic treatment process of the present invention is shown by the Table I below.
TABLE I______________________________________ Oil viscosity, relative units Before 15 min 30 min 15 min 30 minOil Samples AT AT AT after AT after AT______________________________________Oil I 10.65 9.71 9.13 9.94 10.64II, Sample 1 40.6 35.8 28.1 30.9 34.0II, Sample 2 40.2 33.7 27.9 29.9 31.8II, Sample 3 39.8 33.9 28.8 29.9 32.7II, Sample 4 43.1 33.1 29.0 31.4 33.6II, Sample 5 39.5 34.1 28.9 31.6 33.8II, Sample 6 40.0 33.6 28.7 31.1 33.0III, Sample 1 2490 1685 1268 1500 2177______________________________________ (AT = acoustic treatment)
From the data shown in Table I, it can be seen that, with an acoustic treatment apparatus, such as shown in FIG. 2, suspended in a tank of oil (which is typical crude oil as produced from candidate wells for this treatment) that, in all cases while the acoustic treatment device is run, the oil viscosity (measured at different times) decreases. When the acoustic treatment device is turne off, the fluid viscosity increases somewhat, but only in the case of Oil I, Sample 1, does it return nearly to the original value. In the other cases, viscosity remains less than its initial value even after the acoustic treatment is stopped. This clearly indicates the lasting benefits of this treatment in producing wells.
A second embodiment of an acoustic radiation tool according to concepts of the present invention is illustrated schematically. In the tool of FIG. 3, an embodiment is shown having two spaced acoustic transducers elements 52 which are spaced apart a specified distance by using magnetostrictve transformers in the shape of rods 52, a range of frequencies from 5-30 kilohertz can be achieved by the transducer which still has a diameter small enough to pass through production tubing in the well.
The magnetostrictive rod transducers also have higher reliability than toroidial shaped transducers since they are less susceptible to mechanical stress during the manufacturing process. By the proper choice of an operating frequency and spacing distance between the two acoustic transducers 52, the energy of the acoustic waves may be concentrated in a plane passing through the longitudinal axis of the two acoustic transducers. The angular distribution in this plane of the acoustic energy s influenced by the selection of the distance spacing, the distance apart of the two acoustic transducers. It has been found that when the distance Δ is between 0.2 and 0.5 times Λ (where Λ is the wavelength of the frequency of the acoustic radiator) that optimal angles of radiation occur having maximum side lobes from the tool longitudinal axis. FIGS. 5, 6, and 7 respectively illustrate the acoustic radiation lobes for spacings of 0.05 times Λ, 0.3 times Λ, and 0.7 times Λ. It will be noted that, for example in FIG. 6, other lobes than the main energy lobes are nearly absent when Δ spacings is appropriately chosen.
In view of the range of densities of well fluids normally encountered and for pressures and temperatures normally encountered in wells in which this instrument can be successfully utilized, the Δ spacing of approximately 0.2 to 0.5Λ has been shown as optimum for operating the device somewhere between about 5 and 30 kilohertz.
Returning now to FIG. 3, a well logging cable is shown schematically entering a cable head 54 to connect to a power supply to provide acoustic power to the spaced acoustic transducers 52 which comprise the magnetostrictive rods as previously discussed. The interior of the entire instrument is filled with a dielectric fluid 60, such as oil or the like. An expansion bellows 66 is located at the lower end of the tool in order to compensate for fluid expansion variations. A cross section along the line A--A through one of the acoustic transducers is shown in FIG. 3A. The two acoustic rods 52 are held in place in the interior of the sonde by two brackets 51 illustraed more particularly in FIG. 3A showing how the brackets on the two rod transducer elements to form a transducer assembly. Appropriate magnetic fields, of course, are introduced into the magnetostrictive rods by the windings 55 about each of the elements. Power from the cable is supplied via a power supply 53 therein. The outer tool housing 56 maybe constructed of an acoustically transparent material of sufficient thickness to with stand expected pressure differentials between the interior and the exterior of the tool. However, due to the pressure compensating bellows 66 and the dielectric oil 60 on the interior, the tool interior pressure remains near prevailing pressure in the well borehold at all times during its operation.
FIG. 4 shows schematically a wiring diagram which illustrates electrical conductors from a typical armored logging cable 72 employed in transferring power from the logging cable to the spaced acoustic transducers 52 spaced at a distance Δ in the downhole tool. A seven conductor cable having an outer armor 83 and having a center conductor 82 is illustrated. Balanced conductor pairs of cable conductors may be connected in parallel to conduct larger currents from the cable to the directly to the transducers 52 in the manner illustrated in FIG. 4. Of course, it will be realized by those skilled in the art that the illustration of FIG. 4 merely shows one possible alternative for connecting logging cable conductors as three parallel pairs to the acoustic transducers assuming that a remote acoustic power oscillator were used to form the high power 5-30 khz electrical signal along the cable directly to the transducers 52 as illustrated in the device of FIG. 4. An equally attractive alternative might be to employ the cable conductors in a more conventional manner to deliver power to a downhole power supply located in the upper portion of the instrument (see FIG. 2) in order to drive a sonde supported oscillator in the manner previously described with respect to the instrument shown in FIG. 2.
In operation, the device of FIG. 3 is utilized in a manner similar to that previously discussed with respect to the device of FIG. 2. The instrument having the spaced acoustic transducers is lowered through the well head lubricator into the production tubing and through the top packer of the producing zone down into the producing zone. During this process, the pressure is equalized inside the tool by the operation of the expansion bellows 66. The instrument is lowered to a position where the two acoustic transducers are located to bracket the depth at which treatment is desired. The acoustic transducers are then activated producing the pattern in the normal plane between the two transducers similar to that shown in FIG. 6. This concentrates the acoustic energy generated by the transducer devices optimally to produce maximum agitation in that plane of activity. This process is continued for several minutes, between 5 and 30 minutes typically, and then the device moved vertically to a different location to treated the formation at different perforations in the producing zone. The process is then repeated at each desired depth in the producing zone until the all the perforations of the well are treated in this manner. Treatment of wells in the manner described in the present invention has been observed to increase the production of fluids from the well and to dislodge and clean fines from the perforations and the formation structure surrounding perforations. This is evidenced by the presence of fines in the produced fluids.
The foregoing descriptions may make other alternative embodiment according to the concepts of the present invention apparent to those of skill in the art. It is the aim of the impended claim to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A method and apparatus for stimulating fluid production in a producing well wherein a well stimulating tool comprising a sealed tool housing with an acoustic transducer in the housing. The tool is run into a producing well on an electric wireline and placed at a depth opposite perforations in a producing zone. The sealed housing of the tool contains a liquid to couple and enable pulses of acoustic energy from the acoustic transducer to be transmitted through the housing into well formation fluids surrounding the housing to reduce the viscosity of the formation fluids by agitation and thereby enhance fluid flow from the formation into the producing well. | 4 |
FIELD OF THE INVENTION
The present invention relates to a flexible fluid containment vessel (sometimes hereinafter referred to as “FFCV”) for transporting and containing a large volume of fluid, particularly fluid having a density less than that of salt water, more particularly, fresh water, and the method of making the same.
BACKGROUND OF THE INVENTION
The use of flexible containers for the containment and transportation of cargo, particularly fluid or liquid cargo, is well known. It is well known to use containers to transport fluids in water, particularly, salt water.
If the cargo is fluid or a fluidized solid that has a density less than salt water, there is no need to use rigid bulk barges, tankers or containment vessels. Rather, flexible containment vessels may be used and towed or pushed from one location to another. Such flexible vessels have obvious advantages over rigid vessels. Moreover, flexible vessels, if constructed appropriately, allow themselves to be rolled up or folded after the cargo has been removed and stored for a return trip.
Throughout the world there are many areas which are in critical need of fresh water. Fresh water is such a commodity that harvesting of the ice cap and icebergs is rapidly emerging as a large business. However, wherever the fresh water is obtained, economical transportation thereof to the intended destination is a concern.
For example, currently an icecap harvester intends to use tankers having 150,000 ton capacity to transport fresh water. Obviously, this involves, not only the cost in using such a transport vehicle, but the added expense of its return trip, unloaded, to pick up fresh cargo. Flexible container vessels, when emptied can be collapsed and stored on, for example, the tugboat that pulled it to the unloading point, reducing the expense in this regard.
Even with such an advantage, economy dictates that the volume being transported in the flexible container vessel be sufficient to overcome the expense of transportation. Accordingly, larger and larger flexible containers are being developed. However, technical problems with regard to such containers persist even though developments over the years have occurred. In this regard, improvements in flexible containment vessels or barges have been taught in U.S. Pat. Nos. 2,997,973; 2,998,973; 3,001,501; 3,056,373; and 3,167,103. The intended uses for flexible containment vessels is usually for transporting or storing liquids or fluidisable solids which have a specific gravity less than that of salt water.
The density of salt water as compared to the density of the liquid or fluidisable solids reflects the fact that the cargo provides buoyancy for the flexible transport bag when a partially or completely filled bag is placed and towed in salt water. This buoyancy of the cargo provides flotation for the container and facilitates the shipment of the cargo from one seaport to another.
In U.S. Pat. No. 2,997,973, there is disclosed a vessel comprising a closed tube of flexible material, such as a natural or synthetic rubber impregnated fabric, which has a streamlined nose adapted to be connected to towing means, and one or more pipes communicating with the interior of the vessel such as to permit filling and emptying of the vessel. The buoyancy is supplied by the liquid contents of the vessel and its shape depends on the degree to which it is filled. This patent goes on to suggest that the flexible transport bag can be made from a single fabric woven as a tube. It does not teach, however, how this would be accomplished with a tube of such magnitude. Apparently, such a structure would deal with the problem of seams. Seams are commonly found in commercial flexible transport bags, since the bags are typically made in a patch work manner with stitching or other means of connecting the patches of water proof material together. See e.g. U.S. Pat. No. 3,779,196. Seams are, however, known to be a source of bag failure when the bag is repeatedly subjected to high loads. Seam failure can obviously be avoided in a seamless structure. However, since a seamed structure is an alternative to a simple woven fabric and would have different advantages thereto, particularly in the fabrication thereof, it would be desirable if one could create a seamed tube that was not prone to failure at the seams.
In this regard, U.S. Pat. No. 5,360,656 entitled “Press Felt and Method of Manufacture”, which issued Nov. 1, 1994 and is commonly assigned, the disclosure of which is incorporated by reference herein, discloses a base fabric of a press felt that is fabricated from spirally wound fabric strips. The fabric strip of yarn material, preferably being a flat-woven fabric strip, has longitudinal threads which in the final base fabric make an angle in what would be the machine direction of the press felt.
During the manufacture of the base fabric, the fabric strip of yarn material is wound or placed spirally, preferably over at least two rolls having parallel axes. Thus, the length of fabric will be determined by the length of each spiral turn of the fabric strip of yarn material and its width determined by the number of spiral turns.
The number of spiral turns over the total width of the base fabric may vary. The adjoining portions of the longitudinal edges of the spirally-wound fabric strip are so arranged that the joints or transitions between the spiral turns can be joined in a number of ways.
An edge joint can be achieved, e.g. by sewing, melting, and welding (for instance, ultrasonic welding as set forth in U.S. Pat. No. 5,713,399 entitled “Ultrasonic Seaming of Abutting Strips for Paper Machine Clothing” which issued Feb. 3, 1998 and is commonly assigned, the disclosure of which is incorporated herein by reference) of material or of non-woven material with melting fibers. The edge joint can also be obtained by providing the fabric strip of yarn material along its two longitudinal edges with seam loops of a known type, which can be joined by means of one or more seam threads. Such seam loops may for instance be formed directly of the weft threads, if the fabric strip is flat-woven.
While that patent relates to creating a base fabric for a press felt such technology may have application in creating a sufficiently strong tubular structure for a transport container. Moreover, with the intended use being a transport container, rather than a press fabric where a smooth transition between fabric strips is desired, this is not a particular concern and different joining methods (overlapping and sewing, bonding, stapling, etc.) are possible. Other types of joining may be apparent to one skilled in the art.
It should be noted that U.S. Pat. No. 5,902,070 entitled “Geotextile Container and Method of Producing Same” issued My 11, 1999 and assigned to Bradley Industrial Textiles, Inc. does disclose a helically formed container. Such a container is, however, intended to contain fill and to be stationary rather than a transport container.
It should also be noted that in the papermaking art it is known to create a fabric for use in the papermaking industry having a knitted substrate. In this regard, U.S. Pat. No. 4,948,658 issued Aug. 14, 1990 discloses a fabric which is made from a core filament comprised of a bundle of threads, whose composition may vary, enclosed by a loop thread on a knitting machine. Machine filling threads or yarns transverse the core filament and the loops of the loop threads to create the base fabric. Such a fabric may then be subject to further processing.
Also, it is well known in the papermaking art to create fabric which is impermeable to fluids, a characteristic required for an FFCV. Such fabrics involve a base substrate which may be woven of reinforcing yarns and then impregnated with a suitable resin. Examples of such structures are U.S. Pat. Nos. 6,290,818 B1 and 5,238,537.
With this in mind, the construction or make up of the fabric or tube of the FFCV, whether formed as a single piece or in segments, has to take into account various factors including flexibility, durability, tear and puncture resistance, whilst of course, as aforesaid, being impermeable to sea water. Also, in the absence of flotation devices, the buoyancy of the FFCV, particularly when being emptied and empty is also a consideration. Moreover, the construction or make up of the fabric used should be cost effective. Accordingly, depending upon the application, alternative forms of fabric construction is desirable.
SUMMARY OF THE INVENTION
It is therefore a principal object of the invention to provide for a fabric construction for an FFCV which provides for the various characteristics required.
It is a further object of the invention to provide for a fabric construction for an FFCV which may be readily varied to meet possible changing requirements for the FFCV.
A yet further object of the invention is to provide for a fabric construction which facilitates the coating thereof, or avoids or minimizes the need for the separate coating altogether.
A still further object of the invention is to provide for a fabric construction which is an alternative to a woven fabric.
Accordingly, the present invention is directed towards providing a construction of the fabric used for the tube of an FFCV. In this regard, the fabric is constructed of a number of layers of components, like that of a laminate. The layers may comprise reinforcing components, buoyancy layer or layers, layers that are impermeable or that facilitate later coating, all of which may be bound together by warp knit or stitch bonded binder yarns. The fabric may be made in strips and then assembled into a tube as set forth in U.S. Pat. No. 5,713,399 or in segments and joined together in any number of ways, including that set forth in co-pending U.S. patent application Ser. No. 10/016,640 entitled “Segment Formed Flexible Fluid Containment Vessel” filed contemporaneously herewith which is commonly assigned. In addition, the fabric may be manufactured as a flat roll of cloth and joined endless using either a spiral winding technique, splice or other means suitable for the purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
Thus by the present invention, its objects and advantages will be realized the description of which should be taken in conjunction with the drawings wherein:
FIG. 1 is a somewhat general perspective view of a prior art FFCV which is cylindrical having a pointed bow or nose;
FIG. 2 is a somewhat general perspective view of an FFCV which is formed in segments, incorporating the teachings of the present invention;
FIG. 3 is a side sectional view of the fabric structure incorporating the teachings of the present invention; and
FIG. 4 is a perspective view of the fabric structure incorporating the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The proposed FFCV 10 is intended to be constructed of an impermeable textile tube. The tube's configuration may vary. For example, as shown in FIG. 2, it would comprise a tube 12 having a substantially uniform diameter (perimeter) and sealed on each end 14 and 16 . The respective ends 14 and 16 may be closed, pinched, and sealed in any number of ways. A means for loading and unloading cargo (e.g. fresh water) would be provided. The resulting impermeable structure which is fabricated out of segments or strips of material 18 will be flexible enough to be folded or wound up for transportation and storage.
In designing the FFCV to withstand the loads placed thereon, certain factors should be considered. In this regard, in co-pending U.S. patent application Ser. No. 09/832,739 filed Apr. 11, 2001 entitled “Flexible Fluid Containment Vessel” such factors are set forth in detail, along with possible materials for the fabric, their construction and possible coatings and methodology to apply to it to render the fabric impermeable, in addition to other features which may be desirable with regard to the FFCV. Accordingly, further discussion thereof will not be repeated herein rather reference is made to said application.
Also, the present device may have application with regard to the spiral formed FFCV as disclosed in co-pending U.S. patent application Ser. No. 09/908,877 filed Jul. 18, 2001 entitled “Spiral Formed Flexible Fluid Containment Vessel”. While there is discussed therein means and methods for joining the wound strips together to form an FFCV, an alternative thereto is disclosed in the aforesaid first mentioned patent application for all or part of the joining process. For example, in high load portions of the FFCV, typically the front and rear, one methodology may be used. For less stressful locations another methodology may be used.
In addition, reference is made to U.S. patent application Ser. No. 09/921,617 filed Aug. 3, 2001 entitled “End Portions for a Flexible Fluid Containment Vessel and a Method of Making the Same” which relates to possible construction of the end portions of the FFCV and U.S. patent application Ser. No. 09/923,936 filed Aug. 7, 2001 entitled “Coating for a Flexible Fluid Containment Vessel and a Method of Making the Same” which discloses additional construction for the fabric, in addition to possible coatings therefor.
The fabric 18 can be that of a patchwork to create the FFCV, wound strip or of other configuration suitable for the purpose. For example, it may be made in segments of flat fabric that has one of its dimensions equal to that of the circumference of the FFCV which is formed into a tube and joined with other so formed segments. The variations are endless.
Turning now more particularly to FIG. 3, there is shown the side view of one embodiment of fabric 18 . The fabric 18 includes layers 20 , 22 , 24 and 26 of reinforcing components. These components are typically multifilament or monfilament yarns which may be of the type set forth in the aforesaid applications. Positioned between the reinforcement layers 22 - 26 is a scrim layer 28 . This layer can be woven or non-woven, spun bonded, wet laid or air laid non-woven web, impermeable, semi-impermeable or permeable depending upon how the fabric 18 is to be processed further. For example, as noted in the aforesaid applications, the fabric making up the FFCV must be impermeable to salt water and salt water ions. One of the ways to render the fabric impermeable is to coat it. Suggested coatings and methods of doing it are set forth in certain of the aforesaid application. One of the problems envisioned in coating the fabric is bleed through. In other words, if an endless fabric is coated while laid flat, the coating may pass through the fabric and cause it to stick to the layer of fabric below it. Several methods of avoiding this problem are suggested in the aforesaid applications.
With, however, the present structure of the fabric, the scrim layer 28 can be impermeable at least with regard to the coating being applied. Accordingly, one or both sides of the fabric can be coated without concern for bleed through or sticking. In addition, if the scrim 28 is impermeable to salt water and salt water ions, it might minimize or eliminate the need for coating altogether, since it will act as a barrier. Of course, there may be other reasons for coating as will be later discussed herein.
In addition, the properties of the scrim layer 28 may address other concerns with regard to the FFCV. For example, it is desirable that the FFCV be buoyant when empty so that, for example, it does not sink when empty or otherwise impede the loading and unloading of the cargo. Accordingly, the scrim layer 28 can be made of a buoyant structure or material, for example, it may be made of a reticulated or non-reticulated foam of polyurethane. Other examples in this regard are disclosed in the aforesaid applications
Also, the scrim layer 28 may be so formed so as to add structural integrity to the fabric. For example, it may comprise a woven base substrate impregnated with a resin to render it impermeable which is then incorporated as a layer of fabric 18 . As to such incorporation, as illustrated in FIG. 3, the reinforcing layers 20 - 26 and scrim layer 28 are warp knitted or stitch bonded together. Binder yarn 30 is illustrated for this purpose.
Turning now to FIG. 4, there is shown for illustrative purposes a multi-component fabric 40 having layers 42 - 50 which is being stitch bonded (via binder yarns 52 ) together. The layers may be woven or non-woven with the scrim layer positioned at the center of the structure or it may comprise any one of the layers. By using a multi-component structure, variations in the design to meet desired characteristics are numerous.
Also, if the structure was not buoyant, it may be desirable to provide a foamed coating on the inside, outside, or both surfaces of the fabric or otherwise coat it in a manner set forth in the aforesaid applications to render the fabric buoyant.
In view of the closed nature of the FFCV, if it is intended to transport fresh water, as part of the coating process of the inside thereof, it may provide for a coating which includes a germicide or a fungicide so as to prevent the occurrence of bacteria or mold or other contaminants.
In addition, since sunlight also has a degradation effect on fabric, the FFCV may include as part of its coating, or the fiber used to make up the fabric, a UV protecting ingredient in this regard.
Although a preferred embodiment has been disclosed and described in detail herein, its scope should not be limited thereby; rather its scope should be determined by that of the appended claims. | A flexible fluid containment vessel or vessels for transporting and containing a large volume of fluid, particularly fresh water which is fabricated out of a fabric made out of a plurality of separately formed layers which are bound together. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates in general to the field of information handling system network storage, and more particularly to a system and method for managing replication in an object storage system.
[0003] 2. Description of the Related Art
[0004] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
[0005] Large scale object storage systems, such as the DX6000 developed by Dell Inc., store information in a network “cloud” by using a universally unique identifier (UUID) token to store and retrieve the information. In order to prevent data loss, object storage systems may provide content replication between independent network locations, such as with many-to-many replication. In some instances, an application provides redundancy across network sites via multi-site writes, while in other cases, the storage subsystem provides redundancy across network sites by replicating objects at different network sites. Object storage systems protect against data loss by using RAID, RAIN or content replica-based policy storage to address data redundancy challenges at each network site location. With a content replica-based storage policy subsystem, a content addressed storage (CAS) policy typically replicates content based upon the UUID of the content and a cluster level policy that sets the number of replicas. For example, with a typical replica policy each cluster replicates each object at least twice at each independent network site. Creating redundant copies of the same object increases storage costs by eating up storage space, however, provides greater protection against potential data loss presented when only one copy is maintained.
[0006] Although cluster storage advantageously improves data security and flexibility, one difficulty with content addressed storage in a “cloud” network environment is managing the number of replicas where storage of a particular object is not tied to a physical storage device. This allows content objects to be distributed and re-distributed to enable load balancing by assigning a UUID token for content object access to each object written to object storage. Having multiple replicas at each site of network storage adds significant costs since each independent site lacks a co-relation between an object copy of different sites once replication is completed. Hence, if different independent sites replicate content to each other with two or more copies at each site, the number of replicas grows exponentially increasing total storage requirements. By comparison, applications that have no binding between sites and have a replica count set at 1 for a site can experience a silent data loss. For example, if the application is keeping a single replica at a remote site and a storage system failure occurs that results in a lost or corrupted replica, the failure may go unnoticed until the application attempts to access the data. End users of a content addressed storage system face the difficult choice of reducing costs by having one replica per site and accepting the risk of data loss, or accepting increased costs by having multiple replicas of content at each site in order to reduce the risk of data loss. For example, in one common configuration, two copies of a content object are maintained at a source site directly accessed by an application with two copies at each replica site so that the number of replicas grows to exponentially increase required storage size for a given set of data.
SUMMARY OF THE INVENTION
[0007] Therefore a need has arisen for a system and method which manages replication across the object storage system.
[0008] In accordance with the present invention, a system and method are provided which substantially reduce the disadvantages and problems associated with previous methods and systems for replicating information stored in an object storage system. A virtual identifier indicates the presence of a replica at a network location to prevent replication of an object when existing replicas provide adequate data availability. The virtual identifier applies at the node storing the object but is transparent to an application or node that attempts to access an object associated with the virtual identifier because an application accessing an identifier does not know if the identifier has actual content or virtual content. If the virtual identifier is called to provide an object, such as when another replica at a network location has become invalid, a replica is created and provided in response to the request for the virtual identifier.
[0009] More specifically, content addresses storage system stores objects at a network location by reference to a UUID unique identifier token. A publisher module at the network location publishes the object to a subscriber module of a distal network location so that the subscriber module creates a replica of the object at the distal network location to provide desired data redundancy. Network locations have a replica policy engine that calls for two or more copies of each object to be stored at each network location to prevent data loss, however, the replica policy engine intervenes to alter the replica policy if an object is itself a replica created as a redundant copy of an object at another network location. Instead of creating additional copies of an object sent for replication by a primary network location, the replica policy engine creates one replica at a secondary network location and “tricks” the secondary network location to believe that a second replica is created by reference to a virtual identifier. In the event that a replica object associated with a virtual identifier is called for retrieval, such as if the actual replica of the secondary network location becomes invalid, then the replica policy engine provides a high priority request for retrieval of the object from the primary network location to the secondary network location to create a replica for association with the virtual identifier.
[0010] The present invention provides a number of important technical advantages. One example of an important technical advantage is that improved management of replicas in an object storage system provides protection from data loss with reduced storage space requirements. A content addressed storage system creates a virtual identifier that has the UUID but lacks an associated object and therefore uses minimal storage space. This scheme allows the creation of an actual object (UUID) and a pointer (virtual UUID) to the actual object irrespective of the location of the actual object at a local or remote site. Monitoring of original content associated with the virtual identifier allows a timely creation of an actual content object for association with the virtual identifier should original content become unavailable. Adjusting storage priorities to allow for rapid replication when failure is detected results in minimal impact on system performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.
[0012] FIG. 1 depicts a block diagram of an object storage system that manages replication of objects to adjust storage usage;
[0013] FIG. 2 depicts a flow diagram of a process for creating a virtual identifier to indicate multiple replicas at a secondary network location;
[0014] FIG. 3 depicts a flow diagram of a process of creating an object to associate with the virtual identifier if a virtual replica is called at a secondary network location; and
[0015] FIG. 4 depicts a flow diagram of a process of creating an object to associate with the virtual identifier if an application requests a virtual replica from the secondary network location.
DETAILED DESCRIPTION
[0016] Replicas in an object storage information handling system having plural network locations are managed by creating virtual object identifiers at one or more network locations and creating an associated content object upon retrieval of the virtual object identifier. For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (PO) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
[0017] Referring now to FIG. 1 , a block diagram depicts an object storage system that manages replication of objects to adjust storage usage. Content addressed storage system 10 provides storage through a network 12 at plural network locations 14 , such as a primary network location 16 accessed by an application 18 and a secondary network location 20 that provides redundancy for information stored at primary network location 18 . For instance, application 18 executing on a client information handling system interfaces through network 12 , such as the network, to communicate with primary network location 16 , such as a storage area network having a server information handling system 22 and plural storage devices 24 . Application 18 stores information on storage devices 24 by interacting through server information handling system 22 . Information generated by application 18 is stored as an object 26 on one or more storage devices 24 and is tracked as content with a UUID token. A replica policy engine 28 executing on a CPU 30 and RAM 32 of server information handling system 22 generates one or more replica objects 34 that are stored by reference to a UUID on storage devices 24 of primary network location 16 . By having a replica policy of 2 copies of each object on each primary network location, ready access to a redundant copy of the object is available in the event that the primary object becomes invalid.
[0018] In addition to maintaining an object 26 and replica 34 at primary network location 16 , which is the source network location of application 18 , content addressed storage system 10 also maintains a copy of object 26 as a replica 34 on secondary network location 20 , which is remote to primary network location 16 . A publisher module 36 executing on CPU 30 at primary network location 16 publishes object 26 to a subscriber module 38 running on CPU 30 at secondary network location 20 . Replica policy engine 28 running on CPU 30 at secondary network location 20 detects publication by subscriber module 38 and manages the number of replica objects stored on secondary network location 20 according to a replica policy. For example, in order to conserve storage space replica policy engine 28 creates only one replica at secondary network location 20 when replica policy engine 28 detects that the replica supports a primary network location 16 that stores an object 26 and a replica 34 . In order to “trick” content addressed storage system 10 into the desired replica policy, replica policy engine 28 creates a replica 34 tracked by a UUID and also creates a virtual UUID 40 that indicates a second replica was created even though the second replica is not created at secondary network location 20 . Those of skill in the art will recognize that the term “virtual UUID” broadly references an indication of storage of an object that does not in fact exist, and may also be referenced as a virtual replica or similar term. The virtual UUID applies to the node that stores the virtual content, however, to other nodes or applications the virtual UUID appears as a valid UUID having associated content. The virtual nature of a UUID is transparent to applications and other nodes that want content associated with a UUID so that requests are made to the virtual UUID as if it is a standard UUID associated with the content. In operation, an HTTP request based upon content to a content addressed storage system returns a UUID token, which may be filled by any object having the UUID or an associated identifier to provide the content associated with the UUID.
[0019] During normal operations, three copies of object 26 exist for access by application 18 through a request of a UUID associated with the object 26 . Application 18 is served by primary network location 16 , which provides object 26 or replica 34 in response to a request for the stored information with a UUID ticket. In the event that object 26 and replica 34 of primary network location 16 is not available, content addressed storage system 10 will respond to the UUID token by providing replica 34 of secondary network location 20 as a redundant object to primary network location 16 . Alternatively, application 18 can attempt to retrieve object 26 by making a request to secondary network location 20 . During the retrieval process, if a fault is detected with the object replica 34 stored at secondary network location 20 , replica policy engine 28 will attempt to generate a replica to associate with virtual UUID 40 so that secondary network location 20 can respond to the UUID with the virtual replica after creation of an actual replica object.
[0020] Replica policy engine 28 runs at each network location node 14 , 16 and 20 to check replication policy and data integrity for each UUID residing on each node. A replica policy engine 28 learns of replica objects on other network locations from UUID mapping or via bidding. If a replica policy engine 28 cannot access the object associated with a UUID and the replica policy calls for 1 replica at a distal network location, then replica policy engine 28 determines that the UUID without a content object is a virtual UUID 40 . If replica policy engine 28 detects that a UUID exists for a replica object but that no virtual UUID exists, then it bids out for a virtual UUID creation and the winning node bid stores the virtual UUID without a content object. As an example, this situation could arise if a replica is created to associate content with a virtual UUID in response to a request for content so that another virtual UUID is created after the replica is created. As an alternative example, an object with the actual UUID may be created so that the virtual UUID is left intact. If replica policy engine 28 detects that a virtual UUID exists but that no UUID exists, a high priority request is made to the source network location for the content object associated with the UUID to generate a replica at the secondary network location. If an application 18 requests content associated with a UUID from a secondary network location, the node with the virtual UUID 40 provides a lower priority response to the request than the node with the replica UUID 34 so that the node having an actual content object will win the bid to fill the request for the content object. If the replica UUID is not found or is not valid in response to the winning bid, then replica policy engine 28 initiates a high priority request to create a replica object associated with the virtual UUID 40 so that application 18 's request for the content object can be filled with a content object associated with the virtual UUID.
[0021] Increased priority for a request to create a content object associated with a virtual UUID helps to limit delays for pending content requests. A “retry after timeout” error provided in response to a request for a content object indicates to the application 18 that only a virtual UUID was found and a delay will occur while the content object is retrieved from a source/publisher node to create a replica object associated with the virtual UUID. By the timeout time frame, the object from the source node is requested and another node within the subscriber network location stores the content and bids to fill the application request.
[0022] Referring now to FIG. 2 , a flow diagram depicts a process for creating a virtual identifier to indicate multiple replicas at a secondary network location, even though no replica object exists for the virtual identifier. The process starts at step 42 with storage of a content object at a primary network location of an object storage system, such as a content addressed storage system. At step 44 , the content object is replicated at the primary network location, such as another node within a cluster, so that a local redundant replica exists for the content object. At step 46 , the UUID of the content object is returned to the application host. This allows the application to retrieve the content object by submitting the UUID and receiving in response the primary object or the replica object from the primary network location. At step 48 , the content object is published via a multicast snoop or other mechanism to a secondary network location in accordance with a replication policy that has replicas created at distal network locations. At step 50 , a UUID list is obtained from the primary network location to coordinate a UUID for a replica of the object at the secondary network location. At step 52 , a subscribe module at the secondary network location replicates the object from the primary network location and assigns a UUID. The assigned UUID may be the same as that of the primary network location, a variant of the primary network location or otherwise associated with the UUID of the primary network location. At step 54 , a virtual copy of the replica is created at the secondary network location by association with a virtual UUID having the same value as the replicated object but no content. At step 56 , a successful replication of two copies of the content object is reported to the publisher along with the UUID.
[0023] Referring now to FIG. 3 , a flow diagram depicts a process of creating an object to associate with the virtual identifier if a virtual replica is called at a secondary network location. The term “virtual replica” applies to nodes that store information or objects but is transparent to applications that use objects because the applications do not know the difference between a virtual and non-virtual UUID, but rather see virtual UUIDs as normal content source. The process begins at step 58 with monitoring of a replica at a secondary network location to detect an invalid content object. If an invalid replica is detected, the process continues to step 60 to request a virtual copy represented by a virtual UUID. At step 62 , a request is made from the secondary network location to the primary network location for the content object associated with the virtual UUID. The request includes an indication of increased priority so that the content object is transferred in a more rapid manner relative to other requests for content objects. At step 64 , the UUID request is received by the publisher of the primary network location. At step 66 , the publisher of the primary network location initiates replication of the content object associated with the UUID from the primary network location to an object associated with the virtual UUID at the secondary network location. At step 68 , the subscriber of the secondary network location generates a content object for association with the virtual UUID. At step 70 , the subscriber of the secondary network location generates a virtual UUID to replace the virtual UUID that was just associated with a content object.
[0024] Referring now to FIG. 4 , a flow diagram depicts a process of creating an object to associate with the virtual identifier if an application requests a virtual replica from the secondary network location. The process begins at step 72 with a request for a content object by a UUID made from an application host. At step 74 , the secondary network location finds a virtual UUID associated with the request and lacking content. Such a situation might arise if the node supporting the virtual UUID underbids the node supporting a replica object, but the replica object is found invalid so that the virtual UUID must provide a content object that does not actually exist. At step 76 , the contend associated with the virtual UUID is requested from the replication policy engine of the secondary network location, which at step 78 sends a request for the content object to the publisher of the primary network location. At step 80 , the publisher retrieves the content object form the primary network location by reference to the UUID and, at step 82 sends the content object with the publisher of the primary network location to the subscriber of the secondary network location. At step 84 , the subscriber of the secondary network location replicates the object at the secondary network location is association the virtual UUID of the secondary network location. At step 86 , the newly replicated object associated with the virtual UUID is provided to the application host in response to the request for the object from the secondary network location with the UUID. At step 88 , a new virtual UUID is generated at the secondary network location to provide a redundant copy object for the newly generated replica object formerly associated with a virtual UUID.
[0025] Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims. | An object storage system, such as a content addressed storage system, manages replication of objects across network locations to balance storage space and data security. Network locations set a policy of replicating each object at the object's primary network location and a secondary network location. The secondary network location creates a first replica of the object and a virtual unique identifier representing a second replica of the object at the secondary network location. Creation of the second replica is suppressed unless the first replica becomes invalid so that storage space is conserved without substantially increasing the risk of loss of information represented by the object. | 6 |
FIELD
The present disclosure relates to socks, and in particular, socks having a support structure integrally knit therewith.
BACKGROUND
There are a number of over-the-counter arch supports and supportive insoles available for providing or improving support for the arches of the feet.
Custom-made orthotics are also available, although they are much more expensive.
Alternatively, the provision of arch support can also be done by wrapping a separate elastic bandage around the foot. Wrapping of the bandage, however, may prove uncomfortable if wrapped too tightly, or not so effective if wrapped too loosely. There may also be an element of discomfort in that the wearer's existing footwear may not have enough room to accommodate an additional thickness of the bandage.
As a more accessible and convenient option, attempts have been made to attach or incorporate arch support bands or pads into socks. Being one of the basic commodities of everyday life, socks provide a convenient framework into which support means can be incorporated, by way of sewing or knitting. Despite the inherent convenience, socks with an integrally formed arch bands or pads have some drawbacks in that they do not necessarily deliver sufficient or adequate level of support.
Therefore, it would be advantageous to provide socks with improved support.
SUMMARY
Socks having a support structure are disclosed herein.
The embodiments of the present disclosure provide a support sock which has an integrally knit support structure. The sock also has a toe area, an ankle area, and an intermediate area for covering a wearer's instep, ball and sole.
According to one aspect, the integrally knit support structure may include an arch wrap, an upper support band and a lower support band. The arch wrap defines at least a portion of the intermediate area. The arch wrap has a proximal end facing toward the ankle area and a distal end facing toward the toe area. The upper support band bridges between the proximal end of the arch wrap and the ankle area, and the lower support band extends from the distal end of the arch wrap.
According to another aspect, the integrally knit support structure may include an arch wrap, and one of an upper support band and a lower support band.
In one embodiment, the upper support band extends from the proximal end of the arch wrap toward the ankle area, encircles the ankle area, and extends back to the proximal of the arch wrap.
In one example, the upper support band may have an inverted U-shape. In another example, the upper support band may have a generally loop shape.
The lower support band may be dimensioned to cover at least a portion of the instep of the wearer, and/or at least a portion of the ball of the wearer. In one example, the lower support band may be dimensioned to cover a substantial portion of the ball.
According to the present disclosure, the arch wrap is configured for stretching in a radial direction.
The arch wrap may have a knit construction of a repeating two-wale pattern, where the first wale includes knit and float stitches, and the second wale include knit stitches.
In a preferred embodiment, the upper and lower support bands may comprise reinforcement yarns. The reinforcement yarns may include 70 denier nylon. In one embodiment, the upper and lower support bands may have diamond patterns.
According to one aspect, the support sock may include a leg area. In one embodiment, the leg area may have an elasticity of gradual compression.
A further understanding of the functional and advantageous aspects of the disclosure can be realized by reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is an elevation side view of one embodiment of the sock according to the present disclosure;
FIG. 2 is a diagram of a knit construction of an arch wrap of the sock shown in FIG. 1 ; and
FIG. 3 is an elevation side view of a sock similar to FIG. 1 , but showing an alternative shape of a support band.
A further understanding of the functional and advantageous aspects of the disclosure can be realized by reference to the following detailed description and drawings.
DETAILED DESCRIPTION
Embodiments described herein provide socks having a support structure integrally knit therewith. The support structure of the present disclosure includes an arch wrap configured for supporting and lifting the arch of a wearer. The support structure also includes at least one support band configured for assisting the lifting and supporting effect of the arch wrap.
Various embodiments and aspects of the disclosure will be described with reference to details discussed below. The following description and drawings are illustrative of the disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.
As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not be construed as preferred or advantageous over other configurations disclosed herein.
The selected embodiments as described below are directed to a sock having a support structure integrally knit therewith. The embodiments of the present disclosure provide improved support for the feet of a wearer, in particular, the arch areas.
Referring to FIG. 1 , a support sock having an integrally knit support structure is shown at 10 . The sock 10 has a toe area 11 , an ankle area 12 , and an intermediate area 13 . The intermediate area 13 covers at least portions of the instep, ball, and sole of the wearer.
In the exemplary embodiment shown in FIG. 1 , the support sock 10 has an arch wrap 14 and two support bands, namely, the upper support band 15 and the lower support band 16 .
The arch wrap 14 defines at least a portion of the intermediate area 13 . The arch wrap 14 has a proximal end 17 facing toward the ankle area 12 and a distal end 18 facing toward the toe area 11 . In the present embodiment, the arch wrap 14 is configured for stretching in a radial direction. In one preferred embodiment, the arch wrap 14 has a knit construction of a repeating two-wale pattern.
Referring to FIG. 2 , the repeating two-wale pattern is shown at 20 . In this embodiment, the first wale comprises knit stitches 22 and float stitches 24 , and a second wale consists of knit stitches 22 only. The knit construction 20 enables the arch wrap 14 to stretch in a radial direction, while limiting the migration of stretch in an axial direction. The arch wrap 14 helps lift and support the arch in place, thereby providing improved support to the arch of the wearer.
The support structure according to the present disclosure also includes at least one support band configured for assisting in the lifting and supporting effect of the arch wrap 14 .
The embodiment shown in FIG. 1 illustrates the support sock 10 having two support bands. The upper support band 15 extends from the proximal end 17 of the arch wrap 14 , and continues to the ankle area 12 . The upper support band 15 then encircles the arch area 12 , and returns to the proximal end 17 of the arch wrap 14 .
As shown in FIG. 1 , the upper support band 15 may have an inverted U-shape. However, the shape of the upper support band is not restricted to the embodiment shown in FIG. 1 , and any other shapes may be used for the upper support band.
Referring to FIG. 3 , the support sock 30 is similar to the sock 10 shown in FIG. 1 , but has an alternative shape of the upper support band shown at 35 . In this embodiment, the upper support band 35 defines a generally loop shape, where the band 35 extending from the central area 32 of the proximal end 17 of the arch wrap 14 encircles the ankle area 12 . The upper support band 35 then returns back to the central area 32 of the proximal end 17 of the arch wrap 14 .
Referring to FIGS. 1 and 3 , the lower support band 16 is dimensioned to cover at least a portion of the instep area A of the wearer. The lower support band 16 may be dimensioned to cover at least a portion of the ball B of the wearer. In one preferred embodiment, the lower support band 16 is dimensioned to cover a portion of the instep A as well as a substantial portion of the ball B. In another preferred embodiment, the lower support band 16 may be dimensioned to encircle the ball B of the wearer.
The support bands 15 , 35 and 16 are configured to assist in the lifting and supporting effect of the arch wrap 12 . To this end, the support bands may be made from reinforcement yarns.
In one embodiment, the support bands 15 , 35 and 16 comprise 70 denier nylon. In one specific embodiment, the support bands 15 , 35 and 16 may have diamond patterns.
In one embodiment as shown in FIG. 1 , the support sock of the present disclosure may also include a leg area 19 . In this embodiment, the leg area 19 may have an elasticity of gradual compression. In one example, some portion of the toe area 11 , instep area A and ankle area 12 have the elasticity similar to that of the leg area 19 . Alternatively, at least one of the toe area 11 , instep area A and ankle area 12 have an elasticity different from that of the leg area 19 .
The support sock according to the present disclosure may be of any desired length. For example, as shown in FIG. 3 , the sock may be of an ankle length.
In another example, the sock may have a length that also covers at least a portion of the leg, or a knee high or thigh high. In another example, the support socks may be attached together to form stockings.
The support sock 10 and 30 according to the present disclosure provide improved support for the feet of a wearer, in particular, the arch areas. Therefore, the support sock disclosed herein may help those with plantar fasciitis. Moreover, the support bands provided at the proximal end and/or the distal end of the arch wrap assist in the supporting and lifting power of the arch wrap, and provide additional support to the feet, including the arches and ankle areas.
As used herein, the terms “comprises” and “comprising” are to be construed as being inclusive and opened rather than exclusive. Specifically, when used in this specification including the claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or components are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
Furthermore, nothing in the present disclosure is to be construed as the promise of the invention. | A support sock having a support structure integrally knit therewith. The sock has a toe area, an ankle area, and an intermediate area for covering a wearer's instep, ball and sole. The integrally knit support structure has an arch wrap defining at least a portion of the intermediate area. The integrally knit support also includes an upper and/or lower support band for assisting in the arch wrap. The upper support band bridges between the proximal end of the arch wrap and the ankle area. The lower support band extends from the distal end of the arch wrap. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present disclosure relates to novel iturin biosynthesis genes, and more particularly, to novel iturin biosynthesis genes derived from Bacillus subtilis subsp. krictiensis ATCC 55079 and uses thereof.
[0003] 2. Description of the Related Art
[0004] Biological control is a means of controlling pathogenic microorganisms that cause disease injuries in plants through the use of other microorganisms that have antagonistic actions. Most representative biopesticides have been primarily used for controlling various plant pathogens, insects harming crops, insect pests such as mites, nematodes, and weeds through direct or indirect use of microorganisms themselves. Studies on this biological control started in early 1990s, and since then, many efforts have been made to inhibit plant pathogens by using various kinds of bacteria and fungi. However, since the soil ecosystems are complex and complicated interactions are associated between plants and microorganisms, the results of studies were very unsatisfying. Recently, interactions between plants and microorganisms have been gradually identified and outstanding results have been reported thanks to developments in biotechnology, such as molecular biology. Currently, about 40 kinds of biological control agents have been developed all around the world (H. D. Burges, Formulation of microbial biopesticides, Kluwer Academic Publisher, Dordrecht, The Netherlands, p. 187-202, 1998) and 25 kinds of biological control agents are registered and commercially available only in the U.S. (B. B. McSpadden Gardener, et al., Plant Health Progress [Internet], May 10, 2002 [cited Aug. 13, 2010], Available from: http://www.plantmanagementnetwork.org/pub/php/review/biocontrol/).
[0005] Registered products are mainly for the control of soil borne plant diseases by Fusarium, Pythium, Rhizoctonia , and Sclerotinia ( Phytophthora ), but, these products have not yet captured a large share of the market. So far, one of the most successful examples of biological control is the control of crown gall, a disease of roots in fruit trees, caused by Agrobacterium tumefaciens (A. Kerr, Plant Dis., 64: 25-30, 1980). Controlling this plant disease cannot be carried out with chemosynthetic pesticides. However, it has been known that an antibiotic agrocin produced by Agrobacterium radiobacter inhibits the invasion of A. tumefaciens , and then, several products that improved A. radiobacter by using genetic engineering techniques have been developed and thought to have a considerable worldwide market share (names of products: Nogall, Norbac, Galltrol-A, etc.). Another successful example is the study on the control of root rots of wheat using Pseudomonas fluorescens , and research teams at the USDA and Washington State University succeeded in isolating P. fluorescens which exhibits strong antagonistic activity against Gaeumannomyces graminis var. tritici causing the root rots of wheat from soil through 10-year researches (D. M. Weller, Annu. Rev. Phytopathol., 26: 379-407, 1988; D. M. Weller, et al., Can. J. Plant Pathol., 8: 328-334, 1986; R. J. Cook, Can. J. Plant. Pathol., 14: 76-85, 1992). When wheat seeds were treated with this antagonistic microorganism and sown, the yield of wheat increased by 10 to 20% and it was concluded that this effect was caused by phenazine antibiotics (L. S. Thomashow, et al., Appl. Environ. Microbiol., 56: 908-912, 1990; C. Keel, et al., Mol. Plant-Microbe Interact., 5: 4-13, 1992) and 2,4-diacetyl phloroglucinol antibiotic produced by Pseudomonas (C. Keel, et al., Mol. Plant-Microbe Interact., 5: 4-13, 1992). To overcome the differences in control activities depending on application time and region, revealed through a field experiment over 8 years, research teams introduced genetic engineering techniques to maximize the gene expression of Pseudomonas sp. related with the production of phenazine antibiotics and succeeded in overcoming the irregularity of the control effect of root rots of wheat (M. H. Ryder, et al., Improving plant productivity with Rhizobacteria , CSIRO Divisions of soils, Adelaide, South Australia, p. 247-249, 1994).
[0006] Bacillus subtilis ( B. subtilis ) has been received attention of many researchers due to not only many kinds of antibiotics but also its characteristic to produce various enzymes, and along with Saccharomyces cerevisiae ( S. cerevisiae ), and Lactobacillus sp., it is recognized as a harmless strain to a human body and the environment by the U.S. Food and Drug Administration. Examples of formulations of microbial pesticides developed by using B. subtilis include Epic, Kodiak, Companion, HiStick, Serenade, etc. and these are largely widely used for seed treatment or post-harvest application, and for protecting putrefaction of vegetables and the like (B. B. McSpadden Gardener, et al., Plant Health Progress [Internet], May 10, 2002 [cited Aug. 13, 2010], Available from: http://www.plantmanagementnetwork.org/pub/php/review/biocontrol/). Especially, Serenade which was registered in early 2,000s by AgraQuest Co. has been produced by using B. subtilis QST713 and is registered as a fungicide and a bactericide in 25 countries, and currently, various products depending on their uses are commercially available. In addition, a research team at the USDA found that iturin antibiotics produced by B. subtilis inhibited Monilinia fructicola , the pathogen of peach brown rot, and attempted a study to develop B. subtilis as a preservative during storage of tree fruits (R. C. Gueldner, et al., J. Agric. Food Chem., 36: 366-370, 1988).
[0007] Besides, a research team lead by Dr. Pusey at the USDA found that B. subtilis has an inhibitory effect on many plant diseases (P. L. Pusey, et al., Pesticide Sci., 27: 133-140, 1989) and Phae et al. also isolated B. subtilis NB22 having a wide inhibitory effect on plant pathogens from decomposed soil for compost and proved that its active components are iturin-based materials (C. G. Phae, et al., J. Ferment. Bioeng., 69: 1-7, 1990). Like these, iturin, a cyclic peptide antibiotic, has long been widely used as a biological control agent, but, study on iturin biosynthesis genes at the molecular level has hardly been made, except for one published in J. Ferment. Bioeng. by a Japanese research team in 1990.
[0008] The complete genome sequence of B. subtilis 168 strain having a gene responsible for biosynthesis of surfactin, another cyclic peptide other than iturin was published in 1997 (Kunst, F., et al., Nature, 390: 249-256, 1997), and the result of study on a gene responsible for biosynthesis of mycosubtilin from B. subtilis ATCC 6633 was reported by a German research team in late 1990s (E. H. Duitman, et al., Proc. Natl. Acad. Sci., 96: 13294-13299, 1999). Since then, cloning, base sequence, and characteristics of iturin A gene from B. subtilis RB14 was published by a Japanese research team in 2000s (K. Tsuge, et al., J. Bacteriol., 183: 6265-6273, 2001). Furthermore, a German research team found that B. amyloliquefaciens FZB42 which promotes plant growth and suppresses plant pathogens at the same time produced cyclic peptides, surfactin, fengycin, and bacillomycin D as secondary metabolites, and investigated and reported genetic structures and functional characteristics of produced secondary metabolites at the molecular level (A. Koumoutsi, et al., J. Bacteriol., 186: 1084-1096, 2004). Besides, the above German research team reported that B. amyloliquefaciens FZB42 produces polyketide-based antibiotics, macrolactin, bacillaene, and difficidin, in addition to the above three cyclic peptides (Chen, et al., Nature Biotechnol., 25: 1007-1014, 2007). Likewise, while reports on various cyclic peptide antibiotics have been made intermittently, there is hardly a report on various kinds of iturin biosynthesis genes.
[0009] Thus, the present inventors cloned iturin biosynthesis genes from B. subtilis subsp. krictiensis ATCC 55079 (S. H. Bok, et al., U.S. Pat. No. 5,155,041, 1992. 10. 13) which is effective for various plant pathogens isolated from domestic soils and produces six kinds of iturins (iturin A to F) and obtained the U.S. patent in 1992, identified iturin biosynthesis genes by determining base sequences of the genes, analyzed their characteristics, and found that the above iturin biosynthesis genes are novel iturin biosynthesis genes that show many differences in base sequences, compared to conventional iturin genes, thereby leading to completion of the present invention.
SUMMARY OF THE INVENTION
[0010] One object of the present invention is to provide novel iturin biosynthesis genes, proteins encoded by the genes, and uses thereof.
[0011] In order to achieve the objects, the present invention provides an iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:6 or an iturin biosynthesis gene having 95% or more sequence identity to the gene.
[0012] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:5.
[0013] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:3.
[0014] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:7.
[0015] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:8.
[0016] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:7.
[0017] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:8.
[0018] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:7, and SEQ ID NO:8.
[0019] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:1.
[0020] The present invention also provides an iturin protein encoded by the gene in accordance with the present invention.
[0021] Furthermore, the present invention provides a vector comprising nucleotide sequence of the gene in accordance with the present invention.
[0022] The present invention also provides a transformant transformed with the vector comprising nucleotide sequence of the gene in accordance with the present invention.
[0023] Furthermore, the present invention provides iturin protein produced by the transformant in accordance with the present invention.
[0024] The present invention also provides a biological control agent comprising the transformant producing the iturin protein in accordance with the present invention or its culture medium.
[0025] Furthermore, the present invention provides the transformant of the present invention or its culture medium for use as a biological control agent, or the iturin protein produced by the transformant of the present invention for use as a biological control agent.
[0026] Hereinafter, the present invention will be described in detail.
[0027] The present invention provides an iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:6 or an iturin biosynthesis gene having 95% or more sequence identity to the gene, or iturin protein encoded by the gene.
[0028] In the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:6 may comprise ORF 3 of the iturin biosynthesis gene, and the protein encoded by the iturin gene may be, but not limited to, conventionally known iturin biosynthesis protein.
[0029] In a specific example of the present invention, first, the present inventors used B. subtilis 168, which is known that produces surfactin, but does not produce iturin, to identify the novel iturin biosynthesis gene. Surfactin and iturin are cyclic lipopeptide antibiotics composed of seven amino acids and a fatty acid. They are different from each other only in amino acid composition and sequences, and are known to be very similar in their molecular weights. Since surfactin gene is as large enough to be 32 kb in size, the size of iturin gene is thought to be similar to that. It is also assumed that the biosynthetic pathways of these two antibiotics are not distinct from the beginning, but the same pathway is utilized up to established steps, and then, two antibiotics are synthesized using separate biosynthetic pathways. Since some B. subtilis strains are known that produce both iturin and surfactin, the present inventors assumed that each gene is less likely to exist separately in consideration of the size of two genes. That is, cyclization of peptides and acylation process of connecting peptides and fatty acids during the biosynthetic process of two antibiotics are assumed to utilize the same pathway for biosynthesis of surfactin and iturin, considering each gene size. On the basis of these assumptions, the present inventors obtained surfactin biosynthetic genes from the database of B. subtilis 168 which was used in the Bacillus genome project and tried the cloning of iturin biosynthetic genes of B. subtilis subsp. krictiensis with a DNA homology based method. In a specific example of the present invention, PCR and electrophoresis were conducted using the chromosomal DNAs of B, subtilis 168 and B. subtilis subsp. krictiensis as the template. Among gene products obtained from B. subtilis subsp. krictiensis , about 1.8 kb of a DNA fragment, the same size with the gene product from B. subtilis 168, was obtained ( FIG. 1 ).
[0030] Also in a specific example of the present invention, when the amino acid sequence of the DNA fragment obtained from B. subtilis subsp. krictiensis was compared to amino acid sequences of other peptide biosynthesis genes using NCBI database, it showed 82 to 85% homology with three different surfactin biosynthesis genes and 80% homology with lichenysin biosynthesis gene produced by B. licheniformis.
[0031] Also in a specific example of the present invention, to clone genes responsible for acylation process of connecting peptides and fatty acids, PCR was conducted using designed 20 primers and about 0.4 kb of a DNA fragment was obtained and the sequence was determined ( FIG. 3 ). As a result of NCBI database search to compare amino acids, this gene product had 56 to 83% homology with acyl carrier protein reductases derived from other microorganisms ( FIG. 4 ). Especially, it showed 83% homology with acyl carrier protein reductases derived from other B. subtilis and it was thought to be usable for genomic library screening of B. subtilis subsp. krictiensis.
[0032] Also in a specific example of the present invention, to clone the iturin biosynthetic genes from genomic library of B. subtilis subsp. krictiensis , the genomic DNAs of B. subtilis subsp. krictiensis were partially digested with Sau3A. Then, to 30 kb of a DNA fragment was inserted into the cosmid vector pLAFR3 and E. coli HB101 was transformed with the vector to construct the genomic library. Colony hybridization and Southern hybridization were conducted using the constructed genomic library of B. subtilis subsp. krictiensis and 1.8 kb of peptide biosynthesis gene, which was already cloned in Example <3-1> as a probe. Consequently, two clones that showed homology with the probe DNA at 27 kb and 32 kb positions were observed and named as pJJ815 and pJJ121, respectively ( FIG. 5 ).
[0033] Also in a specific example of the present invention, a restriction enzyme map was constructed by digesting cosmid clones with various kinds of restriction enzymes and leaving out the regions which were overlapped each other. Base sequences of some fragments were investigated. As a result, some fragment of pJJ121 showed 57 to 90% homology with surfactin synthetase I, tyrocidine synthetase II, gramicidine S synthetase I, and peptide synthetase 2. From the result, the present inventors assumed that two cosmid clones include some genes related with peptide synthesis of iturin biosynthetic process.
[0034] Also in a specific example of the present invention, Southern hybridization was conducted at 50° C. and 65° C. using chromosomal DNAs of B. subtilis subsp. krictiensis and B. subtilis 168 to determine whether the genes in the cosmid clones are responsible for iturin or surfactin biosynthesis. Six EcoRI fragments which were obtained by digesting cosmid clones pJJ121 and pJJ815 with EcoRI were subcloned and the fragments were prepared as probe DNAs. Consequently, at 65° C., while B. subtilis subsp. krictiensis showed homologies with all probe DNAs of six EcoRI fragments, B. subtilis 168 did not show homology with any probe DNAs of six EcoRI fragments. The result of Southern hybridization at 50° C. was the same as above, but, B. subtilis 168 showed only weak homology for pJJ121E3 fragment. Accordingly, the genes in the cosmid clones hardly showed similarity with surfactin biosynthesis genes and it was assumed that the genes are likely to be responsible for iturin biosynthesis ( FIG. 7 and FIG. 8 ).
[0035] In a specific example of the present invention, bidirectional sequence was determined with EcoRI fragments cloned from those two cosmid clones to obtain 21,253 bp. However, the present inventors found that some genes were missing. To further obtain the missing sequence, the present inventors obtained the genes through a genomic library screening and determined sequence to obtain a total of 37,682 bp of sequence. Seven ORFs which were assumed to be responsible for iturin biosynthesis were found within the sequence ( FIG. 9 ). When each of seven ORFs which were assumed to be responsible for iturin biosynthesis of cosmid clones was compared with other cyclic lipopeptide biosynthetic genes, they showed 76 to 86% similarity to surfactin genes derived from B. subtilis , but they showed 92 to 100% similarity to surfactin genes derived from B. amyloliquefaciens . Especially, ORF 2-1 (543 bp), ORF 2-2 (9,927 bp), and ORF 3 (10,757 bp) which were assumed to be directly engaged in iturin biosynthesis showed 92 to 98% similarity to surfactin genes derived from B. amyloliquefaciens , respectively (Table 1). While ORF 2-1 showed 94% similarity to B. amyloliquefaciens FZB42 of which number starts with CP000560.1 among strains listed in Table 1, it showed 98% similarity to the entire sequence (37,682 bp). However, since the strain was reported to produce cyclic peptides, surfactin, fengycin, and bacillomycin D (Chen, et al., Nature Biotechnol., 25: 1007-1014, 2007), but not iturin, the present inventors assumed that ORF 2-1, ORF 2-2, and ORF 3 of the cosmid clones were novel iturin biosynthesis genes.
[0036] In a specific example of the present invention, antifungal activities of iturin and surfactin were examined against three kinds of test microorganisms, the rice blast fungus Magnaporthe grisea , the fungus causing athlete's foot Trichophyton mentagrophytes , and the fungus causing wilt disease of the family Solanaceae Fusarium oxysporum . Consequently, as shown in FIG. 10 , standard compounds iturin A and surfactin showed antifungal activities against Magnaporthe grisea and Trichophyton mentagrophytes . Iturin showed antifungal activity against Fusarium oxysporum , whereas surfactin did not show antifungal activity against Fusarium oxysporum ( FIG. 10 ).
[0037] Also in a specific example of the present invention, when antifungal activity was examined using the supernatant of culture broth of Bacillus producing iturin or surfactin, B. subtilis subsp. krictiensis producing iturin showed antifungal activities against Magnaporthe grisea, Trichophyton mentagrophytes , and Fusarium oxysporum , just like the examination result for antifungal activities using standard compounds. On the other hand, B. subtilis JH642 and B. subtilis 168 which do not produce antibiotics did not showed antifungal activities against the above test microorganisms. B. subtilis C9 which is assumed to produce both surfactin and iturin showed antifungal activities against Fusarium oxysporum against which iturin showed antifungal activity. Based on these results, the present inventors decided to use Fusarium oxysporum as a test microorganism for selecting iturin mutants ( FIG. 11 ).
[0038] Also in a specific example of the present invention, the present inventors transformed fragments of cosmid clones into B. subtilis subsp. krictiensis ( FIG. 12 ), and then observed antifungal activity against Fusarium oxysporum . Consequently, pBT6 fragment (including ORF 2-2 and ORF 3) showed the strongest antifungal activity against Fusarium oxysporum in the transformed B. subtilis subsp. krictiensis ( FIG. 13 ).
[0039] Also in a specific example of the present invention, to confirm that among fragments of cosmid clones responsible for iturin biosynthesis, pBT6 is the region related to iturin biosynthesis, pJJ121E2 fragment containing pBT6 fragment was cloned into pTZ18 vector, and p121E3 vector having a spectinomycin-resistant gene was digested with BamHI and XbaI, and a ClaI site was attached thereto by PCR, and then, the fragment was digested with ClaI. Again, the ClaI-digested spectinomycin-resistant gene-containing fragment was inserted into the ClaI site of the pTZ18 vector into which pJJ121E2 fragment was inserted, and a SalI site was removed to prepare pJJ121E2-1 vector. Then, B. subtilis subsp. krictiensis was transformed with pJJ121E2-1 vector ( B. subtilis subsp. krictiensis mutant-10) and whether the ability for iturin biosynthesis is lost or not was examined ( FIG. 14 ). Consequently, B. subtilis subsp. krictiensis showed a strong antifungal activity against Fusarium oxysporum , whereas B. subtilis subsp. krictiensis mutant-10 showed significantly decreased antifungal activity ( FIG. 15 ). In addition, as shown in FIG. 16 , it was confirmed that the spectinomycin-resistant gene was inserted into the chromosome of B. subtilis subsp. krictiensis mutant-10 strain through Southern hybridization ( FIG. 16 ).
[0040] Also in a specific example of the present invention, metabolites of B. subtilis subsp. krictiensis and B. subtilis subsp. krictiensis mutant-10 strain were analyzed by HPLC. Consequently, peaks observed in both B. subtilis subsp. krictiensis and the commercially available standard compound iturin A were identical, whereas the peak of iturin A was not observed in B. subtilis subsp. krictiensis mutant-10 strain ( FIG. 17 ). The molecular weights for these peaks were determined by LC-Mass, and consequently, it was confirmed that peaks which were observed in B. subtilis subsp. krictiensis , but not in B. subtilis subsp. krictiensis mutant-10 corresponded exactly to iturins A to F ( FIG. 18 to FIG. 20 ).
[0041] That is, the present inventors cloned iturin biosynthesis genes derived from B. subtilis subsp. krictiensis , analyzed the cloned gene sequences, and confirmed that these are novel iturin biosynthetic genes of which sequences are different from those of the previously known cyclic lipopeptide biosynthetic genes.
[0042] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:5, or iturin protein encoded by the iturin biosynthesis gene.
[0043] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:3, or iturin protein encoded by the iturin biosynthesis gene.
[0044] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:7, or iturin protein encoded by the iturin biosynthesis gene.
[0045] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:8, or iturin protein encoded by the iturin biosynthesis gene.
[0046] In the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:6 may comprise ORF 3 of the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:3 may comprise ORF 2 of the iturin biosynthesis gene, and the nucleotide sequence of SEQ ID NO:5 may comprise ORF 2-2, one part of ORF 2 of the iturin biosynthesis gene, but the present invention is not limited to such. In addition, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:6 may have nucleotide sequence of SEQ ID NO:14, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:3 may have nucleotide sequence of SEQ ID NO:11, and the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:5 may have nucleotide sequence of SEQ ID NO:13, but the present invention is not limited to such.
[0047] Also, in the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:7 may comprise ORF 4 of the iturin biosynthesis gene, and the nucleotide sequence of SEQ ID NO:8 may comprise ORF 5 of the iturin biosynthesis gene, but the present invention is not limited to such. In addition, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:7 may have nucleotide sequence of SEQ ID NO:15, and the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:8 may have nucleotide sequence of SEQ ID NO:16, but the present invention is not limited to such.
[0048] The nucleotide sequence of SEQ ID NO:3 is characterized by the entire nucleotide sequence of ORF 2 of the iturin biosynthesis gene, and in order to determine a specific region encoding the iturin biosynthesis gene, the present inventors divided ORF 2 region into ORF 2-1 (SEQ ID NO:4) and ORF 2-2 (SEQ ID NO:5) to use in Examples.
[0049] In a specific example, when the iturin biosynthetic genes were compared to amino acids of other cyclic lipopeptide biosynthetic genes, there was a significant difference in the size of the entire iturin gene. Thus, the present inventors prepared fragments including ORFs which compose the iturin biosynthesis gene and experimented to identify regions responsible for iturin biosynthesis protein. Consequently, the present inventors confirmed that when the vector comprising nucleotide sequences of ORF 2-2 and ORF 3 was used, antifungal activity of iturin protein was elevated, thereby identifying the gene responsible for iturin biosynthesis.
[0050] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:7, or iturin protein encoded by the iturin biosynthesis gene.
[0051] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:8, or iturin protein encoded by the iturin biosynthesis gene.
[0052] The present invention also provides an iturin biosynthesis gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:7, and SEQ ID NO:8, or iturin protein encoded by the iturin biosynthesis gene.
[0053] The nucleotide sequence of SEQ ID NO:6 of the iturin biosynthesis gene may comprise ORF 3 of the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:3 may comprise ORF 2 of the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:7 may comprise ORF 4 of the iturin biosynthesis gene, and the nucleotide sequence of SEQ ID NO:8 may comprise ORF 5 of the iturin biosynthesis gene. But the present invention is not limited to such and any nucleotide sequence which can produce iturin proteins in iturin biosynthesis genes may be included.
[0054] For the protein encoded by the iturin biosynthesis gene, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:6 may have nucleotide sequence of SEQ ID NO:14, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:3 may have nucleotide sequence of SEQ ID NO:11, the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:7 may have nucleotide sequence of SEQ ID NO:15, and the protein encoded by the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:8 may have nucleotide sequence of SEQ ID NO:16. But the present invention is not limited to such and any nucleotide sequence which can produce iturin proteins in iturin biosynthesis genes may be included.
[0055] Furthermore, the present invention provides an iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:1, or iturin protein encoded by the iturin biosynthesis gene.
[0056] In the iturin biosynthesis gene, the nucleotide sequence of SEQ ID NO:1 may comprise seven nucleotide sequences of ORFs 1 to 6 included in the iturin biosynthesis gene shown in FIG. 9 , but the present invention is not limited to such.
[0057] In a specific example, the nucleotide sequence exhibited a significant difference, compared to conventional genes responsible for iturin biosynthesis, and thereby, the present inventors found that the nucleotide sequence is the novel iturin biosynthesis gene. Among ORFs composing the iturin biosynthesis gene, antifungal activity of the transformant comprising the fragment which comprises a part of ORF 2 (ORF 2-2) and ORF 3 was the most increased. Antifungal activity of transformant comprising the fragment which comprises other ORFs was confirmed.
[0058] Therefore, the present inventors identified the novel iturin biosynthesis gene having the nucleotide sequence of SEQ ID NO:1.
[0059] Furthermore, the present invention provides a vector comprising nucleotide sequence of the iturin biosynthesis gene in accordance with the present invention.
[0060] The nucleotide sequence of iturin biosynthesis gene which is included in the vector may comprise the iturin biosynthesis gene having nucleotide sequence of SEQ ID NO:1, preferably the gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:7, the gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:3, and SEQ ID NO:8, or the gene having nucleotide sequences of SEQ ID NO:6, SEQ ID NO:7, and SEQ ID NO:8, preferably the gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:5, the gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:3, the gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:7, or the gene having nucleotide sequences of SEQ ID NO:6 and SEQ ID NO:8, and more preferably, the gene having nucleotide sequence of SEQ ID NO:6, or the iturin biosynthesis gene having 95% or more sequence identity to the gene having nucleotide sequence of SEQ ID NO:6. But, the present invention is not limited to such.
[0061] The present invention also provides a transformant transformed with the vector comprising nucleotide sequence of the iturin biosynthesis gene in accordance with the present invention.
[0062] Furthermore, the present invention provides iturin protein produced by the transformant in accordance with the present invention.
[0063] Bacillus subtilis, Saccharomyces cerevisiae , and Bacillus amyloliquefaciens may be used for the transformant, but the present invention is not limited to such. In addition, methods for introducing the recombinant vector into the strain may be heat-shock method, electroporation method, and preferably Spizizen method, but they are not limited to such. Known techniques may be used for introduction.
[0064] In the iturin protein encoded by the iturin biosynthesis gene in accordance with the present invention, iturin proteins may be encoded by the vector comprising the gene or the transformant, but the present invention is not limited to such.
[0065] In a specific example, it was confirmed that antifungal activity of the strain which was transformed with the vector comprising nucleotide sequences in accordance with the present invention was increased. Therefore, culture broth of the transformed strain may be used as a biological control agent and such transformant itself may be efficiently used as a biological control agent. By using the transformant itself, it may be possible to reduce processes, transportation, and storage that are required for obtainment of iturin proteins.
[0066] The present invention also provides a biological control agent comprising the transformant producing the iturin in accordance with the present invention or its culture broth.
[0067] Furthermore, the present invention provides the transformant of the present invention or its culture broth for use as a biological control agent, or the iturin protein produced by the transformant of the present invention for use as a biological control agent.
[0068] The iturin protein, the transformant producing iturin protein, and its culture broth in accordance with the present invention may have control effect against rice blast pathogen Magnaporthe grisea , wilt pathogen Fusarium oxysporum , gray mold rot pathogen Botrytis cinerea , barley powdery mildew pathogen Erysiphe graminis f. sp. hordei , tomato leaf mold pathogen Fulvia fulva , anthracnose pathogen Colletotrichum gloeosporioides , Ginseng root rot pathogen Cylindrocarpon destructans , the pathogen of damping-off of ginseng Rhizoctonia solani , the pathogen of Alternaria leaf spot of green onions Alternaria porri , the pathogen of Alternaria leaf spot of apples Alternaria mali , the pathogen of Alternaria blight of ginseng Alternaria panax , the pathogen of damping-off of ginseng Pythium sp. or Salmonella typhimurium , and preferably against rice blast pathogen Magnaporthe grisea and wilt pathogen Fusarium oxysporum , but the present invention is not limited to such.
[0069] In a specific example, the present inventors transformed B. subtilis subsp. krictiensis with the fragments of cosmid clones and observed antifungal activity against Fusarium oxysporum . As a result, the present inventors observed that the pBT6 fragment-transformed B. subtilis subsp. krictiensis showed remarkably increased antifungal activity, compared to untransformed control B. subtilis subsp. krictiensis.
[0070] Therefore, the iturin protein encoded by novel iturin biosynthesis genes identified in the present invention, the transformant producing thereof, and culture broth thereof may be used effectively as biological control agents.
[0071] As stated above, through gene cloning, base sequence determination, and antifungal activity examination, the present inventors identified iturin biosynthesis genes from B. subtilis strain producing six kinds of iturins described in the present invention. In addition, through mutants and instrumental analyses, the present inventors reconfirmed that metabolites are iturins and confirmed that the genes are novel genes which are different from the genes reported up to date. Based on these, it is considered that with the use of iturin biosynthesis genes, strains may be modified to antifungal activity-enhanced strains to use as a biological control agent. On the other hand, it is considered that the gene may be transformed into bacteria showing other biological control activities, and thus, be applied to novel strain development.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0073] FIG. 1 is an electrophoresis photo for verifying PCR products obtained from B. subtilis subsp. krictiensis ATCC 55079 and B. subtilis 168 strain:
[0074] Lane 1:1 kb ladder;
[0075] Lane 2: PCR products obtained from B. subtilis 168 strain by using SrfB7 and SrfB8 primers (products of surfactin gene);
[0076] Lane 3: PCR products obtained from B. subtilis subsp. krictiensis strain by using SrfB7 and SrfBB primers (products of putative iturin gene);
[0077] Lane 4: PCR products obtained from B. subtilis 168 strain by using SrfB9 and SrfB10 primers (products of surfactin gene); and
[0078] Lane 5: PCR products obtained from B. subtilis subsp. krictiensis strain by using SrfB9 and SrfB10 primers (products of putative iturin gene).
[0079] FIG. 2 is a figure showing comparative analysis of the amino acid sequence obtained from B. subtilis subsp. krictiensis strain by using SrfB9 and SrfB10 primers with the amino acid sequence of surfactin biosynthesis gene and the amino acid sequence of lichenysin biosynthesis gene using CLUSTAL W:
[0080] 1: amino acid sequence of the PCR product obtained from B. subtilis subsp. krictiensis strain by using SrfB9 and SrfB10 primers (amino acid sequence of product of putative iturin gene);
[0081] 2, 3, 4: amino acid sequence of three different domains of the surfactin biosynthesis gene; and
[0082] 5: amino acid sequence of the lichenysin biosynthesis gene.
[0083] FIG. 3 is a figure showing nucleotide and peptide sequences of 0.4 kb PCR product obtained from B. subtilis subsp. krictiensis strain by using SrfA5 and SrfA6 primers.
[0084] FIG. 4 is a figure showing comparative analysis of the amino acid sequence of PCR product obtained from B. subtilis subsp. krictiensis strain by using SrfA5 and SrfA6 primers with amino acid sequences of other strains using CLUSTAL W:
[0085] 1: amino acid sequence of an acyl carrier protein reductase of Cuphea lanceolata plant;
[0086] 2: amino acid sequence of an acyl carrier protein reductase of Bacillus subtilis strain;
[0087] 3: amino acid sequence of an acyl carrier protein reductase of Salmonella typhimurium strain;
[0088] 4: amino acid sequence of an acyl carrier protein reductase of Deinococcus radiodurans strain; and
[0089] 5: amino acid sequence of PCR product obtained from B. subtilis subsp. krictiensis strain using SrfA5 and SrfA6 primers.
[0090] FIG. 5 is a figure showing the result of genomic library screening of B. subtilis subsp. krictiensis:
[0091] FIG. 5A is a figure showing the result of colony hybridization;
[0092] FIG. 5B is the result of agarose electrophoresis after digesting the DNAs of cosmid clones obtained by colony hybridization with EcoRI; and
[0093] FIG. 5C is a figure showing the result of Southern hybridization, in which two clones exhibited homology with radioisotope-labeled probe DNA.
[0094] FIG. 6 is a restriction enzyme map of cosmid clones obtained by genomic library screening.
[0095] FIG. 7A to FIG. 7F are figures showing the results of hybridization at 65° C. of EcoRI-digested fragments of pJJ815 and pJJ121 clones obtained by genomic library screening from B. subtilis subsp. krictiensis and B. subtilis 168 strain:
[0096] Lane 1: lambda DNA digested with HindIII;
[0097] Lane 2: genomic DNA of B. subtilis subsp. krictiensis;
[0098] Lane 3: genomic DNA of B. subtilis 168; and
[0099] Lane 4: probe DNA.
[0100] FIG. 8A to FIG. 5F are figures showing the results of hybridization at 50° C. of EcoRI-digested fragments of pJJ815 and pJJ121 clones obtained by genomic library screening from B. subtilis subsp. krictiensis and B. subtilis 168:
[0101] Lane 1: lambda DNA digested with HindIII;
[0102] Lane 2: genomic DNA of B. subtilis subsp. krictiensis;
[0103] Lane 3: genomic DNA of B. subtilis 168; and
[0104] Lane 4: probe DNA.
[0105] FIG. 9 shows genetic organization of iturin biosynthesis gene obtained by genomic library screening from B. subtilis subsp. krictiensis strain:
[0106] ORF1: transcriptional regulator;
[0107] ORF2-1: Itu A-1;
[0108] ORF2-2: Itu A-2;
[0109] ORF3: Itu B;
[0110] ORF4: Itu C;
[0111] ORF5: Itu D; and
[0112] OFR6: asparate transaminase-like protein.
[0113] FIG. 10 is a figure showing comparison of antifungal activity of standard compounds, iturin and surfactin.
[0114] FIG. 11 is a figure showing comparison of antifungal activity of B. subtilis subsp. krictiensis, B. subtilis 168, B. subtilis JH642, and B. subtilis C9 against three kinds of test microorganisms:
[0115] Wild type: B. subtilis subsp. krictiensis producing iturin;
[0116] B. subtilis 168: B. subtilis strain having surfactin gene but not producing surfactin;
[0117] B. subtilis JH642: B. subtilis strain producing neither iturin nor surfactin; and
[0118] B. subtilis C9: putative B. subtilis strain producing both surfactin and iturin.
[0119] FIG. 12 shows EcoRI fragments of cosmid clones and construction of the vector comprising the fragments.
[0120] FIG. 13 is a figure showing comparison of antifungal activity of B. subtilis subsp. krictiensis transformants containing various EcoRI fragments derived from cosmid clones:
[0121] 1: pBT1 fragments; fragments of cosmid pJJ121 digested with SmaI and EcoRI
[0122] 2: pBT3 fragments; EcoRI fragments of cosmid pJJ815
[0123] 3: pBT6 fragments; EcoRI fragments of cosmid pJJ121
[0124] 4: untransformed B. subtilis subsp. krictiensis strain.
[0125] FIG. 14 is a schematic diagram of construction of a vector for preparing an iturin-less mutant.
[0126] FIG. 15 is a figure showing comparison of antifungal activity of B. subtilis subsp. krictiensis producing iturin and the iturin-less mutant against Fusarium oxysporum.
[0127] FIG. 16 shows the result of Southern hybridization for examining whether spectinomycin which was inserted within the mutant was inserted into chromosomes or not:
[0128] Lane 1:1 kb ladder;
[0129] Lane 2: fragments of genomic DNA of B, subtilis subsp. krictiensis strain digested with ClaI;
[0130] Lane 3: fragments of genomic DNA of B. subtilis subsp. krictiensis mutant-10 strain digested with ClaI; and
[0131] Lane 4: p121E3 vector digested with BamHI and XbaI.
[0132] FIG. 17 is a HPLC chromatogram for examining whether iturin was produced or not from B. subtilis subsp. krictiensis and the iturin-less mutant.
[0133] FIG. 18 is HPLC chromatograms for analyzing six kinds of iturins produced by B. subtilis subsp. krictiensis:
[0134] A: Iturin A;
[0135] B: Iturin B;
[0136] C: Iturin C;
[0137] D: Iturin D;
[0138] E: Iturin E; and
[0139] F: Iturin F.
[0140] FIG. 19 shows the result of LC-Mass analysis for examining whether iturin A, B, and C among six iturins were produced from B. subtilis subsp. krictiensis.
[0141] FIG. 20 shows the result of LC-Mass analysis for examining whether iturin D, E, and F among six iturins were produced from B. subtilis subsp. krictiensis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0142] Hereinafter, the present invention will be described in more detail with reference to examples.
[0143] However, the following examples and experimental examples are provided for illustrative purposes only, and the scope of the present invention is not limited thereto.
Example 1
[0144] Culture of Bacillus Strains
[0145] B. subtilis subsp. krictiensis ATCC 55079 was a strain isolated by the present inventors, and the strain was described in U.S. patent. The strain was also deposited in American Type Culture Collection (ATCC). B. subtilis 168, B. subtilis JH642, and B. subtilis C9 used in examples of the present invention were provided from Bio-Chemical Research Center at Korea Research Institute of Bioscience and Biotechnology.
[0146] Bacillus subtilis and E. coli were cultured in an LB medium (Bacto-tryptone 10 g, Bacto-yeast extract 5 g, sodium chloride 10 g/L). For a medium of Bacillus subtilis strains for producing active materials, a complex medium (sucrose 30 g, soytone 10 g, yeast extract 5 g, K 2 HPO 4 0.5 g, MgSO 4 2 g, MnCl 2 4 mg, CaCl 2 5 mg, FeSO 4 .7H 2 O 25 mg, pH 7.0/L) was used.
[0147] For transformation, Spizizen's medium (50% glucose 10 mL, 2% casein hydrolysate 10 mL, 10% yeast extract 10 mL, 1 M MgCl 2 2.25 mL, KH 2 PO 4 6 g, K 2 HPO 4 14 g, (NH 4 ) 2 SO 4 2 g, Sodium citrate 1 g, MgSO 4 0.2 g/L) was used.
Example 2
[0148] Construction of Genomic Library of B. subtilis Subsp. krictiensis
[0149] <2-1> Extraction of Chromosomal DNA from B. subtilis subsp. krictiensis
[0150] Since surfactin and iturin, which are cyclic lipopeptide antibiotics, are similar in molecular weights and different from each other only in amino acid composition and sequences, and surfactin gene is as large enough to be 32 kb in size, the present inventors thought that the size of iturin gene is similar to that of surfactin gene, and assumed that these two antibiotics are synthesized using the same biosynthetic pathway up to some steps, and then, from the established step, two antibiotics are synthesized using different biosynthetic pathways.
[0000]
[0151] Especially, cyclization of peptides and acylation process of connecting peptides and fatty acids during the biosynthetic process of two antibiotics are assumed to utilize the same pathway for biosynthesis of surfactin and iturin. Various kinds of primers were designed from nucleotide sequence of B. subtilis 168 which is known to produce surfactin, and PCR was conducted. By conducting PCR with the chromosomal DNAs of B. subtilis 168 strain and B. subtilis subsp. krictiensis strain as the template, a 1.8 kb PCR product which was produced from both two strains was obtained. The sequence of the gene product was determined and whether the gene product is associated with a peptide synthetase or not was examined. Then, the present inventors tried to clone iturin biosynthetic genes by colony hybridization and Southern hybridization.
[0152] First, in order to extract DNAs from B. subtilis subsp. krictiensis and B. subtilis 168, each single colony of two strains was inoculated into 250 mL of LB medium, and cultured at 30° C., 250 rpm, until late logarithmic phase (A 600nm =1.0-2.0), and then centrifuged (8,000×g, 10 min, RT). The pellets were washed with 100 mL of lysis buffer [100 mM Tris-HCl, 1 mM EDTA, 10% SDS, pH 8.0] and suspended into 40 mL of lysis buffer. 100 mg of lysozyme was added thereto, and stationary culture was performed for 10 min. After stationary culture, 3 mL of 20% SDS was added thereto, and culture was performed for min. Then, 40 mL of TE-saturated phenol was added and mixed. A DNA layer was separated by centrifugation (10,000×g, 10 min, 4° C.). The DNA layer was extracted with phenol/chloroform and was isolated. 0.1 volume of 3 M sodium acetate (pH 5.2) and 2.5 volume of cooled ethanol were added to precipitate DNAs. DNAs were washed with 70% ethanol and air-dried to obtain DNA pellets. The obtained DNA pellets were dissolved in TE buffer.
[0153] <2-2> Partial Digestion
[0154] In order to determine the partial digestion condition, 10 μg of isolated DNA and buffer solution were mixed and adjusted to 150 μL, and then, 15 μL aliquots were dispensed into nine eppendorf tubes, and a 30 μL aliquot was dispensed into No. 1 tube and allowed to stand in ice. 4 unit of restriction enzyme was added to No. 1 tube and mixed well, and then, a 15 μL aliquot was transferred into No. 2 tube and mixed well. Again, a 15 μL aliquot was sequentially transferred and mixed well into each tube until No. 8 tube. No. 9 tube was used as untreated. No. 1 to No. 8 tubes were cultured at 30° C. for 1 hr, and the reaction was stopped by adding EDTA to a final concentration of 20 mM. 3 μL of gel-loading dye was added to each tube and the amount of Sau3A to obtain 20 to 30 kb DNA was determined by performing electrophoresis on 0.5% agarose gel. The cosmid vector pLAFR3 was digested with BamHI and treated with phosphatase.
[0155] <2-3> Construction of Genomic Library of B. subtilis subsp. krictiensis in E. coli
[0156] To clone the iturin biosynthetic gene from genomic library of B. subtilis subsp. krictiensis strain, the chromosomal DNA of B. subtilis subsp. krictiensis strain extracted in Example <2-1> was partially digested with Sau3A. Then, 20 to 30 kb DNA fragments were inserted into cosmid vector pLAFR3 (obtained from Department of Applied Biology and Chemistry, College of Agriculture and Life Science, Seoul National University). E. coli HB101 was transformed with the DNA fragment-inserted cosmid vector pLAFR3 to construct the genomic library.
Example 3
[0157] Screening of Iturin Biosynthesis Gene from B. subtilis subsp. krictiensis
[0158] <3-1> Preparation of DNA Probe
[0159] Since iturin and surfactin genes are similar in their molecular weights, and their seven peptides form a cyclic ring, and it was reported that the size of surfactin gene is as large enough to be 32 kb in size, the present inventors assumed that iturin biosynthesis gene is equal to surfactin gene in size. Since some B. subtilis strains are reported that produce both iturin and surfactin, cyclization of peptides and acylation process of connecting fatty acids are assumed to utilize the same pathway for biosynthesis, considering each gene size. On the basis of these assumptions, primers were prepared using DNA base sequence information of surfactin gene. PCR with primer pair for surfactin gene were conducted using the genomic DNAs obtained in Example <2-1> from B. subtilis 168 having surfactin gene and B. subtilis subsp. krictiensis producing iturin as the template. PCR condition was 30 cycles at 94° C. for 30 sec, 50° C. for 30 sec, 72° C. for 60 sec; and 72° C. for 5 min. The used primers are as follows:
[0000]
SrfA1 (SEQ ID NO: 18):
5′-CGG GAA AGC GCT GGG GAA TAA CCG C-3′;
SrfA2 (SEQ ID NO: 19):
5′-CCT TCA AAG CTT TGA ACA GGT GGT C-3′;
SrfA3 (SEQ ID NO: 20):
5′-CTC GCT TGG CGG AGA TTC CAT CAA AG-3′;
SrfA4 (SEQ ID NO: 21):
5′-GTT CTG TCT CTT CAG CAG TCA GCG AG-3′;
SrfA5 (SEQ ID NO: 22):
5′-GCG ATT GAT TAT GCG CTT GTT GAG-3′;
SrfA6 (SEQ ID NO: 23):
5′-TCG GCA CAT ACG CTG ATT GAA CTG C-3′;
SrfA7 (SEQ ID NO: 24):
5′-GGG TAA AGG ATC GCC TCA ATC GTT-3′;
SrfA8 (SEQ ID NO: 25):
5′-CGA AAT AGG CTA TCT CGC ACT CAG-3′;
SrfA9 (SEQ ID NO: 26):
5′-TTC AGA ATA GGG CTT ATC AAG CA-3′;
SrfA10 (SEQ ID NO: 27):
5′-GCT GTG TTG CCG CCT TTA TCT TTG A-3′;
SrfB1 (SEQ ID NO: 28):
5′-ATG TCT CAG ATG CAT GGA GC-3′;
SrfB2 (SEQ ID NO: 29):
5′-CTG GCA ACT AAT AGG CTG AC-3′;
SrfB3 (SEQ ID NO: 30):
5′-ATT GAA GCT TGT GCC GCC TG-3′;
SrfB4 (SEQ ID NO: 31):
5′-TCC TTT AAA GCT TTG CAC AG-3′;
SrfB5 (SEQ ID NO: 32):
5′-GAA ACA GCA GCG ATT ATG AAC GAC-3′;
SrfB6 (SEQ ID NO: 33):
5′-AGA CAT CGA GCC AGT ATT CCT CAT C-3′;
SrfB7 (SEQ ID NO: 34):
5′-ATT TCG AGC GGC CAG CTG AAC G-3′;
SrfB8 (SEQ ID NO: 35):
5′-TTT CAT CCG GCG CCG TAT AGG TTT-3′;
SrfB9 (SEQ ID NO: 36):
5′- GCA AAA TTT CCG GAC AGC GGG ATA T-3′;
and
SrfB10 (SEQ ID NO: 37):
5′- TCG ATC CGG CCG ATG TAT TCA AT-3′.
[0160] Electrophoresis of PCR products was conducted, and each gene product obtained from B. subtilis 168 and B. subtilis subsp. krictiensis was investigated. When PCR was conducted using SrfB9 and SrfB10 primer pair, about 1.8 kb of a DNA fragment, which has the same size as gene products of B. subtilis 168, derived from B. subtilis subsp. krictiensis was observed ( FIG. 1 ). The present inventors used the DNA fragment as the probe for screening the genomic library constructed in Example 2.
[0161] <3-2> Sequence Comparison Between the Screened Iturin Biosynthesis Gene and Peptide Biosynthesis Genes
[0162] Amino acid sequence of the putative probe for iturin biosynthesis gene obtained from B. subtilis subsp. krictiensis in Example <3-1> was compared to amino acid sequences of other peptide biosynthesis genes.
[0163] Amino acid sequences of surfactin and lichenysin biosynthesis genes obtained by using NCBI database were compared by using CLUSTAL W program, and as shown in FIG. 2 , the amino acid sequence obtained from B. subtilis subsp. krictiensis showed 82 to 85% homology with three different surfactin biosynthesis genes and 80% homology with the lichenysin biosynthesis gene from B. licheniformis ( FIG. 2 ).
[0164] <3-3> Screening of Genes Responsible for Acylation Process of Peptides and Fatty Acids of Iturin
[0165] To clone the genes responsible for acylation process of connecting peptides and fatty acids, PCR with 20 primers designed in Example <3-1> were performed to obtain about 0.4 kb DNA fragment. Then, nucleotide sequence for the DNA fragment was analyzed.
[0166] Nucleotide and peptide sequences of 0.4 kb PCR product obtained from B. subtilis subsp. krictiensis strain by using SrfA 5 and SrfA 6 primers were shown in FIG. 3 .
[0167] To comparatively analyze amino acids shown in FIG. 3 , the NCBI database was searched. Consequently, this gene product showed 56 to 83% homology with acyl carrier protein reductase derived from other microorganisms, and especially, it showed 83% homology with acyl carrier protein derived from other B. subtilis ( FIG. 4 ).
[0168] <3-4> Screening of Iturin Biosynthesis Genes Using Colony Hybridization
[0169] To search for iturin biosynthesis genes, colony hybridization was performed using the genomic library of B. subtilis subsp. krictiensis constructed in Example <2-3>.
[0170] To use the 1.8 kb DNA fragment obtained from B. subtilis subsp. krictiensis in Example <3-1> as a probe for colony hybridization, the 1.8 kb DNA fragment was boiled at 100° C. for min for denaturation and cooled rapidly in ice. Reaction solution was prepared with 5 μL of a labeling buffer (5×), 2 μL of dNTP mixed solution, 7 μL of denatured DNA template, 2 μL of BSA (10 mg/mL), 5 μL of 32 P-CTP, 1 μL of Klenow enzyme, and 3 μL of D.W. and allowed to react with the 1.8 kb DNA fragment at 37° C. for 1 hr. Then, the reaction was stopped with 0.5 M EDTA. 2.5 μL of 3 N NaOH was added thereto, allowed to react again at 37° C. for 1 hr, and then, the reactant was used as a probe.
[0171] First, the genomic library of B. subtilis subsp. krictiensis constructed in <Example 2> was spread to produce 100 to 200 colonies per plate onto LB plate medium to which tetracycline was added to a final concentration of 10 μg and cultured overnight at 37° C. until the colony size becomes about 1 mm in diameter. Colonies were transferred to a nylon membrane, and the membrane was cultured in 10% SDS for 5 min, a denaturing solution [0.5 N NaOH, 1.5 M NaCl] for 5 min, and a neutralizing solution [1.5 N NaCl, 0.5 M Tris-HCl, pH 7.4] for 5 min, and then washed with 2×SSC solution [20×SSC solution was 10-fold diluted to use; 20×SSC solution consists of 0.15 M NaCl, 0.01 M sodium citrate, and 0.001 M EDTA.] and dried, and then baked in a vacuum oven at 80° C. for 1 to 2 hrs. Then, the membrane was treated with a prehydridization solution [1 mM EDTA, 250 mM Na 2 HPO 4 , 1% casein hydrolysate, 7% SDS, pH 7.4] and allowed to react at 80° C. for 2 hrs. Labeled probe mix [14 μL of template DNA, 5 μL of 5×labeling buffer solution (Promega), 1 μL of dNTP (ATP, TTP, GTP), 1 μL of Klenow enzyme, 2 μL of 32 P-dCTP] was added to the membrane and allowed to react for overnight. After reaction, the membrane was washed with washing solutions [Washing solution I: 20×SSC 10 mL, 10% SDS 1 mL, distilled water 89 mL; Washing solution II: 20×SSC 10 mL, 10% SDS 10 mL, distilled water 80 mL; Washing solution III: 20×SSC 0.5 mL, 10% SDS 1 mL, distilled water 98.5 mL], and exposed to X-ray film. Then, the exposed positive colonies were selected.
[0172] Consequently, as shown in FIG. 5A , it was observed that colonies showing homology with the DNA fragment obtained from B. subtilis subsp. krictiensis appeared ( FIG. 5A ).
[0173] <3-5> Screening of Iturin Biosynthesis Genes Using Southern Hybridization
[0174] To clone iturin biosynthesis genes from genomic library of wild type B. subtilis subsp. krictiensis , the genomic DNA of wild type B. subtilis was partially digested with Sau3A to obtain DNA fragments with various sizes. Among them, various kinds of DNA fragments with 20 to 30 kb were inserted into cosmid vector pLAFR3 to construct the genomic library in E. coli HB01. Then, the obtained various kinds of colonies were digested with EcoRI and each clone was analyzed using Southern hybridization.
[0175] As shown in FIG. 5B , clones digested with EcoRI restriction enzyme were electrophoresed on 0.7% agarose gel, and dyed with ethidium bromide, and allowed to react with Solution I [Tris-HCl 100 mM, NaCl 150 mM, pH 7.5] for 15 min, and then allowed to react with Solution II [Tris-HCl 100 mM, NaCl 150 mM, blocking reagent 0.5%, pH 7.5] for 30 min. After reaction, the gel was allowed to react with Solution III [Tris-HCl 100 mM, NaCl 100 mM/L, MgCl 2 100 mM, pH 9.5] for 30 min, and a nylon membrane was put on the gel, and DNA fragments were transferred to the membrane. The DNA fragments-transferred membrane was dried and hybridization was performed. During hybridization, the membrane was washed with a hybridization buffer solution containing no probe [1 mM EDTA, 250 mM Na 2 HPO 4 , 1% casein hydrolysate, 7% SDS, pH 7.4] for 2 hrs, and then washed twice with each solution, in order of Solution I, Solution II, and Solution III, 15 mL per each wash and solution was removed. Then, labeled probe mix [14 μL of template DNA, 5 μL of 5×labeling buffer solution (Promega), 1 μL of dNTP (ATP, TTP, GTP), 1 μL of Klenow enzyme, 2 μL of 32 P-dCTP] was added to the membrane and allowed to react for overnight. After reaction, probe DNA was removed and the membrane was dried, put on a X-ray film, allowed to stand at −70° C. for overnight, and the X-ray film was developed ( FIG. 5C ).
[0176] Consequently, as shown in FIG. 5B and FIG. 5C , it was confirmed that sequence of the DNA probe obtained from B. subtilis subsp. krictiensis existed in two lanes, and these two clones were named as pJJ815 and pJJ121, respectively.
Example 4
[0177] Construction of Restriction Enzyme Map of pJJ815 and pJJ121 Clones
[0178] Restriction enzyme map of pJJ815 and pJJ121 clones obtained in <Example 3> was constructed. When the above two clones were digested with SmaI and EcoRI, and their restriction enzyme maps were constructed, the clone pJJ121 was divided into pJJ121E2 (the part of ORF 2-2 to ORF 3, 8,020˜2,3480 bp in SEQ ID NO:1), pJJ121E3 (the part of ORF 3˜ORF 4), pJ815E4 (the part of ORF 4), pJJ815E6 (the part of ORF 4˜yczE, 29,167 bp˜32,819 bp in SEQ ID NO:1) and the clone pJJ815 was divided into pJJ121E2, pJJ121E3, pJJ815E4, pJJ815E6, pJJ815E5, pJJ815E2 (the part of yczE˜ycyA) ( FIG. 9 ).
Example 5
[0179] Southern Hybridization Using the Clones pJJ815 and pJJ121
[0180] To examine whether the cosmid clones pJJ815 and pJJ121 obtained by screening the genomic library of B. subtilis subsp. krictiensis are genes associated with iturin biosynthesis or not, the cosmid clones pJJ815 and pJJ121 were digested with EcoRI and genomic Southern hybridization was performed using B. subtilis 168 which is known to produce surfactin and B. subtilis subsp. krictiensis.
[0181] <5-1> Construction of Probes Required for Southern Hybridization
[0182] To perform genomic Southern hybridization, six fragments (pJJ121E2, pJJ121E3, pJJ815E4, pJJ815E5, pJJ815E6, and pJJ815E2) by digesting the clones with EcoRI were constructed as probes. Specifically, six fragments obtained by cloning cosmid clones pJJ121 and pJJ815 stated in Example <2-3> in E. coli HB101 and digesting with EcoRI were used as probes and each fragment was labeled with 32 P-dCTP isotope by the same method described in Example <3-4> and used for hybridization experiment.
[0183] <5-2> Southern Hybridization Reaction Depending on Temperature
[0184] Using six fragments (pJJ121E2, pJJ121E3, pJJ815E4, pJJ815E5, pJJ815E6, and pJJ815E2) prepared in Example <5-1> as probes, Southern hybridization was performed with chromosomal DNAs of B. subtilis subsp. krictiensis and B. subtilis 168. In addition, Southern hybridization was performed at 50° C. and 65° C. to examine the effect of Southern hybridization temperature on the reaction.
[0185] First, clones in which genomic DNAs of B. subtilis subsp. krictiensis and B. subtilis 168 were digested with EcoRI were electrophoresed on 0.7% agarose gel, and dyed with ethidium bromide, and allowed to react with Solution I [Tris-HCl 100 mM, NaCl 150 mM, pH 7.5] for 15 min, and then allowed to react with Solution II [Tris-HCl 100 mM, NaCl 150 mM, blocking reagent 0.5%, pH 7.5] for 30 min. After reaction, the gel was allowed to react with Solution III [Tris-HCl 100 mM, NaCl 100 mM/L, MgCl 2 100 mM, pH 9.5] for 30 min, and a nylon membrane was put on the gel, and DNA fragments were transferred to the membrane. The DNA fragments-transferred membrane was dried and hybridization was performed. During hybridization reaction, the membrane was washed with a hybridization buffer solution containing no probe [1 mM EDTA, 250 mM Na 2 HPO 4 , 1% casein hydrolysate, 7% SDS, pH 7.4] for 2 hrs, and then washed twice with each solution, in order of Solution I, Solution II, and Solution III, 15 mL per each wash and solution was removed. Then, each 32 P-dCTP isotope-labeled probe DNA was added to the membrane and allowed to react for overnight. After reaction, probe DNA was removed and the membrane was dried, put on a X-ray film, allowed to stand at −70° C. for overnight, and the X-ray film was developed.
[0186] As shown in FIG. 7 , when Southern hybridization was performed at 65° C., it was observed that the probe DNA sequences existed in B. subtilis subsp. krictiensis . However, no of six EcoRI fragments used as probes existed in the genomic DNA of B. subtilis 168 containing the surfactin biosynthesis gene ( FIG. 7 ).
[0187] In addition, when Southern hybridization was performed at 50° C., genomic DNA of B. subtilis 168 showed only weak homology for pJJ121E3 fragment probe, but it showed the same results for other fragments as in Southern hybridization at 65° C. ( FIG. 8 ). Therefore, from the results of FIG. 7 and FIG. 8 , it was concluded that temperature did not affect Southern hybridization reaction. In addition, the above results taken together, six EcoRI fragments hardly showed any similarities with the surfactin biosynthesis gene isolated from B. subtilis 168, except pJJ121E3 fragment which exhibited weak response at 50° C., whereas they showed similarities in B. subtilis subsp. krictiensis , suggesting that six fragments (pJJ121E2, pJJ121E3, pJJ815E4, pJJ815E5, pJJ815E6, and pJJ815E2) which were obtained by digesting cosmid clones pJJ815 and pJJ121 are likely to be genes responsible for iturin biosynthesis.
Example 6
[0188] Nucleotide Sequence Determination and Characterization of Iturin Biosynthesis Genes (Clones pJJ815 and pJJ121)
[0189] <6-1> Nucleotide Sequence Determination of Iturin Biosynthesis Genes (pJJ815 and pJJ121)
[0190] Bidirectional sequence was determined with EcoRI fragments cloned from the cosmid clones pJJ815 and pJJ121 to obtain 21,253 bp and to further obtain some missing gene nucleotide sequence, the present inventors obtained the genes through a genomic library screening and determined sequence to obtain a total of 37,682 bp of sequence and seven ORFs which are associated with iturin biosynthesis were found within the sequence ( FIG. 9 ).
[0191] ORF 1 includes the nucleotide sequence at positions 2868 to 3219 of SEQ ID NO:1 (SEQ ID NO:2), ORF 2-1 includes the nucleotide sequence at positions 3810 to 4353 of SEQ ID NO:1 (SEQ ID NO:4), and ORF 2-2 includes the nucleotide sequence at positions 4632 to 14559 of SEQ ID NO:1 (SEQ ID NO:5). ORF 3 includes the nucleotide sequence at positions 14583 to 25341 of SEQ ID NO:1 (SEQ ID NO:6), ORF 4 includes the nucleotide sequence at positions 25378 to 29209 of SEQ ID NO:1 (SEQ ID NO:7), ORF 5 includes the nucleotide sequence at positions 29231 to 29960 of SEQ ID NO:1 (SEQ ID NO:8), and ORF 6 includes the nucleotide sequence at positions 30084 to 31392 of SEQ ID NO:1 (SEQ ID NO:9).
[0192] <6-2> Comparison of Nucleotide Sequences Between Iturin Biosynthesis Gene ORF and Cyclic Peptide Biosynthesis Genes
[0193] Each of seven ORFs which were assumed to be responsible for iturin biosynthesis was compared with other cyclic lipopeptide biosynthetic genes.
[0194] Consequently, ORFs showed 76 to 86% similarity to surfactin genes derived from B. subtilis , but they showed 92 to 100% similarity to surfactin genes derived from B. amyloliquefaciens . Especially, ORF 2-1 (543 bp), ORF 2-2 (9,927 bp), and ORF 3 (10,757 bp) which were assumed to be directly engaged in iturin biosynthesis showed 92 to 98% similarity to surfactin genes derived from B. amyloliquefaciens , respectively (Table 1).
[0195] However, among these B. amyloliquefaciens strains, B. amyloliquefaciens FZB42 which shows 98% similarity is known that produce cyclic peptides surfactin, fengycin, and bacillomycin D (Chen, et al., Nature Biotechnol., 25: 1007-1014, 2007), but it has been reported that B. amyloliquefaciens FZB42 does not produce iturin. Accordingly, the present inventors compared homology of entire genes between B. subtilis subsp. krictiensis with B. amyloliquefaciens FZB42 (Table 2).
[0196] Consequently, when the entire gene sequences of the above two strains were compared, they showed 98% homology, however, considering the entire size of the gene, 37,682 bp, two strains showed 2% difference, that is about 753 bp or more, and especially, B. amyloliquefaciens FZB42 has already been reported not to produce iturin (J. Bacteriol., 186: 1084-1096, 2004; Nature Biotechnol., 25: 1007-1014, 2007). Therefore, there is a great difference between B. amyloliquefaciens FZB42 and B. subtilis subsp. krictiensis producing iturin.
[0197] Especially, though B. amyloliquefaciens FZB42 showed 92%, 98%, and 98% homology with ORF 2-1, ORF 2-2, and ORF-3, respectively, which are assumed to play a key role in iturin synthesis, there is a great difference in cyclic lipopeptide antibiotics produced by B. amyloliquefaciens FZB42 and B. subtilis subsp. krictiensis , suggesting that iturin and surfactin are likely to share significant part of the biosynthesis pathways (Table 2, Table 3, and Table 4).
[0198] In addition, the iturin biosynthesis genes derived from B. subtilis subsp. krictiensis showed 41% similarity with iturin A gene published in 2001 by the Japanese research team (K. Tsuge, et al., J. Bacteriol., 183: 6265-6273, 2001) and they showed 40% similarity with iturin A gene published by the German research team. Therefore, it was thought that the iturin biosynthesis genes derived from B. subtilis are likely to be novel genes (Table 5).
[0000]
TABLE 1
Max.
Identity
ORFs
Significant alignment
(%)
ORF1
(CBI41437) transcriptional regulator [ Bacillus
97
amyloliquefaciens ]
(YP01419994) transcriptional regulator [ Bacillus
96
amyloliquefaciens ]
ORF2-1
(CP00560) surfactin synthetase AA [ Bacillus
94
amyloliquefaciens ]
(FN597644) surfactin synthetase AA [ Bacillus
92
subtilis ]
ORF2-2
(CP000560) surfactin synthetases AA, AB [ Bacillus
97
amyloliquefaciens ]
(AJ575642) surfactin synthetases AA, AB [ Bacillus
97
amyloliquefaciens ]
(FN597644) surfactin synthetases AA, AB [ Bacillus
93
amyloliquefaciens ]
ORF3
(YP0141996) surfactin synthetase AB [ Bacillus
98
amyloliquefaciens ]
(CBI41439) surfactin synthetase AB [ Bacillus
95
amyloliquefaciens ]
(ZP06875171) surfactin synthetase AB [ Bacillus
76
subtilis ]
ORF4
(YP01419998) surfactin synthetase AC [ Bacillus
96
amyloliquefaciens ]
(ZP06875172) surfactin synthetase [ Bacillus
86
subtilis ]
ORF5
(AC099323) surfactin synthetase AD [ Bacillus
100
amyloliquefaciens ]
(YP0141999) surfactin synthetase AD [ Bacillus
99
amyloliquefaciens ]
ORF6
(ACX10665)aspartate transaminase-like protein
99
[ Bacillus amyloliquefaciens ]
(CAE02535) amino transferase [ Bacillus
99
amyloliquefaciens ]
[0199] The following Table 2 showed the comparative results of the entire nucleotide sequence, 37,682 bp, of the iturin biosynthesis gene and other strains including B. subtilis subsp. krictiensis , using Blast N.
[0000]
TABLE 2
Sequences producing significant alignments:
Query
Max
Accession
Description
Max score
Total score
coverage
E value
ident
Links
CP000560.1
Bacillus amyloliquefaciens FZB42, complete genome
5.353e+04
6.687e+04
99%
0.0
98%
AJ575642.1
Bacillus amyloliquefaciens yciC gene, yx01 gene, yckc gene, yckD
5.358e+04
6.485e+04
96%
0.0
98%
AF534916.1
Bacillus sp. CY22 surfactin synthetase gene cluster, partial sequenc
7969
7969
13%
0.0
97%
AF233756.1
Bacillus subtilis putative surfactin synthetase (srfC) gene, partial cd
7594
7594
12%
0.0
97%
AL009126.3
Bacillus subtilis subsp, subtilis str. 168 complete genome
6455
2.931e+04
68%
0.0
100%
AY040867.1
Bacillus subtilis strain B3 putative thioesterase (srfDB3), aspartate
6368
6368
10%
0.0
98%
X70356.1
B. subtilis srfA-sfp gene region for surfactin synthetase
6346
2.214e+04
62%
0.0
85%
D50453.1
Bacillus subtilis DNA, 25-36 degree region
6346
2.394e+04
67%
0.0
84%
X72672.1
B. subtilis ORF1, ORF2 and ORF3 for surfactin synthetases
5053
9303
44%
0.0
79%
GO931469.1
Bacillus amyloliquefaciens strain B55 Sfp gene, partial cds; Asp gen
4159
4159
6%
0.0
99%
D13262.1
Bacillus subtilis srfAA and srfAB genes for surfactin synthetase, co
4048
1.513e+04
45%
0.0
79%
GO981471.1
Bacillus amyloliquefaciens strain B76 Sfp gene, partial cds; Asp gen
3958
3958
6%
0.0
98%
A8062550.1
Bacillus subtilis sfp-8 gene for biosurfactants production protein of
2998
2998
4%
0.0
98%
X77636.1
B. subtilis putative amino acid transporter gene
2281
2281
6%
0.0
84%
GU013559.1
Bacillus sp. CS93 SrfAA gene, partial cds
2037
2037
3%
0.0
98%
FJ904932.1
Bacillus amyloliquefaciens strain C31 SrfAD (srfAD) gene, complete
1873
1873
2%
0.0
99%
AY009114.1
Bacillus subtilis YckJ (yckJ), Yckl (yckl), YczE(yczE), and phosphoo
1829
1829
4%
0.0
86%
AF520863.1
Bacillus subtilis clone Tn3 1 srfAB surfactin synthetase (srfAB) and
1482
1482
2%
0.0
98%
AF520865.1
Bacillus subtilis clone F148r SrfAA surfactin synthetase (srfAA) gene
1282
2456
4%
0.0
95%
EU382344.1
Bacillus amyloliquefaciens strain 96-79 Sfp (sfp) gene, complete cd
1184
1184
1%
0.0
98%
EU882347.1
Bacillus amyloliquefaciens strain 96-82 Sfp (sfp) gene, complete cd
1179
1179
1%
0.0
98%
D21876.1
Bacillus subtilis Ipa-14 gene encoding lipopeptide antibiotics itunin A
1175
1175
1%
0.0
98%
L17438.1
Bacillus subtilis surfactin (sfpo) gene, complete cds
1136
1136
3%
0.0
85%
FJ919233.1
Bacillus subtilis strain 916 phosphopantetheinyl transferase (Ipa-91
1134
1134
1%
0.0
97%
EU797520.1
Bacillus subtilis strain RP24 lipopetide antibiotic iturin A (Ipa-14) ge
1083
1083
1%
0.0
97%
EU797521.1
Bacillus subtilis strain mutant RP24 nonfunctional lipopeptide antibio
1059
1059
1%
0.0
95%
indicates data missing or illegible when filed
[0200] The following Table 3 showed the comparative results of the nucleotide sequence of ORF 2-1 (550 bp) of B. subtilis subsp. krictiensis and other strains, using Blast X.
[0201] The following Table 4 showed the comparative results of the nucleotide sequence of ORF 2-2 (9,940 bp) of B. subtilis subsp. krictiensis and other strains, using Blast X.
[0202] The following Table 5 showed the comparative results of the nucleotide sequence of ORE 3 (10,770 bp) of B. subtilis subsp. krictiensis and other strains, using Blast X.
Example 7
[0203] Preparation of Assay Plates
[0204] <7-1> Preparation of Plate for Magnaporthe grisea
[0205] For preparation of spore suspension, the rice blast pathogen Magnaporthe grisea was slant-cultured on a potato dextrose agar medium for 12 to 15 days, and 5 mL of distilled water was added thereto, and then spores were suspended with a Pasteur pipette, allowed to stand for an appropriate time, and the absorbance of the supernatant at 550 nm wavelength was adjusted to 1.5. The bioassay plate for Magnaporthe grisea was used an overlaid plate. First, rice leaf extract was added with 0.15% sucrose and 1.5% agar, and sterilized, and mixed with citrate phosphate buffer (pH 5.0) at a ratio of 1:1. 25 mL of the mixture was dispensed into each plate. After the dispensed medium was hardened, rice extract was added again with 0.15% sucrose and 1.5% agar, and sterilized, and mixed with citrate phosphate buffer (pH 5.0) at a ratio of 1:1, and maintained at 45° C. to make the overlaid medium. 5 mL of the prepared spore suspension was added to and mixed well with 50 mL of the sterilized overlaid medium, and then, each 5 to 10 mL of the mixture was overlaid onto the previously solidified base layer depending on the plate size to make a bioassay plate.
[0206] <7-2> Preparation of Plate for Trichophyton mentagrophytes
[0207] Mycelium slant-cultured in Sabouraud's dextrose agar medium for 10 to 14 days were used, and Sabouraud's dextrose agar was used as a basic medium for the plate for Trichophyton mentagrophytes . The fungus causing athlete's foot Trichophyton mentagrophytes was inoculated into Sabouraud's dextrose broth, shaking-cultured for 2 to 3 days, and homogenized with a sterilized waring blender. The absorbance of inoculum at 550 nm wavelength was adjusted to 1.5. 5 mL of inoculum was added to and mixed well with 50 mL of the Sabouraud's dextrose agar which was sterilized and adjusted to 50° C., and then each 5 to mL of the mixture was overlaid onto a base layer wherein Sabouraud's dextrose agar was dispensed and solidified in advance depending on the plate size to make a bioassay plate.
[0208] <7-3> Preparation of Plate for Fusarium oxysporum
[0209] Fusarium oxysporum grown on a potato dextrose agar medium was inoculated into a potato dextrose broth, shaking-cultured for 2 to 3 days, and homogenized with a sterilized waring blender. The absorbance of inoculum at 550 nm wavelength was adjusted to 1.5. 10 mL of inoculum was added to and mixed uniformly with 50 mL of the potato dextrose agar which was sterilized and adjusted to 50° C., and then each 5 to 10 mL of the mixture was overlaid onto a base layer wherein a potato dextrose agar was dispensed and solidified in advance depending on the plate size to make a bioassay plate.
Example 8
[0210] Measurement of Antifungal Activity of Bacillus
[0211] <8-1> Measurement of Antifungal Activity by Standard Compounds
[0212] To assay whether iturin is produced or not from iturin-producing strains obtained through mutation or recombination of them, it should depend on instrumental analysis, but it requires time and efforts. Accordingly, the present inventors tried to establish a simple method of examining whether iturin is produced or not in a laboratory. First, in order to compare antifungal activities between B. subtilis subsp. krictiensis producing iturin and B. subtilis 168 containing surfactin genes, the present inventors purchased standard compounds, surfactin and iturin A from Sigma Co. and Wako Co. For test microorganisms, three kinds of microorganism, the rice blast fungus Magnaporthe grisea , the fungus causing athlete's foot Trichophyton mentagrophytes , and the fungus causing wilt disease of the family Solanaceae Fusarium oxysporum were used to investigate antifungal activity of standard compounds, iturin A and surfactin.
[0213] Four different concentrations of surfactin or iturin A were prepared by two-fold serial dilution on the Magnaporthe grisea plate, Trichophyton mentagrophytes plate, and Fusarium oxysporum plate prepared in Example 7, and the range of surfactin or iturin A concentration was 1.56 to 12.56 μg/mL against the rice blast fungus, 3.12 to 25 μg/mL against the fungus causing athlete's foot, and 6.25 to 50 μg/mL against the fungus causing wilt disease of the family Solanaceae. 100 μL of each compound of four different concentrations was dispensed to sterilized cups (external diameter 6.6 mm, height 8.6 mm, stainless, Fisher Co.) placed onto the plates containing test microorganisms and the test microorganisms were cultured at 25° C. for 1 to 3 days. Growth inhibition of test microorganisms was observed to investigate antifungal activity.
[0214] Consequently, iturin A showed strong antifungal activities against Magnaporthe grisea and Trichophyton mentagrophytes , whereas surfactin showed weaker than iturin A, but slight inhibitory activities against them. There was a difference in antifungal activities between iturin A and surfactin, but there was no significant difference in antifungal spectrum. However, while iturin A showed a strong antifungal activity against the test microorganism Fusarium oxysporum , surfactin did not show antifungal activity. Two compounds showed obvious difference in antifungal activity against Fusarium oxysporum ( FIG. 10 ).
[0215] <8-2> Measurement of Antifungal Activity by the Supernatant of Culture Broth of Bacillus
[0216] Since analysis of iturin production or selection of iturin-less mutants, using wild type B. subtilis through instrumental analysis requires great time and efforts, the present inventors tried to develop a simple bioassay system using test microorganisms. First, when antifungal activity was examined using authentic iturin and surfactin, the present inventors found that only iturin showed antifungal activity against Fusarium strain. Then, the present inventors used various kinds of B. subtilis strains associated with iturin and surfactin production kept in the relevant laboratory and Bio-Chemical Research Center at Korea Research Institute of Bioscience and Biotechnology to examine antifungal activity. In order to use strains as various as possible, the present inventors collected strains that are known to produce iturin and surfactin from various researchers and in this context, B. subtilis C9 was also collected and used. Bacillus strains were liquid-cultured and their antifungal activities against three test microorganisms were investigated.
[0217] B. subtilis subsp. krictiensis producing iturin and B. subtilis JH642 producing neither iturin nor surfactin were used as control. B. subtilis 168 which has a surfactin gene but does not produce surfactin due to natural mutation of sfp gene and B. subtilis C9 which is assumed to produce both surfactin and iturin were used.
[0218] Single colonies of the above Bacillus strains grown freshly in LB agar medium were collected and inoculated into a complex medium for producing bioactive substances [sucrose 30 g, soytone 10 g, yeast extract 5 g, K 2 HPO 4 0.5 g, MgSO 4 2 g, MnCl 2 4 mg, CaCl 2 5 mg, FeSO 4 .7H 2 0 25 mg, pH 7.0, distilled water 1 L] and cultured at 30° C., 200 rpm, for 48 hr. The culture broth was centrifuged at 8,000×g, for 10 min to remove bacterial cell. 100 μL of supernatant filtered through a 0.2 μm membrane filter was added to a paper disk. The paper disks were placed on the bioassay plates prepared in <Example 7>, and cultured at 25° C. for 1 to 3 days. Growth inhibition of test microorganisms ( Magnaporthe grisea, Trichophyton mentagrophytes , and Fusarium oxysporum ) was investigated.
[0219] Consequently, as shown in FIG. 11 , B. subtilis subsp. krictiensis strain showed strong antifungal activities against all the test microorganisms, Magnaporthe grisea, Trichophyton mentagrophytes , and Fusarium oxysporum , just like the examination result of using the standard compound iturin A. However, B. subtilis JH642 and B. subtilis 168 in which sfp gene is naturally mutated did not showed antifungal activities against three test microorganisms. But, B. subtilis C9 strain showed antifungal activities against three test microorganisms. Accordingly, the present inventors assumed that the antifungal activity of B. subtilis C9 shown in the above result was due to the production of iturin, in addition to surfactin. Based on these results, the present inventors used Fusarium oxysporum as a test microorganism for selecting iturin mutants ( FIG. 11 ).
Example 9
[0220] Measurement of Antifungal Activity of Transformed B. subtilis subsp. krictiensis Mutants
[0221] <9-1> Transformation of B. subtilis subsp. krictiensis
[0222] Each of four fragments (pBT6, pBT1, pBT2 and pBT3, FIG. 12 ) which were obtained by digesting DNA fragments of cosmid clones pJJ121 and pJJ815 obtained from B. subtilis subsp. krictiensis in Example <2-2> with EcoRI and the fragment of HCE promoter of pT(II)PLK digested with NdeI were cloned into Bacillus - E. coli shuttle vector, pHPS9 (provided from Bio-Chemical Research Center at Korea Research Institute of Bioscience and Biotechnology) and introduced to B. subtilis subsp. krictiensis . The strain was spread onto a plate containing chloramphenicol antibiotic (5 μg/mL) and colonies were selected as mutant strains.
[0223] Specifically, a single colony of Bacillus subtilis subsp. krictiensis cultured freshly in LB agar medium was inoculated into 2 mL of Spizizen's medium (50% glucose 10 mL, 2% casein hydrolysate 10 mL, 10% yeast extract 10 mL, 1M MgCl 2 2.25 mL, KH 2 PO 4 6 g, K 2 HPO 4 14 g, (NH 4 ) 2 SO 4 2 g, Sodium citrate 1 g, MgSO 4 0.2 g, distilled water 1 L) and cultured at 37° C., 200 rpm, for 16 to 18 hr. Again, the inoculum was inoculated into fresh medium to achieve 1% and cultured under the same condition. When the absorbance of culture broth at 580 nm wavelength was 1.0, 0.5 mL of the culture broth and about 1 μg of DNA (pBT6, pBT1, pBT2, and pBT3) were mixed and shaking-cultured for 1 hr. After shaking culture, an aliquot of culture broth was spread onto a plate containing 5 μg/mL of chloramphenicol and incubated at 37° C. for 24 hr.
[0224] Mutants containing fragments pBT6, pBT1, pBT2 and pBT3 were named as B. subtilis subsp. krictiensis (pBT6), B. subtilis subsp. krictiensis (pBT1), B. subtilis subsp. krictiensis (pBT2) and B. subtilis subsp. krictiensis (pBT3), respectively ( FIG. 10 ).
[0225] <9-2> Measurement of Antifungal Activity of B. subtilis subsp. krictiensis
[0226] The present inventors tried to measure antifungal activities of B. subtilis subsp. krictiensis which was not transformed as control, grown freshly in LB agar medium, and B. subtilis subsp. krictiensis strains (pBT1, pBT3, and pBT6) in which fragments containing ORFs prepared in Example <8-1> were transformed.
[0227] Single colonies of B. subtilis subsp. krictiensis strains (pBT1, pBT3, and pBT6) were collected, inoculated into a complex medium for producing bioactive substances [sucrose 30 g, soytone 10 g, yeast extract 5 g, K 2 HPO 4 0.5 g, MgSO 4 2 g, MnCl 2 4 mg, CaCl 2 5 mg, FeSO 4 .7H 2 0 25 mg, pH 7.0, distilled water 1 L], and cultured at 30° C., 200 rpm, for 48 hrs. The culture medium was centrifuged at 8,000×g, for 10 min to remove bacterial cell. 100 μL of the supernatant filtered through a 0.2 μm membrane filter was added to a paper disk (thick, diameter 8 mm, Toyo Roshi Co.). The paper disks were placed on the bioassay plates prepared in <Example 7>, and incubated at 25° C. for 1 to 3 days. Growth inhibition of the test microorganism Fusarium oxysporum was investigated.
[0228] Consequently, as shown in FIG. 13 , it was observed that the antifungal activity of B. subtilis subsp. krictiensis (pBT6) containing the clone pBT6 was increased two to three-fold over untransformed control B. subtilis subsp. krictiensis . In addition, it was observed that the potency of antifungal activities of transformed strains was increased in order of pBT3, pBT1, and pBT6. These results corresponded with the above result that surfactin did not show the antifungal activity, but iturin showed the antifungal activity against Fusarium oxysporum . That is, since the antifungal activity of B. subtilis subsp. krictiensis (pBT6) was increased due to transformation of the clone pBT6, compared to control B. subtilis subsp. krictiensis , the present inventors assumed that the clone pBT6 included the iturin biosynthesis gene ( FIG. 13 ).
Example 10
[0229] Preparation of Iturin-Less Mutants and Assay of Antifungal Activity
[0230] <10-1> Preparation of Iturin-Less Mutants
[0231] In order to confirm again that iturin biosynthesis genes exist in the cosmid clone pJJ121E2, the present inventors tried to prepare an iturin-less mutant by inserting genes into the chromosome through homologous recombination using mini-Tn100. First, the clone pJJ121E2-2, in which pJJ121 fragment digested with EcoRI was inserted into the vector pBC KS(+/−) (Stratagene), was digested with EcoRI and cloned into the vector pTZ18 (Promega), and the SalI site was removed.
[0232] In addition, from the clone p121E3 ( FIG. 14 ) in which pIC333 vector was contained in a ClaI site of this vector, the spectinomycin gene-containing region was digested with BamHI and XbaI, and a ClaI site was attached thereto by PCR based on the nucleotide sequence of pTZ18 vector, and then, the fragment was digested with ClaI and the spectinomycin gene was inserted to prepare pJJ121E2-1 vector. Then, B. subtilis subsp. krictiensis strain was transformed with pJJ121E2-1 vector. Since the spectinomycin gene region containing mini-Tn100 which was inserted into B. subtilis subsp. krictiensis does not have Bacillus replication origin, cloning could not be done any more, but only gene insertion was done through homologous recombination of similar parts and host chromosome. Accordingly, chromosomal insertion mutants were selected from a spectinomycin-containing medium.
[0233] Specifically, 7,940 bp from 16,430 bp to 24,370 bp of ORF 3 was inserted in B. subtilis mutant-10, and it was thought that iturin biosynthesis did not occur since among the inserted region, spectinomycin was inserted in the ClaI site, 21,046 bp. In order to improve the efficiency of transformation, the SalI site of pJJ121E2-1 vector was digested and removed. The lost region of ORF 3 which was inserted in B. subtilis mutant-10 was the SalI-EcoRI-SalI site, as described in FIG. 14 . The EcoRI-SalI site was derived from pJJ121E2 fragment. The lost nucleotide sequences were 8.41 kb (8,020˜16,430 bp) and the SalI site (33 bp) derived from the vector, on the left of the EcoRI site, and the total size was 8.443 kb.
[0234] <10-2> Measurement of Antifungal Activity of B. subtilis Mutant-10
[0235] The mutant selected from the spectinomycin-containing medium was named as B. subtilis mutant-10. In order to examine antifungal activity, an aliquot of the culture broth of B. subtilis subsp. krictiensis or the culture broth of B. subtilis mutant-10 was loaded onto the plate for the test microorganism Fusarium oxysporum by the same method as <Example 9> for examining antifungal activities.
[0236] Consequently, B. subtilis mutant-10 which lost the function of iturin biosynthesis gene showed so weak antifungal activity to be barely detectable, whereas B. subtilis subsp. krictiensis showed strong antifungal activity. It seemed certain that the obtained gene would be an iturin biosynthesis gene and it was confirmed that the gene was directly associated with the antifungal activity exhibited by B. subtilis subsp. krictiensis ( FIG. 15 ).
[0237] <10-3> Confirmation of Spectinomycin Gene Insertion Using Southern Hybridization
[0238] In order to confirm whether the spectinomycin gene was inserted into the chromosome of B. subtilis mutant-10 prepared in Example <9-1> or not, the spectinomycin-containing fragment, which was obtained by digesting the clone p121E3 containing pIC333 vector with mini-Tn10 by BamHI and XbaI, was labeled with 32 P isotope to prepare a probe, and Southern hybridization was conducted. Genomic DNAs were extracted from B. subtilis subsp, krictiensis and B. subtilis mutant-10 and digested with ClaI. Southern hybridization was conducted using the genomic DNAs of B. subtilis subsp. krictiensis and iturin-less mutant-10 digested with ClaI and the probe wherein the spectinomycin fragment which contained the spectinomycin gene derived from the clone p121E3 by digesting with BamHI and XbaI, was labeled with isotope.
[0239] Consequently, as shown in FIG. 16 , it was confirmed that the spectinomycin gene existed in the 1.5 kb position of the fragment, in which the clone p121E3 containing the spectinomycin gene was digested with BamHI and XbaI, used as the probe. It was confirmed that the spectinomycin gene existed in the same position as the spectinomycin fragment derived from the clone p121E3 also in B. subtilis mutant-10. On the other hand, the spectinomycin gene did not exist in B. subtilis subsp. krictiensis ( FIG. 16 ). From these results, it was confirmed that the reason B. subtilis mutant-10 did not show antifungal activity in Example <10-2> was that the spectinomycin gene was inserted into the chromosome, so that iturin was not produced.
Example 11
[0240] Metabolite Analysis of B. subtilis Subsp. krictiensis and B. subtilis Mutant-10
[0241] <11-1> Metabolite Analysis by HPLC
[0242] The present inventors investigated whether there was a difference in iturin antibiotic production between the culture broth of B. subtilis subsp. krictiensis and the culture broth of B. subtilis mutant-10. The culture broth of B. subtilis subsp. krictiensis and the culture broth of B. subtilis mutant-10 were developed by thin-layer chromatography (TLC) with solvent condition of CHC 3 /MeOH/D.W.=75/25/5. Corresponding regions of each spot from the B. subtilis subsp. krictiensis and B. subtilis mutant-10 were collected and separated by high performance liquid chromatography (HPLC). Iturin production between B. subtilis subsp. krictiensis and B. subtilis mutant-10 was compared and commercially available standard compound iturin A was used as a control.
[0243] Consequently, HPLC chromatogram of B. subtilis subsp. krictiensis and HPLC chromatogram of standard compound iturin A showed considerably similar peak pattern, whereas peaks corresponding iturin A were not observed in B. subtilis mutant-10 ( FIG. 17 ). It was confirmed that the reason B. subtilis mutant-10 did not show antifungal activity against the test microorganism Fusarium oxysporum in Example <10-2> was that the spectinomycin gene was inserted into the chromosome, so that iturin was not synthesized.
[0244] <11-2> Metabolite Analysis by LC-Mass
[0245] In order to investigate whether chromatogram from B. subtilis subsp. krictiensis observed by HPLC means six kinds of iturins, iturin A to F, the molecular weight of these peaks were determined by LC-Mass. As a result of HPLC analysis, through the chromatogram, it was confirmed that six kinds of iturins, iturin A to F were produced from B. subtilis subsp. krictiensis ( FIG. 18 ). When the molecular weights of the produced iturin compounds A to F were determined as [M+Na] + using Mass spectrometry, peaks corresponding to the molecular weights of iturin A to F (A: 1043, B: 1057, C: 1057, D: 1071, E: 1071, F: 1085) were detected. From the LC-Mass result, peaks which were present in B. subtilis subsp. krictiensis , but were not present in B. subtilis mutant-10 corresponded precisely with iturins A to F ( FIG. 19 and FIG. 20 ), and thus, it was reconfirmed that B. subtilis mutant-10 did not show the antifungal activity on the bioassay plate against F. oxysporum because of the inhibition of production of iturin compounds.
[0246] The above results taken together, ORF 2-1, ORF 2-2, and ORF 3 verified in this study showed 74 to 98% similarity with surfactin genes. However, real product encoded by the genes was not surfactin but iturin, and these genes showed low similarity, 41%, with other iturin A biosynthesis genes that have been known until now. Accordingly, the iturin biosynthesis genes of B. subtilis subsp. krictiensis used in this experiment are thought to be novel genes which are different from the genes reported up to date. | The present invention relates to novel iturin biosynthesis genes, and uses thereof. More specifically, the present invention provides novel iturin biosynthesis genes, wherein the iturin biosynthesis genes were cloned from Bacillus subtilis subsp. krictiensis ATCC 55079, the base sequence was determined after checking whether the cloned genes are iturin biosynthesis genes or not, and it was ascertained that the identified genes are novel genes different from the reported gene by comparing the base sequences with that of the reported gene, and uses thereof. | 2 |
BACKGROUND OF THE INVENTION
The present invention concerns the guidance of bundles of fibrils through a part of a spin draw texturizing machine or a draw texturizing machine comprising of a texturizing unit disposed downstream from a pair of draw rolls. The texturized unit has individual texturizing nozzles incorporating a transportation portion and a texturizing portion in which the bundles of fibrils are texturized.
In a texturizing method from the European patent application EP 0 784 109 A1, a plurality of individual bundles of fibrils simultaneously are drawn on a pair of draw rolls and subsequently are texturized in a texturizing unit with a plurality of texturizing nozzles arranged side by side. In this method, it is found that the individual bundles of fibrils are guided on the pair of draw rolls spaced by smaller mutual distances than the distances required from one texturizing nozzle to the next.
As on the other hand, the design height of the machine is to be kept as low as possible in order to permit stringing up of the filament bundles. These filament bundles are sucked in at high speed by means of a so-called suction gun and transported as quickly as possible from one end of the machine to the other end. For this purpose, the distances between the individual operating units are to be kept as small as possible.
These requirements concerning the spacing distances prove particularly disadvantageous in guiding the bundles of fibrils between the supplying draw roll and the texturizing unit. As mentioned, the spacing distance from one bundle of fibrils to the next is to be kept as small as possible, whereas the distance from one texturizing nozzle to the next for various reasons, e.g. concerning lay-out dimensions, must be substantially larger. Thus, the bundles of fibrils must fan out considerably from the draw roll and must be deflected upstream from, or directly at, the inlet into each individual texturizing nozzle.
In this arrangement, the smaller spacing distance from one bundle of fibrils to the next within a group of bundles differs from the somewhat larger distance from one group to the next.
In order to maintain the group distance between the last group, second to last group, and outermost group, in spite of the fanning out of the bundles, guide elements must be provided between the individual draw rolls of a pair of draw rolls. These guide elements guide the last group of bundles of fibrils on the draw roll distanced far enough from the second to last group of bundles of fibrils that, in spite of the delivery width of the last bundles of fibrils from the roll to the texturizing unit, the distance between groups can be provided acceptably large enough that neither rolls of excessive length are required. Also, the danger does not arise that the fanned-out bundles of fibrils of the last group overlap the bundles of fibrils of the preceding group still located on the roll.
The above mentioned guide elements, be it deflecting elements arranged between the rolls or deflecting elements arranged upstream from the inlet of each individual texturizing nozzle, present the disadvantage that they inherently generate a uncontrollable extent of damage to the individual bundle of fibrils, e.g. deformations to the fibril cross-section. The extent of damage is uncontrolled in so far as the deflection, particularly the deflections upstream from the inlet to each individual texturizing nozzle, differs from one texturizing nozzle to the next. These deflections happen in such a manner that differences in the texturizing effect can be generated, which possibly will be visible in the finished product, e.g. in a carpet.
Furthermore, it is known from the Swiss patent application CH 680 140A5 that texturizing nozzles are laid out at their inlet portion. The texturizing and transporting air for taking over the bundle of fibrils is injected into these texturizing nozzles in such a manner that the air injected imparts a twist to the bundle of fibrils. This twist is propagated against the direction of transport of the bundle of fibrils up to a twist stop and is called a false twist. A false twist of this type is generated in order to impart compactness to the bundle of fibrils in such a manner that individual fibrils sticking out are better tied into the bundle in order to obtain an evening effect in the bundle of fibrils.
It has been found, however, that in case the bundles of fibrils are transferred from a draw roll directly into the inlet of the texturizing nozzle, the false twist mentioned above tends to move the individual bundles of fibrils on the roll surface corresponding to the twist direction in the axial direction of the roll. This movement happens in such a manner that a certain migration of the bundles of fibrils in axial direction occurs up to the zone of the roll surface. Owing to the tensile force in the thread on the roll surface, a contacting pressure is generated, which presses the bundles of fibrils against the roll surface in such a manner that a twist stop is formed.
If now, as mentioned already, the bundles of fibrils must be guided in a fan-type arrangement from the roll towards the individual texturizing nozzles, the twist has different effects depending on the angle position of the respective bundle of fibrils in the fan type arrangement. For example, a certain position of a bundle of fibrils can counteract the migration along the envelope line of the roll, whereas another position assists this migration further resulting in a jittery movement of the respective bundle of fibrils.
The disadvantages of the arrangement mentioned above consist in that due to the different compacting action exerted onto the individual bundles of fibrils by the twist or by the jittery movement, respectively, an uneven texturizing effect varying from one bundle of fibrils to the next may be generated. The uneven texturizing results, as mentioned before, are visible and disadvantageous differences in the finished product, e.g. in a carpet.
OBJECTS AND SUMMARY OF THE INVENTION
It thus is a principal object of the present invention to create a device to eliminate the uneven texturizing effect on different bundles of fibrils which cause visible and disadvantageous differences in finished products.
Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
Once preferred embodiment of the present invention comprises a guidance of bundles of fibrils through a part of a spin draw texturizing machine or draw texturizing machine comprising a texturizing unit arranged downstream from a pair of draw rolls with individual texturizing nozzles each with a transporting portion and a texturizing portion in which individual bundles of fibrils are texturized. The guidance of bundles of fibrils are characterized in that the bundles of fibrils each between a roll of the pair of draw rolls, from which the bundles of fibrils are delivered to the texturizing unit, and the individual texturizing nozzles are subject to a predetermined false twist directed in such a manner that the twist induces the corresponding bundle of fibrils to roll on the roll surface in the direction in which the thread tension between the roll and the corresponding texturizing nozzles increases.
In the sense of an example merely, the present invention is explained in the following with reference to illustrated design examples. It is shown in the:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A view according to the state of the art hampered by disadvantages;
FIG. 2 A side view according to the FIG. 1 seen in the direction I (FIG. 1 );
FIG. 3 A view analogous to the FIG. 1 but with an inventive arrangement and without the disadvantages according to the state of the art;
FIG. 4 An enlarged side view according to the FIG. 3 seen in the viewing direction II (FIG. 3 );
FIG. 5 An enlarged view according to the FIG. 4 with additional inventive characteristics;
FIG. 6 A variant of a detail according to the FIG. 5, shown enlarged;
FIG. 7 A part of the detail according to the FIG. 6 shown enlarged and seen in a section along the line I—I according to the FIG. 8;
FIG. 8 A cross-section of the detail according to the
FIG. 7 seen in a section along the line II—II according to the FIG. 7 .
DETAILED DESCRIPTION
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. It is intended that the present application include such modifications and variations.
In the FIG. 1 a pair of draw rolls, also called duo, is shown with the draw rolls 1 A and 1 B on which individual bundles of fibrils 6 are placed in groups 6 . 1 , 6 . 2 and 6 . 3 which, in combination with a further preceding pair of draw rolls, are drawn in a manner known as such.
In this arrangement, as shown in the FIG. 2, the groups are kept spaced by a distance A.
The bundles of fibrils of the last group 6 . 3 (FIG. 2) are deflected and guided by a lower deflecting guide element 2 provided between the draw rolls 1 A and 1 B, and by an upper deflecting guide element 3 , arranged somewhat more towards the front of the free end of the rolls 1 A and 1 B. The upper deflecting guide element also is arranged between the draw rolls 1 A and 1 B in such a manner that the last bundle of fibrils 6 . 3 on the roll 1 A is spaced by a distance B from the preceding group 6 . 2 . Distance B is larger than the distance A between the groups 6 . 1 and 6 . 2 of bundles of fibrils. For this purpose, the deflecting elements 2 and 3 each are provided with a groove for each bundle of fibrils. This precludes that bundles of fibrils of the last group 6 . 3 contact each other or even overlap at a delivery point 15 . This contact is due to the fan type arrangement implied by the much larger distance from one texturizing nozzle center to the next of the individual texturizing nozzles 8 than the distance from one bundle of fibrils to the next within the group 6 . 3 . In this arrangement, the deflecting elements 2 and 3 can be laid out as stationary elements or as rolls driven by the bundles of fibrils.
Furthermore, the delivery point is represented by an imagined straight line 15 extending parallel to the roll axle, also called envelope line, on which the bundles of fibrils pass arranged mutually parallel.
The bundles of fibrils 6 entering the texturizing unit 4 at the inlet of the texturizing unit 4 , as shown in the FIG. 2, are deflected at the inlet of each texturizing nozzle due to the fan-type arrangement of the bundles of fibrils between the delivery point 15 and the inlet into the texturizing unit 4 .
The deflection of the bundles of fibrils 6 on the lower deflecting element 2 and on the upper deflecting element 3 as well as the deflection at the inlet into the texturizing unit 4 can cause undesirable damage differing from one bundle of fibers to the next due to the friction the bundles of fibrils are subjected to. This uncontrollable variation can result in an unevenness in the finished thread.
In order to remedy this disadvantage, the individual texturizing nozzles 8 , as shown in the FIG. 4, are arranged in a fan type arrangement in such a manner that the longitudinal axis 16 of each texturizing nozzle 8 , indicated with dash-dotted lines, extends coaxially with a connecting line 17 , shown with dash-dotted lines, which extends from the delivery point 15 to the exit of each texturizing nozzle 8 . In this arrangement, the connecting lines 17 at the same time correspond to the path of the individual bundles of fibrils 6 from the delivery point 15 into the corresponding individual texturizing nozzle 8 .
Owing to this fan type arrangement of the texturizing nozzles 8 , as shown in the FIGS. 3 and 4, all deflecting elements mentioned above between the rolls 1 A and 1 B and upstream from the texturizing nozzles 8 can be dispensed with.
The texturizing nozzles 8 each supply a texturized bundle of fibrils to a cooling drum 5 allowing each into a cooling path provided for a bundle of fibrils.
The cooling drum 5 is an element known as such from the EP 0 310 890 B1 and is not described further here.
In the FIG. 4, only one half shell 4 . 1 of the texturizing unit 4 according to the FIG. 3 is shown. The other half shell 4 . 2 , as shown in the FIG. 3, is taken off in the direction III or is tilted open. This is shown here merely to facilitate the illustration of the path of the individual bundles of fibrils 6 and illustration of the individual texturizing nozzles 8 .
Texturizing units 4 , which can be tilted open, have been shown and described already in the European patent EP-0 026 360 B1 and in EP-0 039 763 B1 and are not re-described here in detail.
As shown also in the FIG. 4, the individual texturizing nozzles 8 are supplied with a transporting medium via a transporting medium distributing duct 13 by an injection pump system. The bundles of fibrils 6 by means of the transporting medium are sucked into the individual texturizing nozzles 8 and through the transporting portion 9 into the texturizing portion 10 , where the bundles of fibrils are texturized into a plug, or a texturized bundle of fibrils. From there the texturized bundles of fibrils are transferred into an individual cooling path 11 on the cooling drum 5 .
The transporting medium is fed in via a transporting medium supply duct 14 and via internal ducts (not shown) into the transporting medium distributing ducts 13 .
The present invention is not restricted to the arrangement shown of the path of the bundles of fibrils on the roll 1 A according to the FIG. 4 . In principle, the present invention concerns a guidance of the bundles of fibrils which essentially does not cause more intense deflections. According to FIG. 4, the deflection that results from the uppermost envelope line of the roll 1 A to the delivery point 15 depends on the friction between the bundles of fibrils and the surface of the roll 1 A and on the thread tension generated in the individual bundle of fibrils 6 . The thread tension is induced by the suction force of the individual texturizing nozzle 8 , and furthermore on the surface structure of the roll 1 A.
Within the scope of these variations the fan-type arrangement of the individual texturizing nozzles 8 can be varied.
In the FIG. 5, an enlarged view of the FIG. 4 is shown in which the arrows D and D 1 designate a twist direction in the individual bundles of fibrils, which are guided along the connecting line 17 from the delivery point 15 into the corresponding texturizing nozzle 8 .
As mentioned initially, the individual texturizing nozzles comprise means for generating a so-called false twist in the bundle of fibrils 6 between the inlet of the texturizing nozzle and the delivery point 15 , according to the CH 680140A5. In this arrangement, these twist imparting means are provided in such a manner that for the first three bundles of fibrils as seen from the right hand side to the left hand side in the FIG. 5, a right hand twist D (also called clockwise twist) is seen in the direction of transport of the bundles of fibrils. For the three further bundles of fibrils, as seen from the left hand side to the right hand side in the figure, a left hand twist D. 1 (also called counter-clockwise twist), is seen in the direction of transport of the bundles of fibrils is imparted.
The right hand twist of the first three bundles of fibrils tends to move the bundles of fibrils on the roll 1 A from the free end of the roll 1 A towards the supported end until the thread tension no longer permits such movement. In this manner, a stable thread position is established for these three bundles of fibrils at the delivery point 15 and thus also between the delivery point 15 and the inlet duct 20 of the corresponding texturizing nozzles 8 . This stable position of the bundles of fibrils would not be ensured for the next three bundles of fibrils, as seen from the left hand side to the right hand side in the Figure, if these three bundles of fibrils also would be subject to a right hand twist, as due to the inclined position of these bundles of fibrils in the position shown with an additional angle-compared to the direction in which the first mentioned three bundles of fibrils—a right hand twist would assist the movement of the bundles of fibrils towards the supported end of the roll 1 A due to the thread tension and due to the twist in such a manner that these bundles of fibrils would move substantially farther towards the supported end of the roll than the first three bundles of fibrils. Thus, the danger would arise that these three bundles of fibrils could overcome the distance B mentioned earlier and would collide with the neighbouring wraps of the group 6 . 2 or with themselves in such a manner that disturbances would be caused. A further disadvantage of this migration towards the supported end of the roll of the last mentioned three bundles of fibrils consists in that the adhesion of the corresponding bundle of fibrils on the roll surface tends to shift. The shift causes the corresponding tension to fall below the limit tension, allowing the bundle of fibrils to shift again to the right hand side towards the free end of the roll, which results in an oscillation of the bundles of fibrils in this inclined position. Thus, a jittery movement of the bundle of fibrils is generated.
According to the invention in the three bundles of fibrils mentioned, which are in the position with an additional angle, the twist is imparted in the opposite direction D 1 in such a manner that these bundles of fibrils owing to the twist tend to migrate towards the free end of the roll. The migration causes, firstly, the collision with neighbouring bundles of fibrils to be prevented and, secondly, a stable position of the bundles of fibrils at the delivery point 15 and between the delivery point 15 and the corresponding texturizing nozzles to be established.
These differing twist directions in the individual bundles of fibrils (D or D 1 ) can be provided using a pre-established arrangement of the feed air ducts according to CH 680 140A5 on a permanent basis. There is also the possibility, as shown in the FIG. 6, to lay out the inlet portion either of all texturizing nozzles 8 or only a portion of them, as an exchangeable element 19 . As shown in the FIGS. 7 and 8, element 19 is provided with helical (or spiral) ducts 25 , which according to the twist intensity and direction desired can be designed correspondingly. These helical ducts 25 shown in the FIGS. 7 and 8 are designed in such a manner that they impart a right hand twist D in the corresponding bundles of fibrils which pass through the inlet duct 20 of an inlet portion element. These helical ducts extend into the nozzle ducts 24 , shown already in the FIG. 5 but not designated there, and form the main guidance element, as shown in the FIG. 8, for the injected transporting and texturizing air in order to correspondingly generate the twist mentioned in the respective bundle of fibrils.
These exchangeable insert elements 19 are inserted and centered in a bore 21 in the half shell elements 4 . 1 and 4 . 2 of the nozzles and are provided in two half elements just as the nozzle half shells. Seen in the transporting direction of the bundles of fibrils, these exchangeable insert elements 19 are seated with their flange 22 on a support surface 23 in the corresponding half shell of the texturizing unit 4 . 1 and 4 . 2 .
Said half elements of the exchangeable insert elements 19 are fixed in the corresponding half shell of the texturizing unit using screws. The screws are guided in slots (not shown) in such a manner that the corresponding insert elements can be rotated somewhat, as permitted by the length of the slot, in order to change the effect of the twist.
In this arrangement, the twist can be adjusted while the bundle of fibrils is running until the position of the bundles of fibrils between the preceding roll and the texturizing unit assumes a stable position, i.e., no longer oscillates to and fro.
As the half elements of the insert element 19 are separated and fixed separately, the texturizing unit still can be opened and the respective bundles of fibrils can be inserted into the texturizing unit whereupon the two half shell elements are joined again for operation.
Depending on the shape of the helical ducts 25 and of the nozzle ducts 24 the speed of the air injected can be varied in the zone immediately downstream from the outlet mouth of the inlet duct 20 .
Owing to the possibility of varying the helical ducts 25 and the nozzle ducts 24 and owing to the possibility to design the insert element as a shiftable element, the twist imparted to the bundles of fibrils can be varied without affecting the quantities of transporting and texturizing air.
Furthermore, it is understood that twist imparting in the bundles of fibrils in one direction or in the other (D or D. 1 ) is applicable not only in the fan-type arrangement of the texturizing nozzles, but also can be applied in a parallel arrangement of the texturizing nozzles as shown in the FIG. 2 .
Also, the present invention is not restricted to the manner of twist imparting described and shown. It is possible that a twist imparting device known as such, or not known (not shown) is provided in the corresponding path downstream from the roll 1 A, which gives off the bundles of fibrils to the texturizing nozzles, as seen in the direction of the thread transport, upstream from the texturizing nozzles in order to impart a twist to the bundle of fibrils leaving the roll in a predetermined direction.
It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. It is intended that the present invention include such modificiations and variations as come within the scope of the appended claims and their equivalents. | The inventive arrangement of bundles of fibrils in a part of a spin draw texturizing or draw texturizing machine presents a fan-type arrangement of these bundles of fibrils in which preferentially the longitudinal axes of the texturizing nozzles taking up the bundles of fibrils extend coaxially with a connecting line extending from a delivery point on a draw roll to the outlet of each individual texturizing nozzle. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to the construction of pre-stressed structures from prefabricated matched concrete elements.
The invention applies in particular, but not exclusively, to bridges built by cantilevered construction with prefabricated segments having matched coupling surfaces (see for example the article: “Evolution et recents developpements des ponts a voussoirs prefabriques” (“Evolution and recent developments of bridges made of prefabricated segments”) by Jacques Mathivat, Annales de l'lnstitut Technique du Batiment et des Travaux Publics, Supplement to No. 342, September 1976, pages 21—32, or the patent application EP-A-0 462 350).
In this technique, the successively assembled elements (segments) of the bridge are manufactured one after the other, the front face of the element n serving to delimit the rear side of the manufacturing mold of the element n+1. This guarantees the matching of the adjacent faces of the elements to be assembled. These faces are glued one on the other during the placing of the element n+1 on the building site. Complementary raised parts are usually provided on these faces to facilitate their mutual positioning and to help to support the element n+1 before its definitive fixing.
These structures are frequently subjected to a longitudinal pre-stress by means of pre-stressing cables threaded in sheaths embedded in the concrete of several successive elements.
Carrying out this pre-stress is a delicate operation.
The positioning of the sheath sections in the elements must be very precise so that the pre-stressing cables can be threaded without difficulty.
To guarantee the sealing of the sheath at the interfaces between elements is the most difficult. This sealing is necessary to ensure the durability of the pre-stressing subjected to the risks of infiltrations at the level of the joint between the elements. The joint can be made according to two processes: “dry joint” when the concrete faces are placed side by side without any interface product; or “glued joint” when an interface adhesive is placed at the level of the joint. In this second case, the sealing also fulfils the necessity of avoiding the epoxy or similar adhesive placed between the elements being able to penetrate into the sheaths and hinder the introduction of the cables. On the other hand, the sheaths are generally injected with a filling product (cement grouting, grease, wax, resin, etc) serving in particular to protect the cables against corrosion. This product must not escape to the outside of the sheath during the injection.
Certain zones of the structure may have a rather large density of sheaths, and there is not the assurance that the epoxy adhesive will achieve the sealing between these sheaths. The result is the grave risk that grouting injected under pressure into the sheath may infiltrate into one or several neighboring sheaths, where the injection then becomes very difficult, or even impossible.
In general, pneumatic tests are carried out to check the sealing of the pre-stress sheaths before installing the cables and injecting the grouting. If leaks are detected between some sheaths, it is necessary to inject the grouting very carefully in a way to attempt to have a single advancing grouting front in these different sheaths. The resulting injection procedures are extremely complicated and very difficult to control.
The solutions consisting in interposing O rings around the sheaths between the interconnected faces of the elements are not reliable in terms of sealing, these seals being able to be displaced during the positioning of the element n+1.
The patent application FR-A-2 596 439 describes a connection device between pre-stress sheath sections, comprising a cylindrical sleeve engaged between the mouths of two contiguous sections to ensure the continuity of the sheath, and a resilient seal surrounding the cylindrical sleeve to carry out the sealing and to compensate for the positioning irregularities of the units and their dimensional differences.
It has also been proposed to introduce a longitudinally pleated sleeve into the sheath after the gluing, this sleeve being brought at the level of the previously assembled contact surfaces then expanded with the aid of a pneumatic device in order to be glued to the internal wall of the sheath by means of an adhesive placed at the bottom of the pleats. This method involves a very complex implementation, moreover impossible when the sheaths are not rectilinear. Moreover, it does not prevent the infiltrations of adhesive into the sheath during the assembly of the elements.
An object of the present invention is to propose a simple and efficient solution to the problems encountered when carrying out the pre-stressing of structures constructed from matched prefabricated elements.
SUMMARY OF THE INVENTION
The invention thus proposes a process of manufacturing concrete construction elements including at least first and second matched elements, the process including the steps of:
placing in a mold at least one first pre-stress sheath section having an end connected to a first sleeve applied against a wall of the mold, the first sleeve having an internal shape engaging a positioning boss placed on said wall;
pouring concrete into said mold so as to obtain the first element after setting of the concrete;
extracting from the mold the first element, one contact face of which has been shaped by said wall;
constructing a second mold one side of which consists of said contact face of the first element;
placing in the second mold at least one second pre-stress sheath section having an end connected to a second sleeve held in position relative to the first sleeve by means of a positioning joint resiliently held in at least one of the first and second sleeves;
pouring concrete into the second mold so as to obtain the second element after setting of the concrete; and
extracting the second element from the second mold, by disengaging the positioning joint from at least one of the first and second sleeves.
The positioning joint may be the same piece as the joint which will achieve the sealing between the sleeves after the definitive assembly of the elements. In this case, the joint can be left in place in one or other of the two sleeves during the storage of the elements.
The sleeves and the joint ensure a precise and correct positioning of each section of sheath in each element, as well as the good alignment of successive sections. The dimensional differences to be compensated are thus minimized.
During the assembly of two consecutive elements, the sealing joints, with which the sleeves terminating the sheath sections on the face of one of the elements are provided, engage the sleeves ending the corresponding sheath sections of the other element. This engagement provides the sealing of the sheath in relation to the adhesive, with which one of the complementary faces is generally coated. It ensures moreover the absence of communication with the outside or between neighboring sheaths during injection of the cement grouting or other filling product into the sheaths.
The sealing joint may be integral with one of the two sleeves. But it is preferably fixed in a removable manner on one of the two sleeves, for example by screwing or by resilient fitting.
In preferred embodiments, the process of manufacturing concrete construction elements according to the invention has one or other of the following features:
the positioning boss may be provided with resilient coupling means which engage with an annular groove present in the internal shape of the first sleeve in order to hold it in a removable manner in the mold;
the sleeve in which the positioning joint is resiliently held may have an angular opening of at least 30 degrees;
the positioning joint may be resiliently held in each one of the first and second sleeves;
the positioning joint may be screwed in one of the first and second sleeves;
when a feature according to one of the two previous paragraphs is provided, the positioning joint may have an orifice coaxial with the sleeves, extending therethrough, said orifice having a cross-section at least equal to the internal cross-section of the first and second sheath sections, and in this case the positioning joint is left in place in the first or the second sleeve after the extraction of the second element.
The invention is also intended for a construction work comprising an assembly of prefabricated elements of a series of elements such as defined above, the contact faces of the matched elements being applied one against the other so that the sheath sections are placed in the extension one of the other to form completed sheaths, with joints engaged in the sleeves in order to connect in a sealed manner the adjacent sheath sections, and wherein pre-stressing cables and a filling product occupy the interior of the sheaths.
Other features and advantages of the present invention will emerge in the description below of non-restrictive embodiment examples, by reference to the appended drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prefabricated segment to which the present invention can be applied;
FIG. 1A is a partial lateral view illustrating the assembly of two consecutie segments;
FIG. 2 is a section view illustrating the placing of a sheath section in a manufacturing mold of a first element;
FIG. 3 is a partial section view of the first fabricated element;
FIG. 4 is a section view illustrating the placing of a second sheath section in a fabrication mold of a second element;
FIG. 5 is a partial section view of the second fabricated element;
FIG. 6 is a section view showing two alternative embodiments of the junction means of two pre-stress sheath sections; and
FIG. 7 is a section view showing another alternative embodiment of these means.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention is described below in its application to bridges made of prefabricated segments with matched coupling surfaces.
Such a segment 1 is shown in FIG. 1 . The element 1 has the general form of a caisson delimited below by a base 2 , laterally by two symmetrically inclined walls 3 , and above by a deck 4 laterally extended beyond the walls 3 in order to define the width of the bridge.
In the longitudinal direction, the element 1 is delimited by a rear face 6 and a substantially parallel front face 7 . The rear face 6 is intended to come into contact against the front face, of complementary shape, of the previous element installed on the structure during construction (in the case of the first element installed on a bridge pier, the complementary face belongs to this pier). Likewise, the front face 7 of the element 1 is intended to receive the rear face of the next element which is to be placed.
The contact faces of complementary shapes of the adjacent elements are provided with raised parts 8 a , 8 b ensuring a good relative positioning of the elements when they are brought together. In the particular example shown in FIGS. 1 and 1A, these raised parts are located on the end faces of the lateral walls 3 of the elements, and have the shape of trapezoidal profile projections 8 a made during the molding on the front face 7 a of the element 1 a , and on the other hand by complementary trapezoidal profile recesses 8 , 8 b made during the molding on the rear face 6 , 6 b of the element 1 , 1 b.
When an assembly adhesive is used, this is for example an epoxy resin with which one or other of the two complementary faces is coated before assembly. After its placing, the element 1 , 1 b is clamped against the previous element 1 a , so that the trapezoidal profile recesses 8 , 8 b formed on its rear face 6 , 6 b engage the complementary projections 8 a of the front face 7 a of the previous element 1 a in order to support it before setting of the adhesive. After the setting of the adhesive the projecting parts take up at least partly the shearing force exerted at the level of the joint by the structure load.
The element 1 comprises a number of longitudinal sheath sections 10 , intended to receive pre-stressing cables. These cables are anchored on the structure at their ends by means of appropriate anchoring devices. Some of these anchoring devices 11 can possibly be placed on bosses 12 provided inside the caisson shape of the element. The sheath sections 10 emerge on the rear face 6 and/or on the front face 7 of the element. It is important to ensure the continuity and the sealing of each pre-stress sheath at the level of the contact faces of the adjacent elements. To do that, according to the invention, connection pieces are used (sleeves and joints) which are described below.
After placing the element, it is clamped against the previous element, at least until the setting of the assembly adhesive. This clamping can be carried out by placing certain pre-stressing cables if anchoring devices 11 orientated to the rear are provided on the element. Otherwise, or as a complement, external actuators are used to clamp the elements against each other.
Once the successive sections of a complete sheath have been assembled, the sealing of this sheath is verified by means of a pneumatic device. It is then possible to thread the strands of the pre-stressing cable into the sheath, to tension them, to anchor them at their ends, then to inject a filling product such as a cement grout into the sheath in order to fill in the voids and protect the cables against corrosion.
The successive elements 1 are prefabricated in molded concrete. FIGS. 2 to 5 illustrate the prefabrication of two consecutive elements 1 a , 1 b.
To fabricate the first element 1 a , a mold having the required shape is used. On the front side of the element, the mold is delimited by a metal wall 15 (FIG. 2) of general plane shape, having recesses complementary to the projections 8 a in the specified places.
Positioning bosses 16 are fixed on the internal side of the wall 15 , for example by welding. These bosses 16 , of general cylindrical shape, serve to install the sheath sections 10 a of the first element 1 a in the mold.
The front end of each sheath section 10 a is engaged in a sleeve 18 a up to an internal stop 19 a provided in this sleeve. The sealing between the sheath section 10 a and the sleeve 18 a is conventionally carried out by means of a thermo-retractable sheath or by an adhesive tape 20 .
The sleeve 18 a is in a material sufficiently rigid so as not to deform when the concrete is poured into the mold, for example a plastic material such as a high density polyethylene.
Beyond the stop 19 a , the sleeve 18 a has a widened portion 21 a with a shape adapted to engage on the positioning boss 16 . The sleeve 18 a connected to the sheath section 10 a is engaged on the boss 16 by an operator. The sleeve 18 a is thus positioned with precision against the wall 15 of the mold, and held in this place by resilient anchoring means provided on the positioning boss 16 . These means can include a resilient part 22 housed in an annular groove 23 provided in the outside of the cylindrical shape of the positioning boss 16 , and engaging with another annular groove 24 a provided in the internal shape of the widened portion 21 a of the sleeve 18 a . The part 22 consists for example of a flat coiled spring being able to be flattened when it is compressed radially.
Once the different sheath sections 10 a of the element 1 a have been installed in that way, the concrete is poured into the mold. After its setting, the element 1 a can be extracted from the mold, the wall 15 being withdrawn by pulling out the positioning bosses 16 from the sleeves 18 a . This wall 15 releases the front face 7 a of the element. The front end 25 a of the sleeve 18 a , which was applied against the wall 15 , is in the plane of the front face 7 a . The constitution of the element 1 a near the front end of a sheath section 10 a is shown in FIG. 3 .
The front face 7 a of the element 1 a serves to delimit the rear side of the fabrication mold of the following element 1 b (FIG. 4 ).
To mount the sheath sections 10 b of the element 1 b , a positioning joint is engaged in the widened portion 21 a of each sleeve 18 a appearing on the front face 7 a of the first element 1 a.
This joint 30 can be made in a material more flexible than the sleeve 18 a , for example in a low density polyethylene having a modulus of elasticity of the order of 500 N/mm 2 .
A rear part of the joint 30 has an external shape corresponding to the internal shape of the widened portion 21 a of the sleeve 18 a , with in particular an annular ridge 31 complementary to the annular groove 24 a of the sleeve 18 a . This rear part of the joint 30 is pushed into the widened portion 21 a of the sleeve 18 a , where it is held in place by the engagement of the ridge 31 with the annular groove 24 a.
The other (front) part of the joint 30 projects beyond the front face 7 a of the element 1 a . This front part can have an external contour of general frusto-conical shape provided with another annular ridge 32 . Preferably, this frusto-conical shape, which converges away from the element, has a half angle β less than the angle θ formed by the sides of the trapezoidal profile of the raised parts 8 a , 8 b with the perpendicular direction of the end surfaces 7 a , 6 b , which ensures that the part 30 is not damaged during handling of the element 1 b.
Each sheath section 10 b of the second element 1 b is engaged in another sleeve 18 b up to an internal stop 19 b , with a thermo-retractable sheath or an adhesive tape 20 to ensure the sealing between the sheath and the sleeve. Away from the sheath section 10 b , the sleeve 18 b has a widened portion 21 b the internal shape of which is complementary to the external shape of the front projecting part of the positioning joint 30 . In particular, this widened portion 21 b has an internal annular groove 24 b which engages with the annular ridge 32 of the positioning joint to hold the sleeve 18 b in place against the sleeve 18 a in the fabrication mold of the second element (FIG. 4 ).
Once all the sheath sections 10 b of the second element have been placed in the mold by means of the joints 30 and the sleeves 18 b , the concrete is poured into this mold to make the second element. After setting of the concrete and extraction from the mold, by pulling out the joints 30 away from the widened portions 21 b of the sleeves 18 b , the second element 1 b has the configuration shown in FIG. 5 near the rear end of the sheath section 10 b , the sleeve 18 b having its rear end 25 b in the plane of the rear face 6 b of the element.
The fact that the positioning joint 30 stays in place on the first element 1 a rather than on the second element 1 b results from the angular opening of the widened portion 21 b of the sleeve 18 b , which is larger than the angular opening of the widened portion 21 a of the other sleeve 18 a.
The positioning joint 30 staying on the first element 1 a will serve as a sealing joint between the corresponding sheath sections 10 a , 10 b during the assembly of the elements on the building site. This joint 30 is thus provided with an orifice coaxial with the sheath sections 10 a , 10 b , the cross-section of which is preferably at least equal to the internal cross-section of these sheath sections. Because of its external shape complementary to the housing defined between the widened portions 21 a , 21 b of the sleeves, of the relative elasticity of its material and of its constant and relatively small thickness, the joint 30 is subjected to a certain radial compression which ensures the sealing of the sheath at the level of the interface between the elements 1 a , 1 b.
The angular opening of the widened portion 21 b of the sleeve 18 b , which corresponds substantially to the angle 2 β of the front frusto-conical part of the joint 30 is preferably greater than 30 degrees. Because of this arrangement, the joint 30 can easily penetrate into its housing when the second element 1 b is brought to the first element 1 a.
If the front projecting part of the joint 30 is damaged during the storage of the elements, this joint 30 can be pulled from the sleeve 18 a in which it is resiliently held, and replaced by another joint.
Alternatively, the positioning joint 30 used during the prefabrication of the elements 1 a , 1 b could be separate from the sealing joint installed for the definitive assembly of the elements, provided that the joint 30 correctly positions the sleeve 18 b in the fabrication mold of the second element.
In another alternative embodiment, the positioning and sealing joint could be integral with one of the two sleeves. For example, the first element could be fabricated in the way illustrated by reference to FIGS. 2 and 3 (but preferably with sleeves 18 a the widened portion 21 a of which would have a greater angular opening), and the second sleeves joined to the rear ends of the sheath sections 10 b could be extended by a more flexible rear part the external contour of which would be complementary to the internal shape of the widened portion 21 . In order for this rear part to be made more flexible, its thickness can be reduced relative to the rest of the sleeve, and/or this sleeve can be made from two materials having different moduli of elasticity. With such an embodiment, the number of required pieces to achieve the sealing is minimized.
In other embodiments (FIG. 6 ), the positioning and/or sealing joint is screwed into one or other of the two sleeves.
In the embodiment illustrated in FIG. 6, the positioning and sealing joint 50 has a cylindrical rear part engaged in the sleeve 38 a to which is connected the sheath section 10 a of the first element, and a frusto-conical front part provided with an external annular ridge 52 . Between these two parts, the joint 50 has a transverse shoulder 54 which abuts against the front end 45 a of the sleeve 38 a and against the front face of the first element. The cylindrical part of the joint 50 is provided with a female thread 53 complementary to a male thread 46 a provided inside the sleeve 18 a . In this way, the joint 50 can be screwed into the first sleeve 38 a , the threads contributing to the sealing.
In the frusto-conical part of the joint 50 , the sealing results from the engagement of the ridge 52 in the groove 44 b provided inside the widened portion 41 b of the second sleeve 38 b.
In the example shown in the lower part of FIG. 6, the sealing is enhanced by the fact that the two ends of the joint 50 have thinned lips 55 a , 55 b which bend resiliently inwards when the joint 50 is installed in the sleeves 38 a , 38 b . This bending can be caused by curved internal surfaces provided in the sleeves 38 a , 38 b , at the back of the stops 39 a , 39 b receiving respectively the ends of the sheath sections.
In the alternative embodiment shown in the upper part of FIG. 6, an annular housing 47 a , 47 b , open to the front side, is provided in the internal shape of the sleeve 38 a , 38 b , at the back of the stop 39 a , 39 b . The two ends of the positioning and sealing joint then compress flat sealing joints 48 a , 48 b , placed in the housing 47 a , 47 b.
In the embodiment illustrated by FIG. 7, the two sleeves 58 a , 58 b are parts having the same shape:
a cylindrical part 59 to receive the end of the sheath sections 10 a , 10 b ;
an internal shoulder 60 at the end of the cylindrical portion 59 , against which abuts the end of the sheath section;
a constriction 61 to fasten the sleeve to the positioning boss 16 on the wall 15 delimiting the front side of the mold, the coil spring 22 of the boss 16 engaging in the annular groove formed behind the constriction 61 ;
a frusto-conical part 62 widening outwards and extending from the constriction 61 to the front end of the sleeve 58 a , 58 b;
in the frusto-conical part 62 , a cylindrical recess 63 provided with an internal threading 64 towards the front end of the sleeve, and with an annular groove 65 , and the bottom of which comprises an annular rim 66 directed towards the front end.
The positioning and sealing joint 70 has a general shape complementary to that of the frusto-conical parts 62 and the cylindrical recesses 63 of the two opposite sleeves, with a central cylindrical bore having approximately the internal section of the sheath sections. To optimize the sealing, the joint 70 is provided with a series of radial notches 71 in the frusto-conical part of its external surface which makes it more flexible, with two annular ridges 72 which engage in the corresponding grooves 65 of the two sleeves and, on its two end faces, with two respective annular grooves 73 which enable a bending of the portions having the ridges 72 so that these engage resiliently in the grooves 65 of the sleeves, and which define, towards the inside of the joint, annular lips 74 being applied in a sealed manner against the annular rims 66 of the sleeves.
On only one of its sides, the joint 70 has a threading 75 intended to be screwed in the threading 64 of one of the sleeves. This screwing is carried out on the sleeve of the element made first, after its taking from the mold. On the opposite side of the joint 70 , there is no threading 75 , in order to enable the easy assembly of the elements.
The advantage of the embodiment of FIG. 7 is its lower cost considering the identity of the two sleeves 58 a , 58 b used. | A process of manufacturing concrete construction elements is provided. A first sheath is placed in a first mold, the first sheath connected at an end to a first sleeve applied against a wall of the mold, the sleeve engaging a positioning boss placed on the wall. Concrete is poured into the first mold and set to obtain the first element. The first element is extracted from the first mold and includes a contact face shaped by the wall. A second sheath is placed in a second mold, the second mold having one side formed by the contact face. The second sheath includes an end connected to a second sleeve held in position relative to the first sleeve by a positioning joint. Concrete is poured into the second mold and set to obtain a second element. The second element is extracted from the second mold by disengaging the positioning joint. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a seat reclining mechanism for adjusting a tilting angle of a seat back for automotive seats.
In order to take a comfortable position of passenger or to permit easy entry, various types of a seat reclining mechanism for adjusting a tilting angle of a seat back for automotive seats have been proposed. One of them is disclosed in the Japanese Patent Laid Open Publication Hei 7-136032 (published on May 30, 1995). Refer to FIG. 6, this prior reclining mechanism has ratchets 100, 100 formed in an upper arm secured to a seat back frame, pawls 101, 101 slidably supported on a lower arm secured to a seat cushion frame, which engage with and disengage from the ratchets by way of its sliding motion in a radial direction, and a release member or cam member 103 rotatably supported on a rotatable shaft 104 passing through both the arms.
In this case, the rotation of the shaft 104 causes the cam member 103 to be turned in one direction and arms 105, 105 of the cam member 103 to be inserted into grooves or recesses 106, 106, respectively so that the pawls 101, 101 are slid radially inwardly and teeth formed on the pawls 101, 101 are disengaged from the ratchets 100, 100. Thus, the seat back can be tilted forwardly or rearwardly with respect to the seat cushion. In this prior art mechanism, a first engaging portion is defined by engaging notches 106, 106 formed so as to be opened toward side surfaces of the pawls 101, 101 and extending in a direction intersecting the sliding direction of the pawls 101, 101. It should be noted that the notches 106, 106 are formed to be opened toward both the flat surfaces and one side surface of the pawls 101, 101, respectively. Thus, in considering the strength of each pawl 101, it is difficult to enlarge the extension length of each first engaging portion (notch) which intersects the sliding direction of each pawl, and as a result, in consideration of the sliding amount of each pawl with respect to the ratchet, engagement of the notch (first engaging portion) and the arm (a second engaging portion) is inevitably displaced from the vicinity of the center in the width direction of the pawl 101, i.e. it starts from a position in the vicinity of the side surface of the pawl. Due to this, when the pawl is slid, looseness occurs with respect to the sliding direction of the pawl and the power which slides the pawl decreases when the first engaging portion and the second engaging portion are engaged, and as a result there is the possibility that the operating feeling of the release member deteriorates.
The other aspects of the seat reclining mechanisms are disclosed, for example, in the Japanese Utility Model Laid Open Publication Hei 1-169149 (published on Nov. 29, 1989) and U.S. Pat. No. 4,435,013.
SUMMARY OF THE INVENTION
The present invention therefore has as its object to provide a seat reclining mechanism in which engagement of a first engaging portion and a second engaging portion is performed in the vicinity of the center of a pawl in its width direction, without providing a member protruding in the thickness direction of the pawl and reducing the strength of the pawl.
The technical means conceived in the present invention for solving the above technical problems is to make an engaging groove on each pawl which opens toward one side surface of the pawl and one flat surface side in the thickness direction of the pawl.
According to the present invention, there is provided a seat reclining mechanism for vehicles comprising; an upper arm secured to a seat back frame; a lower arm secured to a seat cushion frame; a rotatable shaft for rotatably supporting the upper arm with respect to the lower arm and having a handle for rotation thereof; a cam member disposed in a space defined between both the arms and secured to the rotatable shaft; and at least one pawl disposed in the space and radially slidable in response to a rotation of the cam member; the pawl having teeth formed on an outer surface thereof and engageable with a ratchet formed on one of both the arms, a cam surface formed on an inner surface thereof, and an engaging groove formed on a flat surface thereof to be opened toward one of side surfaces and extending in the direction intersecting with the direction of the sliding movement of the pawl, further the cam member having at least one projection abutted on the cam surface of the pawl and at least one arm extending to be inserted into the engaging groove.
Preferably, the space is defined by a concave portion of the upper arm and a concave portion of the lower arm which has a circular central portion and at least one pawl receiving portion in a rectangular form and extending radially outwardly from the central portion, the pawl receiving portion having opposed side wall surfaces in slidable relation with the side surfaces of the pawl.
According to these technical means, engagement of the groove of the pawl and the arm of the cam member can be performed in the vicinity of the center in the width direction of the pawl, without providing a member protruding in the thickness direction of the pawl and reducing the strength of the pawl.
According to the present invention, the above technical problems can be solved and thereby the operational feeling of the release member can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will be better understood with reference to the following description, appended claims and accompanying drawings, wherein:
FIG. 1 is a side view of a seat on which the seat reclining mechanism of the present invention is mounted,
FIG. 2 is a plan view of the seat reclining mechanism of the present invention,
FIG. 3 is a cross section across the line 3--3 of FIG. 2,
FIG. 4 is an enlarged view corresponding to the upper half of FIG. 2 showing the pawl of the seat reclining mechanism of the present invention,
FIG. 5 is a perspective view the pawl of the seat reclining mechanism of the present invention, and
FIG. 6 is a partial view of a prior reclining mechanism.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 2 and FIG. 3, a lower arm 4 is fixed to a seat cushion 1 (shown in FIG. 1) and an upper arm 2 is fixed to a seat back 3 (shown in FIG. 1). A rotatable shaft 5 is rotatably supported on both the arms 4 and 2, but in a form passing through both the arms 4 and 2. The upper arm 2 is rotatable with respect to the lower arm 4 via a guide mechanism 6 surrounding the rotatable shaft 5. Note that the guide mechanism 6 for guiding the tilt of the upper arm 2 with respect to the lower arm 4 is formed by interlocking a protruding or convex portion 21 formed by half blanking in the upper arm 2 and an corresponding concave portion 41 formed in the lower arm 4.
At the location where the rotatable shaft 5 passes through the lower arm 4 and upper arm 2, rotatable shaft support portions 42 and 22 in the shape of a recess are formed to form a space 7 between the lower arm 4 and the upper arm 2. Also, by forming these rotatable shaft support portions 42 and 22, a ratchet 23 is formed in the upper arm 2 to be exposed to the space 7 and a pair of guide walls 43 and 44 are formed in the lower arm 4 to be exposed to the space 7 and disposed between the ratchet 23 and the rotatable shaft 5. This ratchet 23 has an arc-shaped gear portion 23a and the pair of opposed guide walls 43 and 44 extend in parallel in the radial direction. Further, a pair of stopper walls 24 and 25 are formed in the upper arm 2 by the formation of the rotation shaft support portion 22.
Pawls 8 and a cam member 9 are disposed in the space 7. Each pawl 8 has a main body portion 8d having a rectangular shape and is disposed between the guide walls 43 and 44 of the lower arm 4 so as to be slidable along the guide walls 43 and 44 in the radial direction of the rotation shaft 5 so that they contact the guide walls 43 and 44 with a predetermined gap therebetween. The main body portion includes opposite side surfaces 81a, 81a. A teeth portion 8a is formed on the surface of the main body portion 8b of the pawl 8 to face the gear portion 23a of the ratchet 23. Thus, it is engageable with and disengageable from the gear portion 23a of the ratchet 23 of the upper arm 2 in response to the sliding motion of the pawl 8. Also, a cam surface 8b having a cam shape is formed on a surface opposite to the surface formed with the gear portion 8a of the main body portion 8d of the pawl 8. The cam member 9 is supported by the rotatable shaft 5 so as to rotate integrally therewith. On the portion of the cam member 9 facing the cam surface 8b of the pawl 8, a protruding portion 9a is formed, contacting and separating from the cam surface 8b of the pawl 8 by a rotating motion of the cam member 9. The pawl 8 is slidably operated by contact between the cam surface 8b of the pawl 8 and the protruding portion 9a of the cam 9, engaging and disengaging of the gear portion 8a of the pawl 8 and gear portion 23a of the ratchet 23 are performed.
As shown in FIG. 3 and FIG. 4, the rotation shaft support portion 42 of the lower arm 4 is constructed such that the guide walls 43 and 44 intersect the gear portion 23a of the ratchet 23 of the upper arm 2 and the space 7 exists up to a location facing a protruding portion 21 of the upper arm 2 which forms the guide mechanism 6. As shown in FIGS. 3 through 5, the gear portion 8a of a pawl 8 is formed on the half of the thickness of the pawl 8, and a wall portion 81 is formed in the remaining half of the thickness. This wall portion 81 extends from a main body portion 8d such that it protrudes further beyond the gear portion 8a. The gear portion 8a of the pawl 8 and the gear portion 23a of the ratchet 23 are engageable.
As is shown in FIG. 3 and FIG. 4, in the main body portion 8d of the pawl 8, engaging groove 82 which is cam-shaped in the diametric direction is formed. At least one engaging arm 9b which is engageable with the engaging groove 82 extends in the peripheral direction, and the engaging groove 82 and the engaging arm 9b are engaged by the rotating operation of the cam member 9, and by this engagement the pawl 8 is slidably operated to release the engagement of the gear portion 8a of the pawl 8 and gear or teeth portion 23a of the ratchet 23. As shown in FIGS. 3 through 5, the engaging groove 82 is constructed such that it extends in a direction intersecting the sliding direction of the pawl 8 at approximately half of the thickness of the main body portion 8d in one surface 8c of the main body portion 8d, and opens toward one of the side surfaces 81a of the main body portion 8d. This engaging groove 82 has enough width so that the engaging arm 9b is able to intrude thereinto, and the vertical surface thereof serves as an engaging surface 82a having a cam shape engageable with the engaging arm 9b. This engaging surface 82a is set such that it begins to engage with the engaging arm 9b in the vicinity of the center in the width direction of the pawl 8. Also, in another surface 8e in the thickness direction of the main body portion 8d a wall portion 83 which serves as a wall for the engaging groove 82 is formed.
The ratchet 23, the pair of pawls 8, guide walls 43 and 44, and protruding portion 9a of the cam member 9 are disposed as one unit.
Note that a spring 11 which rotatably urges the upper arm 2 in a counterclockwise direction (in FIG. 1) with respect to the lower arm 4 is provided around the rotatable shaft 5 as shown in FIG. 1 and when a handle (in FIG. 3) is rotated manually the seat back 3 can fall forward with respect to the seat cushion 1. Also, a spring 12 which rotatably urges the rotation shaft 5 in a counterclockwise direction (in FIG. 2) with respect to the lower arm 4 is provided around the rotatable shaft 5 as shown in FIG. 3. By the urging force of the spring 12 the protruding portion 9a normally contacts the cam surface 8b of the pawl 8 and the engagement of the gear portion 23a of the ratchet 23 and the gear portion 8a of the pawl 8 is maintained.
Next, the operation of the present invention will be explained.
In FIG. 2, a set of pawls 8 is pushed radially outwardly by the contact of the cam surface 8b of the pawl 8 and the protruding portion 9a of the cam 9 and engagement of the gear portion 23a of the ratchet 23 and the gear portion 8a of the pawl 8 is performed, whereby the tilt of the upper arm 2 is restricted with respect to the lower arm 4.
In this state, by the rotating operation of the handle (in FIG. 3) against the urging force of the spring 12, the cam 9 also rotates in the clockwise direction of FIG. 2 together with the rotatable shaft 5, and by means of the rotation of the cam 9 the contact between the protruding portion 9a and the cam surface 8b is released and the engaging arms 9b intrude into the engaging groove 82, beginning to engage with the engaging surface 82a of the engaging groove 82 at an engaging point P (shown in FIG. 4) in the vicinity of the center in the width direction of each pawl 8, each pawl 8 being slid toward the rotatable shaft 5. Thereby, engagement between the teeth portion 8a of the pawl 8 and the gear portion 23a of the ratchet 23 is released, and the upper arm 2 becomes rotatable with respect to the lower arm 4. After the upper arm 2 is tilted against the urging force of the spring 11 to a desired position with respect to the lower arm 4, the rotation operation of the handle is released, whereupon the rotatable shaft 5 is rotated in the opposite direction to that described above by receiving the urging force of the spring 12, the pawl 8 is slid toward the ratchet 23, and as a result the gear portion 8a of the pawl 8 and the gear portion 23a of the ratchet 23 are re-engaged and rotation of the upper arm 2 with respect to the lower arm 4 is restricted. As a result, adjustment of the angle of inclination of the seat back 3 with respect to the seat cushion 1 is performed.
As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | A seat reclining mechanism is provided in which engagement of a first engaging portion and a second engaging portion is performed in the vicinity of the center of a pawl in its width direction, without providing a member protruding in the thickness direction of the pawl and without reducing the strength of the pawl. The first engaging portion is an engaging groove which opens toward a side surface of the pawl and extends in a direction intersecting the sliding direction of the pawl at one flat surface side in the thickness direction of the pawl. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2010 007 013.0 filed Feb. 5, 2010, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to an exhaust system, especially of a motor vehicle.
BACKGROUND OF THE INVENTION
[0003] Combustion water, which may lead to problems on the components of the exhaust system, for example, during wintertime operation, is formed during the combustion of fuels. Depending on the composition of the fuel, a volume of combustion water may be released by the combustion, which is comparable to the volume of fuel consumed. This combustion water generated is usually blown off as vapor together with the hot exhaust gases via the exhaust system during the normal medium-load operation of the motor vehicle. However, the temperature may drop below the dew point and liquid combustion water may precipitate in the wintertime as well as during the transition times close to winter. Thus, the dew point of exhaust gases of an internal combustion engine in a motor vehicle may be between about 20° C. and 60° C. Condensate may thus accumulate at such temperatures in the exhaust system. This leads in practice to the possibility of the accumulation of condensate on all components in the exhaust system that are in contact with the exhaust gas and remain below such temperatures because of the environmental conditions of the exhaust system. Most components of current exhaust systems usually reach markedly higher temperatures after a short operating time and the condensate formed can thus be evaporated after a short time and carried by the exhaust gas flowing by. However, increased accumulation of condensate, which may form a condensate sump in the exhaust system, may develop at low outside temperatures especially during operation over short distances, because the difference between the vapor pressures of a hot section of the exhaust system and of a cold section of the exhaust system leads to a constant transport and precipitation of the combustion water and the water will therefore gather at the lowest points of the exhaust system and can form a condensate sump there. Critical in such a condensate sump is the possible increase in the concentration of acid-forming components of the exhaust gas or of other exhaust gas components, which leads to a permanent corrosion burden of precisely these sections of the exhaust system, in which such an accumulation of condensate or such a condensate sump can form. A great variety of measures are therefore currently taken to reduce such a recurring corrosion burden of the exhaust system. For example, the hot exhaust gas can be allowed to flow effectively by, for example, in the last exhaust muffler at the deepest point by placing the exhaust pipe in a low position. The gathering condensate can as a result be both entrained with the flow and heated and possibly evaporated hereby.
[0004] However, if it is possible for design reasons to place the exhaust pipe in the last exhaust muffler in a lower position, one can attempt to draw off the condensate with suction tubes in the manner of a water jet pump and to remove it from the exhaust system. A choking may be additionally inserted for this at the inlet of the pipe in the main pipe in order to lower the pressure at high exhaust gas throughputs to such an extent and hence to generate such a great pressure difference between the condensate collection and the exhaust gas flowing in the exhaust pipe that the collected condensate is entrained by the flow. The drawback of this is that such measures usually only help at medium to high loads of the internal combustion engine. The accumulated condensate can be normally discharged with short accelerations, but the pressure differences developing in the process are usually insufficient for the comprehensive removal of the accumulated condensate during stop-and-go travel in city traffic or in local traffic.
[0005] It may happen without such measures that, for example, the rear muffler may fill with condensate as a consequence of the usually oblique installed position in relation to the rear of the vehicle and to the relatively highly positioned end pipe at correspondingly low outside temperatures. This leads to noise burden as a consequence of sloshing and bubbling noises in this section of the exhaust system and may lead to clogging of the exhaust system in the worst case as a consequence of the freezing of an ice plug in case of return of condensate and permafrost or correspondingly low temperatures.
[0006] The situation may be especially disadvantageous in case of newer components in the exhaust system, for example, in case of Helmholtz resonator chambers connected via pipes or in case of active volumes of active noise suppression means having loudspeakers. Exhaust gas does not obligatorily flow through such components and these are therefore heated by the exhaust gas more poorly and more slowly, but they are nevertheless exposed to the combustion water contained in the exhaust gas just as the areas of the exhaust system through which exhaust gas flows and may experience accumulation of condensate in corresponding operating states of the motor vehicle and low temperatures associated therewith. Attempts are therefore made to usually arrange such components of the exhaust system such that a gradient will always develop from the deepest point of such a component to the hot exhaust pipe, so that condensate formed can run off and it can be driven out of the exhaust system or these components as completely as possible. However, this may lead to unfavorable installation positions in the vehicle in respect to such components, but also in respect to components of the exhaust system that are connected thereto. Thus, the freedom of design of the exhaust system is limited because of the necessity to discharge accumulated condensate from the exhaust system.
SUMMARY OF THE INVENTION
[0007] The present invention pertains to the object of proposing for an exhaust system with a heating means an improved or at least different embodiment, which is characterized especially by a weaker tendency towards the development of condensate accumulations and by a greater freedom in designing the exhaust system, which is associated therewith.
[0008] The present invention is based on the general idea of equipping an exhaust system, especially of a motor vehicle, with a heating means and of positioning at least one heating device of the heating means in an area in which accumulation of condensate is possible, wherein the area in which the accumulation of condensate is possible is arranged within the exhaust system and wherein accumulation of condensate can develop in this area, in which the accumulation of condensate is possible, depending on operating states of the motor vehicle and/or environmental parameters of the exhaust system, wherein the heating device is positioned such that accumulated condensate can be heated and/or evaporated at least by such a heating device. By warming or heating such an area of the exhaust system, in which accumulation of condensate is possible, the vapor pressure ratio between the accumulated condensate and exhaust gas can be shifted in favor of the exhaust gas, so that, on the one hand, less combustion water will separate from the exhaust gas and, on the other hand, condensed water already separated can be returned into the exhaust gas by evaporation. Thus, the formation of condensate can be reduced or prevented and the effect of the condensate on the exhaust system, which is a damaging effect because of corrosion, can be reduced or eliminated by arranging one or more heating devices in the respective critical areas of the exhaust system. This advantageously leads to a prolongation of the service life of the entire exhaust system.
[0009] 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 specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIG. 1 is a schematic view of an exhaust system according to the invention;
[0012] FIG. 2 is a schematic view of an alternate embodiment of the exhaust system according to the invention;
[0013] FIG. 3 is a schematic view of an alternate embodiment of the exhaust system according to the invention;
[0014] FIG. 4 is a schematic view of an alternate embodiment of the exhaust system according to the invention;
[0015] FIG. 5 is a schematic view of an alternate embodiment of the exhaust system according to the invention; and
[0016] FIG. 6 is a schematic view of an alternate embodiment of the exhaust system according to the invention;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring to the drawings in particular, FIG. 1 schematically shows a section of an exhaust system 8 of a motor vehicle. The exhaust system 8 is shown with a flow passage, through which exhaust gas flows as indicated by arrows 4 , having a wall with an exhaust system area 10 in which condensate accumulates and in which accumulation of condensate may take place depending on operating states and/or environmental parameters. The exhaust system 8 has a higher temperature area 12 which has a temperature higher than the temperature of the area 10 in which condensate accumulates to said area in which condensate accumulates.
[0018] A heating means 20 for the exhaust system may have a plurality of heating devices 22 , which may be arranged in different positions at the exhaust system and which have different functionalities concerning the heating of the exhaust system. For example, a heating device 22 may thus be positioned in the area of a catalytic converter 6 arranged in the exhaust system, in which case such a heating device 22 is designed such that it can heat up the catalytic converter 6 to the operating temperature with respect to its catalytic effect. As was already described above, according to the invention a heating devices 22 is provided for avoiding, reducing or removing accumulated condensate.
[0019] Such condensate accumulations may develop in cold areas of the exhaust system. For example, condensate accumulations, which can flow together along the oblique surfaces to the deepest point in the exhaust system, forming a condensate sump, may thus also develop on oblique surfaces. It is consequently advantageous to heat both the areas at which accumulations of condensate can develop and those that tend to form sumps. Consequently, the heating device 22 is to be advantageously provided at precisely these areas 10 of the exhaust system. These may comprise both areas of the flow path of the exhaust gas in the exhaust system 8 and secondary areas 16 of the exhaust system, through which no exhaust gas flow, for example, components of a Helmholtz resonator in an exhaust muffler means, as well as the spaces of an active exhaust muffler exposed to sonic waves by an active actuator.
[0020] Such a heating device 22 for heating areas 10 in which condensate accumulates may be designed as a heat-conducting element, electrically heatable and/or Peltier element and/or have a memory element. Combinations of these embodiments are possible as well.
[0021] As shown in FIG. 2 , the heating device 22 may have a heating element 24 that is formed of a heat-conducting material, by means of which heat can be transmitted from a hot area 12 of the exhaust system to a cold area 10 of the exhaust system. The heating element 24 is connected for this purpose to the hot area 12 of the exhaust system and to the cold area 10 of the exhaust system. Thus, such a heat-conducting element 24 may be designed as a heat-conducting plate, a heat-conducting rod or the like.
[0022] It is equally conceivable to design the heating device as an electrically heatable heating device 26 such as a mat, wire or plate, and a design as a Peltier element is advantageous as well. Such an electrically heatable heating device 26 may be controlled by a heating device control 34 . In FIG. 3 , the a Peltier element 28 is an electrically heatable heating device. In the case of using a Peltier element 28 as the electrically heatable heating device, such a heating device can be used not only to heat the area 10 of the exhaust system in which the Peltier element is arranged, but also to cool same. This is especially beneficial in the area of the active actuator of an active exhaust muffler means, because accumulation of condensate can be reduced and/or accumulated condensate can be removed by heating the actuator area by means of the Peltier element 28 and, on the other hand, precisely this actuator can be cooled in case of rising exhaust gas temperature during running operation in order to guarantee proper function. Furthermore, such a moveable heating device 32 may be provided having a memory element 30 , for example, a bimetal strip as shown in FIG. 4 . The heating of the area 10 in which accumulation of condensate is possible is made possible at a correspondingly low temperature, whereas the mechanical thermal contact with the area 10 in which accumulation of condensate is possible is interrupted (as shown in dashed line) beginning from a predefined temperature because of the deformation of the memory element 30 such that heating of said area 10 will not take place any longer.
[0023] Any desired meaningful combinations of these above-described embodiments are also conceivable. For example, it is thus possible to provide a heat-conducting element with a memory effect or, e.g., to design it as a bimetal, so that the contact between the hot area of the exhaust system and the cold area of the exhaust system is established at a low temperature. The heat-conducting element 32 provided with only one memory effect will be deformed beginning from a certain temperature, as a result of which the contact between the heat-conducting element and the cold or hot area of the exhaust system is interrupted. The heat conduction is thus very extensively interrupted and the further introduction of heat from the hot area of the exhaust system into the cold area of the exhaust system is suppressed. This combination of a memory element 30 is also analogously conceivable in an electrically heatable heating device 26 or the like.
[0024] Such a heating device 22 may be arranged at the exhaust system 8 on the inside and/or on the outside and/or such that it passes through the walls of the exhaust system. For example, as shown in FIG. 5 , it is thus possible to arrange precisely such a heat-conducting element 25 such that it passes through the wall of the exhaust system, so that one end of the heat-conducting element is swept by the hot exhaust gas and the introduction of heat from the exhaust gas into the heat-conducting element 25 is thus increased. The other end of the heat-conducting element may surround, on the outside in the cold area of the exhaust system, precisely this area, so that the heat-conducting area acting as a warm protective area reduces or prevents the accumulation of condensate as a consequence of the heating of this area based on this outside arrangement. Furthermore, the heating devices 22 may be arranged in a flow path of the exhaust system or even in secondary areas 16 as described above. Thus, any desired combination is possible concerning the arrangement and design of the heating device, as this appears from the above-described examples.
[0025] Moreover, insulation 16 , which improves the heat output of the heating device based on the heat-insulating property, may be applied in the area of the heating device, especially if the heating device is arranged on the outside on the exhaust system. This is, of course, also definitely advantageous for an inside arrangement of the heating device. However, a splash guard 18 is also advantageous, especially for the outside arrangement of the heating device, so that corrosion, among other things, of the heating device due to especially salt-containing splash water can be reduced or prevented.
[0026] Such a heating device 22 , especially an electrically heatable heating device 26 , can be controlled by the control 34 , especially the vehicle system control. Thus, the heating device 22 can be operated depending on the operating state of the motor vehicle and depending on environmental parameters. It is also advantageous to switch the heating device 22 preferably into the active state during short-term operation of the motor vehicle and/or during the initial operation of the motor vehicle and/or in stop-and-go operation in city traffic. In addition, activation of the heating device 22 is, of course, also possible beginning from a predetermined outside temperature in the area of the exhaust system. Furthermore, it is also possible to take into account other operating states and environmental parameters if condensate formation may preferably occur in connection with these operating states and environmental parameters.
[0027] The formation of condensate accumulation is advantageously prevented by such a heating device already in advance, because if such an accumulation of condensate develops, mainly acid-forming components of the exhaust gas may dissolve in this accumulated condensate, and the composition of the condensate may change disadvantageously due to such dissolution of acid-forming components of the exhaust gas. If, for example, sulfur dioxide contained in the exhaust gases dissolves in the condensed water, sulfurous acid is formed by the reaction of sulfur dioxide with the condensed water, and this sulfurous acid has a considerably higher boiling point than pure condensed water, so that it may be considerably more difficult to remove an accumulated condensate than to prevent the formation of such an accumulation. Thus, it is definitely advantageous to prevent the formation of condensate accumulations already in advance.
[0028] While specific embodiments of the invention have been described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | An exhaust system, especially of a motor vehicle has at least one heating device positioned in an area in which condensate accumulates, which is arranged within the exhaust system and in which condensate can accumulate depending on operating states and/or environmental parameters. The formation of condensate accumulation is reduced or prevented by the heating device and a condensate accumulation already formed is removed. As a consequence of the corrosive property of the condensate, the service life of the exhaust system is increased by the removal of such condensate accumulations or by preventing such accumulations from forming. At the same time, the freedom of designing the exhaust system concerning the location and position of the individual components is increased. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
The present invention claims priority to its priority document No. 2002-356371 filed Japanese Laid-Open Publication No. 2000-11407 in the Japanese Patent Office on Dec. 9, 2002, the entire contents of which being incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lens driver apparatus and an image capture apparatus that move a lens-holding body to be driven by means of a linear actuator assembly based on a drive coil and a drive magnet.
2. Description of the Related Art
For a conventional actuator of a lens driving mechanism, there is a widely used a method utilizing a stepping motor or a DC motor to convert rotary motion of a motor by means of a gear or the like to linear motion so as to shift a zoom lens and a focus lens in a direction of an optical axis. As performance requirements intensify in recent years, there is employed a new technique of a linear drive through a linear actuator combining a plate magnet and a movable coil as disclosed in Patent Document 1.
In Patent Document 2, a technique aiming at improvement of magnetic efficiency and volume efficiency in a driver using a linear actuator as well as its miniaturization is also disclosed. Further, in Japanese Patent Laid-Open Publication No. 2002-214504, there is disclosed a technique of making the point of action of a thrust closer to the center of gravity of a driving section in view of stable motion of the body to be driven.
Furthermore, in Patent Document 3, a driving coil that is wound flat is widely used as a tracking coil that produces a minute movement of an objective employed for an optical disk device and the like.
[Patent Document 1]
Japanese Patent Laid-Open Publication No. 2002-23037
[Patent Document 2]
Japanese Patent Laid-Open Publication No. 2002-169073
[Patent Document 3]
Japanese Patent Laid-Open Publication No. 2000-11407
SUMMARY OF THE PRESENT INVENTION
Although much as a linear actuator used for such a driving mechanism is capable of high-speed and high-precision control, it has problems described as follows. Namely, the first problem is that since the winding direction of the coil is perpendicular to the direction of a lens movement, a part of the coil in which thrust can be generated is limited, thereby causing inferior magnetic efficiency and volume efficiency, and preventing the miniaturization.
The second problem is that use of a linear actuator causes a system to be susceptible to a frictional force generated between a guide axis and a sleeve of the driving section, hence, in a case where there is a large discrepancy between the point of action of thrust generated by the linear actuator and the center of gravity of the driving section, the frictional force varies and makes the stable driving difficult. Thus, a so-called problem of “stick-slip motion” occurs.
The above-mentioned first problem is dealt with by improving magnetic efficiency and volume efficiency and achieving the miniaturization in Patent Document 2, whereas resolution of the second problem has not been accomplished yet. Another problem of this technique is that it is not suited to long-stroke driving such as zooming.
With regard to the second problem, although the technique of making the point of action of thrust move closer to the center of gravity of the driving section is disclosed (for example, see Japanese Patent Laid-Open Publication No. 2002-214504), improvements of the magnetic efficiency and volume efficiency of the linear actuator have not been carried out yet, whereas the use of two inefficient linear actuators for one movable part aggravates efficiency.
Further, there is the third problem. A flat-wound coil is widely used as a tracking coil that produces a minute movement of an objective employed for an optical disk device or the like. However, it is not suited as a driver that requires a long-stroke movement such as zooming operation of a lens tube.
Moreover, as the fourth problem, while a lens tube has been reduced in size year by year, a question now is how small it can be produced. A conventional actuator, when mounting onto the tube, causes a form of the tube's edge protruding, thus standing in the way of making the tube smaller. The protruding edge may be caused by a U-shaped plate of a stepping motor or a magnet and a yoke of a linear actuator.
The present invention is conceived in view of the above-mentioned problems of conventional techniques. According to the present invention, there is provided a lens driver apparatus that comprises a body that is to be driven and to which a lens is attached, a guide axis to guide and allow the body to be driven to move freely in a direction of the optical axis, a driving coil being flat-wound and fitted to the body to be driven, and a driving magnet being disposed opposite side of the driving coil and along a direction of movement of the body to be driven. In the lens driver apparatus according to the present invention, the driving coil and the driving magnet are shaped in curved forms so as to conform to an outer shape of the lens.
In the present invention, for constructing a linear actuator for moving the object that is to be driven and attached to the lens, the driving coil and the driving magnet are shaped in curved forms so as to conform to an outer shape of the lens. Accordingly, the amount of the protrusion from the lens tube employing such a construction may be suppressed, thereby allowing to achieve the miniaturization. Further, according to such a construction, the center of gravity of this construction may be made closer to the center of gravity of the lens, thereby allowing to realize stable movement operation.
As mentioned above, the present invention provides the following effect. Namely, the volume efficiency and the magnetic efficiency of the driving coil are improved, with additional benefits of space saving and miniaturization. Additionally, it is possible to suppress “stick-slide motion” and realize stable driving. Further, the external shape of the lens tube may be designed in a form closer to a cylindrical shape, thus making it possible to increase freedom of design. Moreover, despite the flat-wound linear actuator drive, long-stroke driving is made possible and application may be made to zooming of a lens and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description of the presently preferred exemplary embodiment of the invention taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a perspective view of an actuator according to a first embodiment;
FIG. 2 is a front view of an actuator according to the first embodiment;
FIG. 3 is a perspective view of a driving coil;
FIG. 4 is a perspective view of a driving magnet;
FIG. 5 is a perspective view of an actuator according to a second embodiment;
FIG. 6 is a perspective view of a driving coil according to the second embodiment;
FIG. 7 is a perspective view of a driving magnet according to the second embodiment;
FIG. 8 is a perspective view of an actuator according to the third embodiment;
FIG. 9 is a front view of an actuator according to the third embodiment;
FIG. 10 is a perspective view of an actuator according to a fourth embodiment; and
FIG. 11 is a schematic sectional view of a fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments according to the present invention will be described with reference to the drawings. Now, a first preferred embodiment will be described. A lens driving mechanism according to the first preferred embodiment is applied to an actuator of a zoom lens at a lens tube of an image capture apparatus such as a video camera.
FIG. 1 is a perspective view of an actuator according to the first preferred embodiment, and FIG. 2 is a front view of the actuator according to the first preferred embodiment. A body 1 to be driven has a sleeve 2 on one side and a hole 3 on the opposite side of the sleeve 2 while having the optical axis in between, for permitting a guide axis 11 to run therethrough.
The body 1 is prevented from turning around by means of guide axes 10 and 11 , which are inserted into the sleeve 2 and the hole 3 , so that the optical axis is fixed. Further, by means of the guide axis 10 inserted in the sleeve 2 , the guiding is performed without any shake in the direction of movement.
A flat-wound driving coil 7 is attached to the body 1 via a driving coil fitting part 12 . Further, the driving coil 7 is provided in a form that is curved along an outer shape of a lens frame of the lens that is attached to the body 1 . Still further, the driving coil 7 is disposed at a position nearer to the sleeve 2 side (guide axis 10 side) of the body 1 .
A driving magnet 4 disposed facing the driving coil 7 is placed in such a manner that a region 4 A and a region 4 B, which are magnetized inversely from each other, are arrayed alternately adjacent to each other along the direction of movement of the body to be driven. The shape of the driving magnet 4 is curved along a curvature of an inner wall of the lens tube or being curved at substantially the same curvature as a curvature of the lens (see FIG. 4 ).
Furthermore, a main yoke 5 and an opposite yoke 6 are provided with having the driving coil 7 in between. The opposite yoke 6 goes through a thru-hole 13 formed in the body 1 . In the present embodiment, it is adapted to have a sufficient clearance between the opposite yoke 6 and the thru-hole 13 to ensure that the opposite yoke 6 and the thru-hole 13 do not come in contact so as not to interfere the movement as the body 1 moves. The shape of the driving coil 7 is curved along a curvature of an inner wall of the lens tube or being curved at substantially the same curvature as a curvature of the lens.
FIG. 3 is a perspective view of the driving coil. The driving coil 7 is flatly wound and shaped along the curvature of the inner wall of the tube or curved at substantially the same curvature as the curvature of the lens. The driving coil 7 generates a driving force to move the body 1 in the direction of the optical axis. Further, the driving coil 7 is a 2-phase coil in which two coils are placed adjacent to each other in a direction parallel to the moving direction of the body 1 .
Degrees of the curvature of the above-mentioned driving magnet 4 , main yoke 5 , opposite yoke 6 , and driving coil 7 are set to be the same level or substantially the same.
According to the configuration mentioned above, when a current is run through the driving coil 7 , there a thrust parallel to the direction of the optical axis is generated in the driving coil 7 due to a relationship with a magnetic flux flowing through between the opposite yoke 6 and the driving magnet 4 (Fleming's left-hand rule). Accordingly, by means of the driving force, the body 1 moves together with the driving coil 7 in the direction of the optical axis.
A position of the body 1 is detected by an MR (magneto-resistance effect) magnet 8 and an MR sensor 9 for positional detection. The MR magnet R is fitted to a MR magnet fitting part 14 provided on the sleeve 2 of the body 1 , and it is alternately magnetized at a predetermined interval.
As shown in FIG. 2 , the driving magnet 4 and the driving coil 7 are disposed substantially within a quadrant circumference of the lens. In addition, the main yoke 5 , and the opposite yoke 6 are similarly disposed in the same quadrant circumference, freeing nearly three-fourths of the cross-sectional area of the lens driver apparatus for use in mounting other optical devices, such as an iris unit. As shown, the occupied quadrant is from about 90 degrees to 180 degrees for the orientation shown in which the uppermost vertical top of the actuator is at 0 degrees.
The MR sensor 9 is attached to an inner wall (not illustrated) of the lens tube to ensure that it may be set up at a certain interval from the MR magnet 8 within a range of the movement of the MR magnet 8 . The MR magnet 8 is so magnetized that the magnetic pole alternately switches along the direction of the movement while the MR sensor 9 is a magneto-resistance effect device whose resistance varies with a change in a magnetic field affecting the sensor.
Accordingly, when the MR magnet 8 moves as the movement of the body 1 , the magnetic field affecting the MR sensor 9 , which is placed at the opposite side of the MR magnet 8 , changes, and then causes changes in the resistance of the MR sensor 9 . Accordingly, by counting the changes in the resistance, the position of the body 1 may be accurately detected.
In the present embodiment, the MR sensor 9 and the MR magnet 8 are employed as means of detecting a position of the body 1 . Alternatively, any other means for positional detection may be used provided that it is a positional detector of a non-contact type.
In such a lens moving mechanism according to the first preferred embodiment, since the driving coil 7 , the driving magnet 4 , the main yoke 5 and the opposite yoke 6 are provided in forms that are curved along the outer shape of the lens frame, it is possible to control such assembly to be protruded from the lens tube and achieve the miniaturization.
Another contributing factor is the curved form of the driving lens 7 , which is curved along the outer shape of the lens frame. Due to the factor, the center of gravity of the driving coil 7 shifts towards the lens center side. Further, the factor causes the point of action of the thrust of the linear actuator disposed near the sleeve 2 and the center of gravity to be closer to each other, thereby enabling a smooth movement.
Further, as a result of the curved shape of the driving coil 7 , the magnetic efficiency and the deposition efficiency are improved more than that of a flat-wound driving coil, thus making it possible to cope with long-stroke driving.
Next, a second preferred embodiment of the present invention will be described. A lens driving mechanism according to the second preferred embodiment is applied to an actuator for a focus lens in a lens tube of a video camera or the like.
FIG. 5 is a perspective view of an actuator according to the second preferred embodiment. A body 1 to be driven has a sleeve 2 on one side and a hole 3 on the opposite side while having the optical axis in between, for permiting a guide axis to run therethrough.
The body 1 is prevented from turning around by means of the guide axes, which are inserted into the sleeve 2 and the hole 3 , so that the optical axis is fixed. Further, by means of the guide axis 10 inserted in the sleeve 2 , the guiding is performed without any shake in the direction of movement.
A flat-wound driving coil 21 is attached to the body 1 via a driving coil fitting part 12 . Further, the driving coil 21 is provided in a form that is curved along an outer shape of a lens frame of the lens that is attached to the body 1 . Still further, the driving coil 21 is disposed at a position nearer to the sleeve 2 side of the body 1 .
A driving magnet 19 disposed facing the driving coil 21 is placed in such a manner that a region 19 A and a region 19 B, which are magnetized inversely from each other, are arrayed alternately adjacent to each other along the direction of movement of the body to be driven. The shape of the driving magnet 19 is curved along an inner wall of the lens tube or curved at substantially the same curvature as a curvature of the lens (see FIG. 7 ).
Furthermore, a main yoke 5 and an opposite yoke 6 are provided with having the driving coil 7 in between. The opposite yoke 6 goes through a thru-hole 13 formed in the body 1 . In the present embodiment, it is adapted to have a sufficient clearance between the opposite yoke 6 and the thru-hole 13 to ensure that the opposite yoke 6 and the thru-hole 13 do not come in contact so as not to interfere the movement as the body 1 moves. The shape of the driving coil 7 is curved along a curvature of an inner wall of the lens tube or being curved at substantially the same curvature as a curvature of the lens.
FIG. 6 is a perspective view of the driving coil. The driving coil 21 is flatly wound and shaped along the curvature of the inner wall of the tube or curved at substantially the same curvature as the curvature of the lens. The driving coil 21 generates a driving force to move the body 1 in the direction of the optical axis. Further, the driving coil 21 according to the second preferred embodiment is a 1-phase coil.
Degrees of the curvature of the above-mentioned driving magnet 19 , main yoke 5 , opposite yoke 6 , and driving coil 21 are set to be the same level or substantially the same.
According to the configuration mentioned above, when a current is run through the driving coil 21 , there a thrust parallel to the direction of the optical axis is generated in the driving coil 21 due to a relationship with a magnetic flux flowing through between the opposite yoke 6 and the driving magnet 19 (Fleming's left-hand rule). Accordingly, by means of the driving force, the body 1 moves together with the driving coil in the direction of the optical axis.
A position of the body 1 is detected by an MR magnet 8 and an MR sensor 9 for positional detection. The MR magnet R is fitted to a MR magnet fitting part 14 provided on the sleeve 2 of the body 1 , and it is alternately magnetized at a predetermined interval.
The MR sensor 9 is attached to an inner wall (not illustrated) of the lens tube to ensure that it may be set up at a certain interval from the MR magnet 8 within a range of the movement of the MR magnet 8 . The MR magnet 8 is so magnetized that the magnetic pole alternately switches along the direction of the movement while the MR sensor 9 is a magneto-resistance effect device whose resistance varies with a change in a magnetic field affecting the sensor.
Accordingly, when the MR magnet 8 moves as the movement of the body 1 , the magnetic field affecting the MR sensor 9 , which is placed at the opposite side of the MR magnet 8 , changes, and then causes changes in the resistance of the MR sensor 9 . Accordingly, by counting the changes in the resistance, the position of the body 1 may be accurately detected.
In the present embodiment, the MR sensor 9 and the MR magnet 8 are employed as means of detecting a position of the body 1 . Alternatively, any other means for positional detection may be used provided that it is a positional detector of a non-contact type.
In such a lens moving mechanism according to the second preferred embodiment, in addition to the effects of the lens moving mechanism according to the first preferred embodiment, it is also applicable to a case where the amount of movement is limited to a small value.
Next, a third preferred embodiment of the present invention will be described. A lens driving mechanism according to the third preferred embodiment is applied to an actuator of a zoom lens in a lens tube of a video camera or the like.
FIG. 8 is a perspective view of an actuator according to the third preferred embodiment, and FIG. 9 is a front view of the actuator according to the third preferred embodiment. A body 1 to be driven has a sleeve 2 on one side and a hole 3 on the opposite side of the sleeve 2 while having the optical axis in between, for permitting a guide axis 11 to run therethrough. The body 1 is prevented from turning around by means of guide axes 10 and 11 , which are inserted into the sleeve 2 and the hole 3 , so that the optical axis is fixed. Further, by means of the guide axis 10 inserted in the sleeve 2 , the guiding is performed without any shake in the direction of movement.
A flat-wound driving coil 7 is attached to the body 1 via a driving coil fitting part 12 . Further, the driving coil 7 is provided in a form that is curved along an outer shape of a lens frame of the lens that is attached to the body 1 . Still further, the driving coil 7 is disposed at a position nearer to the sleeve 2 side of the body 1 .
A driving magnet 4 disposed facing the driving coil 7 is placed in such a manner that a region 4 A and a region 4 B, which are magnetized inversely from each other, are arrayed alternately adjacent to each other along the direction of movement of the body to be driven. The shape of the driving magnet 4 is curved along a curvature of an inner wall of the lens tube or being curved at substantially the same curvature as a curvature of the lens.
In a linear actuator according to the present preferred embodiment, only the main yoke 5 is provided as a yoke along the driving magnet 4 . The shape of main yoke 5 is curved along a curved surface of an inner wall of the lens tube or at the same or substantially the same curvature as the curvature of the lens.
The driving coil 7 is flatly wound and shaped along the curvature of the inner wall of the tube or curved at substantially the same curvature as the curvature of the lens. The driving coil 7 generates a driving force to move the body 1 in the direction of the optical axis. Further, the driving coil 7 is a 2-phase coil in which two coils are placed adjacent to each other in a direction parallel to the moving direction of the body 1 .
Degrees of the curvature of the above-mentioned driving magnet 4 , main yoke 5 and driving coil 7 are set to be the same level or substantially the same.
According to the configuration mentioned above, when a current is run through the driving coil 7 , there a thrust parallel to the direction of the optical axis is generated in the driving coil 7 due to a relationship with a magnetic flux generated by the driving magnet 4 (Fleming's left-hand rule). Accordingly, by means of the driving force, the body 1 moves together with the driving coil 7 in the direction of the optical axis.
A position of the body 1 is detected by an MR magnet 8 and an MR sensor 9 for positional detection. The MR magnet R is fitted to a MR magnet fitting part 14 provided on the sleeve 2 of the body 1 , and it is alternately magnetized at a predetermined interval.
The MR sensor 9 is attached to an inner wall (not illustrated) of the lens tube to ensure that it may be set up at a certain interval from the MR magnet 8 within a range of the movement of the MR magnet 8 . The MR magnet 8 is so magnetized that the magnetic pole alternately switches along the direction of the movement while the MR sensor 9 is a magneto-resistance effect device whose resistance varies with a change in a magnetic field affecting the sensor.
Accordingly, when the MR magnet 8 moves as the movement of the body 1 , the magnetic field affecting the MR sensor 9 , which is placed at the opposite side of the MR magnet 8 , changes, and then causes changes in the resistance of the MR sensor 9 . Accordingly, by counting the changes in the resistance, the position of the body 1 may be accurately detected.
In the present embodiment, the MR sensor 9 and the MR magnet 8 are employed as means of detecting a position of the body 1 . Alternatively, any other means for positional detection may be used provided that it is a positional detector of a non-contact type.
In such a lens moving mechanism according to the third preferred embodiment, it is possible to realize the effects of the lens moving mechanism according to the first preferred embodiment, which is the miniaturization of the tube and a smooth movement. Further, according to the third preferred embodiment with a construction having only the main yoke 5 as a yoke, it is possible to achieve simplification of the mechanism and further miniaturization.
Next, a third preferred embodiment of the present invention will be described. A lens driving mechanism according to the third preferred embodiment is applied to an actuator for a focus lens in a lens tube of a video camera or the like.
FIG. 10 is a perspective view of an actuator according to the fourth preferred embodiment. A body 1 to be driven has a sleeve 2 on one side and a hole 3 on the opposite side of the sleeve 2 while having the optical axis in between, for permitting a guide axis 11 to run therethrough.
The body 1 is prevented from turning around by means of guide axes, which are inserted into the sleeve 2 and the hole 3 , so that the optical axis is fixed. Further, by means of the guide axis inserted in the sleeve 2 , the guiding is performed without any shake in the direction of movement.
A flat-wound driving coil 21 is attached to the body 1 via a driving coil fitting part 12 . Further, the driving coil 21 is provided in a form that is curved along an outer shape of a lens frame of the lens that is attached to the body 1 . Still further, the driving coil 21 is disposed at a position nearer to the sleeve 2 side of the body 1 .
A driving magnet 19 disposed facing the driving coil 21 is placed in such a manner that a region 19 A and a region 19 B, which are magnetized inversely from each other, are arrayed alternately adjacent to each other along the direction of movement of the body to be driven. The shape of the driving magnet 19 is curved along a curvature of an inner wall of the lens tube or being curved at substantially the same curvature as a curvature of the lens.
In a linear actuator according to the present preferred embodiment, only the main yoke 5 is provided as a yoke along the driving magnet 19 . The shape of main yoke 5 is curved along a curved surface of an inner wall of the lens tube or at the same or substantially the same curvature as the curvature of the lens.
The driving coil 21 is flatly wound and shaped along the curvature of the inner wall of the tube or curved at substantially the same curvature as the curvature of the lens. The driving coil 21 is a 1-phase coil and generates a driving force to move the body 1 in the direction of the optical axis.
Degrees of the curvature of the above-mentioned driving magnet 19 , main yoke 5 and driving coil 21 are set to be the same level or substantially the same.
According to the configuration mentioned above, when a current is run through the driving coil 21 , there a thrust parallel to the direction of the optical axis is generated in the driving coil 21 due to a relationship with a magnetic flux generated by the driving magnet 12 (Fleming's left-hand rule). Accordingly, by means of the driving force, the body 1 moves together with the driving coil 21 in the direction of the optical axis.
A position of the body 1 is detected by the MR magnet 8 and the MR sensor 9 for positional detection. The MR magnet R is fitted to the MR magnet fitting part 14 provided on the sleeve 2 of the body 1 , and it is alternately magnetized at a predetermined interval.
The MR sensor 9 is attached to an inner wall (not illustrated) of the lens tube to ensure that it may be set up at a certain interval from the MR magnet 8 within a range of the movement of the MR magnet 8 . The MR magnet 8 is so magnetized that the magnetic pole alternately switches along the direction of the movement while the MR sensor 9 is a magneto-resistance effect device whose resistance varies with a change in a magnetic field affecting the sensor.
Accordingly, when the MR magnet 8 moves as the movement of the body 1 , the magnetic field affecting the MR sensor 9 , which is placed at the opposite side of the MR magnet 8 , changes, and then causes changes in the resistance of the MR sensor 9 . Accordingly, by counting the changes in the resistance, the position of the body 1 may be accurately detected.
In the present embodiment, the MR sensor 9 and the MR magnet 8 are employed as means of detecting a position of the body 1 . Alternatively, any other means for positional detection may be used provided that it is a positional detector of a non-contact type.
In such a lens moving mechanism according to the fourth preferred embodiment, in addition to the effects of the lens moving mechanism according to the third preferred embodiment, it is also applicable to a case where the amount of movement is limited to a small value.
Next, a fifth preferred embodiment of the present invention will be described. The fifth preferred embodiment is an example in which an actuator according to the first or third preferred embodiment mentioned above and an actuator according to the second or the fourth preferred embodiment mentioned above are built-in a lens tube.
FIG. 11 is a schematic section view of the fifth preferred embodiment. Namely, the above-mentioned lens driving mechanism according to the first or the third preferred embodiment is applied to driving a zoom lens group 67 , while the above-mentioned lens driving mechanism according to the second or the fourth preferred embodiment is applied to driving a focus lens group 75 .
A front lens group 61 is disposed at the end of an object's side of a lens tube, and in the latter stage thereof the zoom lens group 67 is disposed movably along the optical axis. In the further latter stage thereof, via an intermediate lens, the focus lens group 75 is disposed movably along the optical axis.
Since the zoom lens group 67 has a wider range of the movement and a heavier lens weight than those of the focus lens group 75 , the above-mentioned lens driving mechanism according to the first or the third preferred embodiment is applied. On the other hand, since the focus lens group 75 has a narrower range of the movement and a lighter lens weight than those of the zoom lens group 67 , the above-mentioned lens driving mechanism according to the second or the fourth preferred embodiment is applied.
The zoom lens group 67 is held by a zoom lens frame 68 to which a flat-wound 2 -phase driving coil 64 is attached. In addition, the zoom lens frame has a sleeve 65 , and a guide axis 77 runs through a hole of formed in the sleeve 65 . Further, on the opposite side of the sleeve 65 of the zoom lens frame 68 , a guide axis 76 goes through. By means of these guide axes 76 and 77 , the movement of the zoom lens frame 68 is guided along the direction of the optical axis.
Still further, opposite the driving coil 64 attached to the zoom lens frame 68 are disposed a driving magnet 63 and a main yoke 62 . The driving coil 64 , the driving magnet 63 and the main yoke 62 are, as mentioned above, provided in forms that are curved along the outer shape of the lens frame of the lens.
Furthermore, the focus lens group 74 is held by a focus lens frame 75 to which a flat-wound 1-phase driving coil 71 is attached. In addition, the focus lens frame 75 has a sleeve 72 , and a guide axis 77 runs through a hole of the sleeve 72 . Further, on the opposite side of the sleeve 72 of the focus lens frame 75 , a guide axis 76 goes through. By means of these guide axes 76 and 77 , the movement of the focus lens frame 75 is guided along the direction of the optical axis.
Moreover, opposite the driving coil 71 attached to the focus lens frame 75 are disposed a driving magnet 70 and a main yoke 69 . The driving coil 71 , the driving magnet 70 , and the main yoke 69 are, as mentioned above, provided in forms that are curved along the outer shape of the lens frame of the lens.
Through application of such lens moving mechanisms of the zoom lens group 67 and the focus lens group 74 , even in the case of a linear actuator, it is possible to bring about miniaturization of a lens tube. Further, a moving mechanism by linear actuator may be realized even where the movement of the zoom lens group 67 covering a wide range of the movement is involved.
It should be noted that all the above-mentioned preferred embodiments are described in terms of construction in which a driving coil is provided in the body 1 with a driving magnet installed at the opposite side, the driving coil moving together with the body 1 . Alternatively, the present invention may also be applicable to a different construction in which a driving magnet is provided in the body 1 with a driving coil installed at the opposite side, the driving magnet moving together with the body 1 . Because the latter case dispenses with a need of connecting wiring to the body 1 , wire-laying work may be facilitated.
It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | In a lens driver apparatus using a linear actuator, spaces for installing a driving coil and a driving magnet are reduced to contribute to making the lens driver apparatus smaller. The present invention relates to the lens driver apparatus including a body that is to be driven and to which a lens is attached, a guide axis to guide and allow the body to be driven to move freely in a direction of the optical axis, a driving coil being flat-wound and fitted to the body to be driven, and a driving magnet being disposed opposite side of the driving coil and along a direction of movement of the body to be driven. In the lens driver apparatus according to the present invention, the driving coil and the driving magnet are shaped in curved forms so as to conform to an outer shape of the lens. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Applicant's invention relates to an apparatus and method to remove fines or small particles from the liquid and particulate mixture used in fracturing or gravel packing a subterranean well.
2. Background Information
Gravel packing a subterranean well addresses the problem encountered by many oil and gas producers; namely, sand flow into the well bore from unconsolidated formations. Sand flow can gradually fill the well bore until production perforations are covered, resulting in decreased production, if not total loss of production. Sand flow also damages equipment. Gravel packing eliminates, or at least reduces to trace amounts, sand flow from unconsolidated formations by placing a filtering system within the well and formation.
The concept of gravel packing is fairly simple. A screen of a pre-selected size is placed inside the well casing adjacent to the producing formation. If well casing is not used, a screen of pre-selected size is hung from the well bore adjacent to the producing formation. A mixture of a premeasured gravel packing particulates and a carrier liquid, such as water or material of similar density, is forced down the well bore under sufficient pressure and volume to deposit the gravel packing particulates against the face of the producing formation and the screen. Thus, creating an avenue through which the oil or gas being produced may travel without interruption to the well bore. The gravel packing particulates used are sized by the oil and gas industry as 20-40, 40-60, etc., grain size (U.S. Sieve) in inches of grain diameter. For example, a 20-40 grain size mixture (U.S. Sieve) contains grain sizes of 0.031" to 0.0165".
In conventional day gravel packing procedures, extreme care is used to initially choose the proper size of gravel packing particulates, and to assure that the particulates are not damaged before use; for example, during shipment to the well site or while being fed into the mixer. Yet, even though the particles are chosen for their size and carefully placed in the mixer, these same particles are forced under at least 50 psi of pressure out of the mixer and at least 1,500 psi of pressure from a high pressure, high volume pump into the well bore. In effecting this type of pressure, the opening and closing of the inlet and outlet valves of the mixer and pump crush some of the gravel packing particulates, producing fines (smaller particles) which clog the avenues created by the undamaged gravel packing particulates, and in turn cause production to decrease.
Fines are also created during the fracturing process. Generally, fracturing is another method used to increase production. Fracturing a well is accomplished by forcing a liquid and particulate mixture down the well bore to open up a new production zone. Just as in gravel packing, the particulates are chosen for their size and shape. Yet, mixers and high pressure, high volume pumps are also used in the fracturing process. Thus, fines are again created by the opening and closing of the inlet and outlet valves of the pump and mixer. Consequently, just as in gravel packing, the avenues created by the fracturing process are also clogged by fines which in turn reduce production. Therefore a need exists for a method and apparatus for removing fines that are created by the inlet and outlet valves of the mixer, pump and other equipment that the particulates come in contact with during the gravel packing or fracturing processes.
SUMMARY OF THE INVENTION
This invention finds great utility in conjunction with gravel packing or fracturing a subterranean well. In accordance with this invention, a fine filtration system is placed in the flow line after the high pressure pumps used in fracturing and gravel packing a subterranean well. This placement of the fine filtration system assures that the fines produced by the inlet and outlet valves of the mixer, pumps and other equipment that may damage the equipment and particulates or decrease the particulate size are removed before the particulate/liquid mixture is forced into or against the formation.
The fine filtration system described by the present invention can be used in any type of gravel packing system, as long as it is located in a flow line after the high pressure pumps. In the fracturing system, the current day method of fracturing may need to be altered so the fracturing compounds are added to the particulate/liquid mixture after the fine filtration system. This would assure the liquid and particle mixture is not so viscous that the fines cannot be removed.
Further objects and advantages of the invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the sheets of drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the current day gravel packing process including the fine filtration system.
FIG. 2 is a schematic of the current day fracturing process.
FIG. 3 is a schematic of the fracturing process in conjunction with the fine filtration system.
FIG. 4 is a side view of the exterior of the fine filtration system.
FIG. 5 is a top view of the lower plate and inner core of the fine filtration system.
FIG. 6 is a side view of the interior of the pressure vessel of the fine filtration system.
FIG. 7 is illustrative of a piston cavity in a standard tri-plex pump on its suction stroke.
FIG. 8 is illustrative of a piston cavity in a standard tri-plex pump on its discharge stroke.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following detailed description is provided in order to aid those skilled in the art to practice the present invention. Even so, the following discussion should not be deemed to unduly limit the present invention, since modifications may easily be made in the procedures herein taught by one of ordinary skill in the art, without departing from the spirit or scope of the present invention. In this regard, the present invention is only to be limited by the scope of the claims dependent hereto and the equivalence thereof.
Referring to FIG. 1, there is shown a gravel packing system 10 incorporating a fine filtration system 6 of the present invention. The gravel packing fluid is maintained in tank 1. The gravel packing fluid can be water, salt water, oil, or any other liquid with a density near that of water. In the preferred embodiment, the gravel packing fluid is salt water. Tank 1 is connected by pipe 2 to combination mixer and centrifugal pump 3. Mixer and centrifugal pump 3 is used to combine the gravel packing fluid from tank 1 and the particles from particle retainer 4. The particles can be resin coated sand mixtures, ceramic bead mixtures, or sand mixtures. In the preferred embodiment, the particles are sand mixtures. Before mixing, the particles are retained in the particle retainer 4. During mixing, the particles are controllably fed into combination mixer and centrifugal pump 3. After the particles and gravel packing fluid have been blended, centrifugal pump 3 forces the mixture under low pressure, 50-100 psi, to high pressure pump 5. High pressure pump 5 exerts approximately 1,500-7,000 psi of pressure on the particle/liquid mixture to eventually force it down well bore 7. High pressure pump 5 is either a tri-plex or piston pump as described below. The only portion of FIG. 1 that is new is the incorporation and use of fine filtration system 6. The rest of the preceding discussion covers the conventional gravel packing method.
FIGS. 7 and 8 are illustrative of the workings of a tri-plex or high pressure piston pump 60. Pump 60 could be the equivalent to pumps 5 and 17 in FIGS. 1-3. However, other types of pumps could be used as pumps 5 and 17, and would cause similar creation of fines. On the suction stroke, as illustrated in FIG. 7, piston 62 is recessed in the piston cavity 64. Inlet valve 66 is open, allowing the particle/liquid mixture coming from mixer and centrifugal pump (3 in FIG. 1, 15 in FIG. 3) under up to 100 psi of pressure into piston cavity 64. Outlet valve 68 is closed.
As piston 62 moves forward through piston cavity 64 to effectuate the necessary pressure, inlet valve 66 closes and the pressure increases up to 7,000 psi inside piston cavity 64. As inlet valve 66 closes, it crushes some of the particles between valve surfaces 63a-b and walls 65a-b of inlet pipe 69 creating fines. When inlet valve 66 is reopened on the next suction stroke. The fines produced by and caught between valve surfaces 63a-b and wall 65a-b are forced into piston chamber 64.
Also, when piston 62 begins its extension into piston cavity 64, as shown in FIG. 8, outlet valve 68 begins to open and the particle/liquid mixture is forced from piston cavity 64 at up to 7,000 psi of pressure. As piston 62 recesses out of the piston cavity 64, outlet valve 68 closes. Just as occurred when the inlet valve 66 closed, outlet valve 68 crushes some of the particles between valve surfaces 61a-b and walls 67a-b of outlet pipe 70, creating fines. When outlet valve 68 is opened again, the fines lodged between valve surfaces 61a-b and walls 67a-b are forced down well 7 in FIG. 1 and 18 in FIGS. 2-3 under up to 7,000 psi of pressure with the particle/liquid mixture from the piston cavity 64.
Fines may also be created by the inlet and outlet valves of combination mixer and centrifugal pump 3 as well as by the action of the mixer. For example, if the mixture uses a blade type mechanism that scraps the sides of the mixer walls, some of the particles may be crushed between the blades and the mixer wall.
Therefore, even though the particles may have been meticulously sized and carefully treated before entry into the gravel packing system, the combination mixer and centrifugal pump 3 and the high pressure pump 5 damage the particles, creating fines which if not removed will clog the avenues created by the gravel packing process and thus reduce production that gravel packing seeks to improve. Consequently, referring to FIG. 1, the fine filtration system 6 is placed in gravel packing system 10 after pump 5 and before well 7, and functions to remove the fines from the mixture in a manner described in more detail below. After the mixture is forced under high pressure into well 7 and the particle/liquid mixture disperses through the zone of interest, the gravel packing fluid is pumped out of well 7 through tubing 8 and returned to tank 1.
A similar schematic to FIG. 1 is shown in FIG. 2, which illustrates the current day hydraulic fracturing process 9. As in FIG. 1., the fracturing process 9 shown in FIG. 2 includes tank 11 which holds the fracturing fluid. The fracturing fluid can be water or salt water. In the preferred embodiment, it is salt water combined with a bacterial agent to help avoid depositing bacteria into the well. The fracturing fluid is transported through pipe 12 into mixing area 13 wherein chemicals are added to the fracturing fluid. These chemicals can be gelling agents, refined gelling agents, or gel breakers which increase the viscosity of the entire mixture. From mixing area 13 the fracturing fluid/gel mixture is transported through pipe 14 into the combination mixer and centrifugal pump 15 wherein the fracturing particles are added from the fracturing particle retainer 16. The fracturing particles can be resin coated sand mixtures, ceramic bead mixtures, or sand mixtures. In the preferred embodiment, they are sand mixtures. The fracturing mixture is pumped out of combination mixer and centrifugal pump 15 at approximately 100 psi of pressure into high pressure fracturing pump 17. Fines are again created by both combination mixer and centrifugal pump 15 and high pressure fracturing pump 17 as was explained in the preceding paragraphs relevant to gravel packing. Consequently, just as in the gravel packing procedure discussed above, the fines that are created are not removed and thus travel into the well 18 with the fracturing mixture.
A schematic of fracturing process 8 incorporating the present invention is shown in FIG. 3. In FIG. 3, mixing area 13 is placed after fine filtration system 6. This change might be required if the chemicals added in mixing area 13 increase the viscosity of the fracturing mixture to a level that would inhibit the effectiveness of the fine filtration system 6. The balance of process 8 shown in FIG. 3 is arranged and functions in much the same manner as is described with respect to FIG. 2.
For the forthcoming explanations, the particle and liquid mixtures used in both gravel packing and fracturing a well will be denoted as a particle/liquid mixture.
Referring to FIGS. 4 and 5, the fine filtration system 6 of the present invention consists of a pressure vessel 24, upper plate 22, and lower plate 23. Pressure vessel 24 is cylindrical and fits into groove 20a (not shown) in the bottom side of upper plate 22 and groove 20b in the upper side of lower plate 23 (see FIG. 5). O-rings 37a-b (37a not shown) are placed between grooves 20a-b (20a not shown) and pressure vessel 24 to help withstand the force and pressure inside pressure vessel 24 caused by the particle/liquid mixture. Upper plate 22 and lower plate 23 are held in place by nuts 25a-d (FIG. 4) and 25e-h (not shown) screwed onto shafts 26a-b (FIG. 4) and 26c-d (not shown) which pass through shaft holes 21a-d (FIG. 5) and 21f-g (FIG. 4) and 21e and 21h (not shown).
FIG. 6 illustrates the interior design of pressure vessel 24. Within pressure vessel 24 is core 32 with a recessed impact area 31 filled with sand particles 38. The bottom edge of core 32 is securely attached to lower plate 23. Surrounding core 32 is screen 34. To retain screen 34 in place, the bottom edge of screen 34 is fitted into screen groove 40b in the upper side of lower plate 23 (FIG. 5). To complete the seal between screen 34 and lower plate 23, an o-ring (not shown) is placed between screen groove 40b and screen 34. The upper edge of screen 34 is retained by upper plate 22 in the same manner, although not shown. Due to the design of fine filtration system 6, screen 34 can be removed and replaced with a different screen if it is worn or if a smaller or larger screen size is required by unscrewing nuts 25a, d, e and h and removing upper plate 22.
The exterior of core 32 has blade-like projections 33a-f which help propel the particle/liquid mixture against screen 34 by centrifugal force. Fines and some liquid are forced through screen 34 by projections 33a-f but most of the fines and some liquid are drawn through screen 34 into fine collection area 39 by the controlled action of chokes 30a-b attached to fine outlet pipes 28a-b. Chokes 30a-b control the opening and closing of fine outlet pipes 28a-b. Chokes 30a-b open fine outlet pipes 28a-b to cause a pressure differential across screen 34 with the lower pressure in fine collection area 39. This pressure differential causes the fines and some liquid to be drawn through screen 34 into fine collection area 39 and out of pressure vessel 24 through outlet pipes 28a-b. The particle/liquid mixture not drawn through screen 34 exits pressure vessel 24 through outlet pipe 29.
Referring to FIG. 6, the particle/liquid mixture is deposited in pressure vessel 24 through inlet pipe 27. As the particle/liquid mixture enters pressure vessel 24 it contacts impact area 31 and sand particles 38. Impact area 31 and sand particles 38 help reduce damage to core 32 due to the force the particle/liquid mixture exerts on core 32 as it is deposited into pressure vessel 24 through inlet pipe 27. The particle/liquid mixture spills over the top edge of core 32 after contacting impact area 31 of core 32 and proceeds down through projections 33a-f which cause the particle/liquid mixture to swirl with centrifical force. Projections 33a-f propel the particle/liquid mixture against screen 34. Some fines and liquid are forced through screen 34 by projections 33a-f, but most of the fines and some liquid is drawn through screen 34 into fine collection area 39 by the pressure differential created by chokes 30a-b as previously discussed. The fines and liquid that are either forced through or drawn through screen 34 exits pressure vessel 24 through outlet pipes 28a-b. The remainder of the particle/liquid mixture that is not forced or drawn through screen 34 exit pressure vessel 24 through outlet pipe 29 and proceeds to well 7 in FIG. 1 and well 18 in FIGS. 2 and 3.
Chokes 30a-b control the opening and closing of outlet pipes 28a-b. As discussed above, outlet pipes 28a-b are normally open while the particle/liquid mixture is passing through pressure vessel 24. Outlet pipes 28a-b can also be open while the system is being flushed at the beginning and end of the gravel packing or fracturing processes. This would also allow for the fine filtration system 6 to be used to filter smaller particles during these flushing periods.
Outlet pipes 28a-b are normally closed while either the gravel packing fluid or fracturing fluid without particulates is being forced into the well. This assures that none of this material is inadvertently pushed or drawn through screen 34 and released from the system through outlet pipes 28a-b. Of course, the rate of particulate placement into the liquid, and/or the size of outlet pipes 28a-b, would ultimately determine whether or not it would even be necessary to close outlet pipes 28a-b. If outlet pipes 28a-b are of a small enough circumference, and the injection rate is sufficiently high, the outlet pipes 28a-b would not be required to be closed off because the pressure would be retained throughout the gravel packing process system 10 in FIG. 1 or fracturing process system 9 in FIGS. 2-3. On the other hand, if the rate of particulate placement is not sufficiently high, outlet pipes 28a-b should be closed to avoid a drop in pressure after the particulate/liquid mixture has passed through fine filtration system 6.
Pressure vessel 24, upper plate 22, lower plate 23, core 32, nuts 25a-h, shafts 26a-d, inlet pipe 27, and outlet pipe 29 are made of hard and durable materials such as, but not limited to, copper, stainless steel, or plastic copolymers. Screen 34 can be constructed of, although not limited by, stainless steel or other materials used for constructing screens currently used in the gravel packing process.
Of course, the embodiment of the invention as reflected in FIGS. 4-6 could be modified to produce the size of separator required. In addition, outlet pipe 29 could be connected to other fine filtration systems or other types of separators in parallel or series to obtain a more thorough separation. | An apparatus and improved method for removing fines or small particles from a particle and liquid mixture, finding particular application in the field of oil and gas well gravel packing and fracturing processes. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application Nos. 196 26 235.6 filed Jun. 29, 1996 and 197 21 758.3 filed May 24, 1997, which are incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application Nos. 196 26 235.6 filed Jun. 29, 1996 and 197 21 758.3 filed May 24, 1997, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a carding machine which, at its output, has a web trumpet with an after-connected pair of calender rolls, downstream of which--as viewed in the direction of sliver run--a sliver coiler is arranged which includes a rotary coiler head having a sliver inlet opening. A sliver drawing unit is disposed between the web trumpet and the sliver inlet opening of the coiler head.
In a known device a sliver drawing unit is provided between the stripper roll--which cooperates with the doffer of the carding machine--and the sliver coiler. At a distance from the stripper roll a web trumpet is disposed whose input is associated with a fiber web chamber while its output is situated immediately at the intake of the drawing unit. The web trumpet is thus arranged simultaneously at the output of the carding machine and at the input of the sliver drawing unit which is a regulated drawing unit. The web trumpet has a dual function: first, it forms, as an output trumpet at the carding machine, a sliver from the fiber web and guides, as an input trumpet, the sliver into the drawing unit. Second, the web trumpet serves as a measuring member to sense the sliver thickness. The thickness measurement signal affects, with the intermediary of regulating devices, the rpm of the feed roll at the input of the carding machine as well as the rpm of a roll pair of the regulated drawing unit. The drawing unit is arranged horizontally approximately at the height level of the stripper roll of the carding machine, and the web trumpet receives the approximately horizontally running sliver. The drawing unit is associated with the sliver coiler and is situated in a vertical direction approximately at one-half the height between the floor plate (platform) and the coiler head of the sliver coiler apparatus.
It is a disadvantage of the above-described arrangement that the web trumpet is, in the horizontal direction, at a distance from the stripper roll so that a web triangle is formed which is prone to rupture. Running speeds of above 100 m/min are not feasible with such an apparatus. It is a further drawback that between the outlet of the drawing unit and the sliver inlet opening of the coiler head of the sliver coiler a significant distance prevails so that the drawn and regulated sliver risks being exposed to unintended stretching along such a travel path, resulting in irregularities in the sliver.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, avoids external effects of the sliver between the drawing unit and the sliver intake opening of the coiler head and furthermore ensures a secure guidance of the sliver thereinto.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus includes a carding machine which has a web trumpet gathering a running fiber web into sliver and a calender roll pair arranged immediately downstream of the web trumpet for pulling the sliver therethrough. The apparatus further includes a sliver coiler having a rotary coiler head through which the sliver passes and a first sliver trumpet having an inlet which constitutes the inlet opening for the coiler head. A sliver drawing unit is arranged at the inlet opening for the coiler head for drawing the sliver running therethrough prior to entering the coiler head. Further, a second sliver trumpet is arranged at the inlet end of the drawing unit for guiding the sliver thereto.
Thus, according to the invention two trumpets are provided, namely, a web trumpet in which the fiber web is gathered to form a sliver and a sliver trumpet arranged at the input (inlet end) of the sliver drawing unit mounted on the sliver coiler. By virtue of the fact that a web trumpet is present which is independent from the drawing unit, the fiber web is, at the outlet of the card immediately following the stripper roll, guided into the web trumpet so that the delicate web triangle is eliminated and running speeds of 300 m/min and above are feasible. By virtue of the fact that a sliver trumpet is situated at the input (inlet end) of the drawing unit independently from the web doffing at the carding machine, the output (outlet end) of the drawing unit is arranged immediately at the sliver inlet opening (that is, the inlet of the first sliver trumpet) for the coiler head so that the conventionally long and risky path of the regulated and drawn sliver is very significantly shortened to thus ensure a secure transfer of the sliver into the coiler head. By using two trumpets (that is, the web trumpet and the second sliver trumpet) contrary to conventional devices, a separation of functions is effected, and harmful effects on the fiber web and also on the regulated and drawn sliver are securely avoided in a simple and advantageous manner. It is of significance that the outlet of the sliver drawing unit is situated in the close vicinity of the sliver inlet opening of the coiler head. It is furthermore of importance that the web trumpet is situated in the close vicinity of the stripper roll.
The invention has the following additional advantageous features:
The outlet of the drawing unit is situated above the level of the sliver inlet opening for the coiler head.
The outlet of the drawing unit is situated at the height level of the sliver intake opening for the coiler head.
The drawing unit is horizontally disposed.
The drawing unit is vertically disposed.
The drawing unit slopes downwardly in the direction of sliver travel, at an acute angle to the horizontal.
The drawing unit slopes upwardly in the direction of sliver travel, at an acute angle to the horizontal.
A deflecting roller is provided between the outlet of the drawing unit and the sliver inlet opening for the coiler head.
The sliver enters into the sliver inlet opening for the coiler head in a short path from the outlet of the drawing unit of the sliver.
The drawing unit is situated above the coiler head plate of the coiler apparatus.
The drawing unit is situated between the outer boundary of the coiler head plate and the sliver inlet opening for the coiler head.
A preferred embodiment of the invention includes a regulating device to which a sliver thickness measuring device, a regulator and a setting device are connected. The measuring (sliver thickness sensing) device is incorporated in the sliver trumpet at the input of the drawing unit. Expediently, the setting device is composed of a regulating motor for driving at least one roll pair of the drawing unit and/or a regulating motor for the feed roller of the carding machine at the input thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a carding machine and an after-connected sliver coiler, incorporating the invention.
FIG. 2 is a view similar to FIG. 1 wherein the carding machine is not shown in detail and wherein the sliver drawing unit is arranged essentially horizontally above the coiler head plate of the sliver coiler.
FIG. 2a is a schematic cross-sectional view of a sliver trumpet forming an inlet device for the coiler head.
FIG. 3 is a schematic fragmentary side elevational view of a sliver coiler illustrating the sliver drawing unit sloping downwardly towards the coiler head plate as viewed in the direction of sliver run.
FIG. 4 is a schematic fragmentary side elevational view of a sliver coiler illustrating the sliver drawing unit sloping upwardly from the coiler head plate as viewed in the direction of sliver run.
FIG. 5 is a view similar to FIG. 3 showing the sliver drawing unit arranged essentially at a vertical orientation above the coiler head plate.
FIG. 6 is a schematic side elevational view, with block diagram, of an electronic regulating and control unit to which at least one regulating motor of the sliver drawing unit, the sliver measuring trumpet and the regulating motor for the feed roll of the carding machine are connected.
FIG. 7 is a schematic side elevational view illustrating a 4-over-3 drawing unit mounted on a sliver coiler incorporating the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a carding machine CM which may be an EXACTACARD DK 803 model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The carding machine CM has a feed roller 1, a feed table 2 cooperating with the feed roller 1, licker-ins 3a, 3b, 3c, a main carding cylinder 4, a doffer 5, a stripper roll 6, crushing rolls 7, 8, a web guiding element 9, a web trumpet 10, calender rolls 11, 12, travelling flats 13 and a sliver coiler apparatus 14 feeding sliver to a coiler can 15. Above the sliver coiler 14 a sliver drawing unit 16 is disposed.
As shown in FIG. 2, downstream of the calender rolls 11, 12 the sliver coiler 14 is situated, having a coiler head 18 which is provided with a sliver guiding tube 19 and which is positioned in a coiler head plate 14a. The sliver inlet opening for the coiler head 18 is formed of the upstream (inlet) opening 20a of a sliver trumpet 20 which is adjoined immediately downstream by a pair of pull-off rollers 21, 22. The cross-sectional configuration of the sliver trumpet 20 is shown in FIG. 2a. The sliver drawing unit 16 is arranged between the web trumpet 10 of the carding machine CM and the sliver inlet opening 20a for the coiler head 18.
At the inlet end 16a of the drawing unit 16 a sliver trumpet 23 is disposed. The sliver drawing unit 16 is oriented horizontally and is thus parallel to the coiler head plate 14a.
Between the outlet end 16b of the sliver drawing unit 16 and the sliver inlet opening 20a for the coiler head 18 a deflecting roller 24 is provided which thus divides the path of the sliver 17 from the drawing unit 16 to the coiler head 18 into respective horizontal and vertical path portions a and b. The length a+b of the sliver path between the outlet end 16b of the sliver drawing unit 16 and the inlet opening 20a for the coiler head 18 is maintained as short as possible and is preferably in the range of between 5 and 30 cm. The sliver drawing unit 16 is situated above the coiler head plate 14a between the outer boundary thereof and the sliver inlet opening 20a for the coiler head 18. Upstream of the sliver trumpet 23 a deflecting roll 25 is arranged for the sliver 17.
The sliver drawing unit 16 has two upper rolls 26a, 27a and two respective, associated lower rolls 26b, 27b. The upper rolls 26a, 27a rotate counterclockwise, while the lower rolls 26b, 27b rotate clockwise. The sliver drawing unit 16 is at a horizontal distance d and at a vertical distance e from the web trumpet 10.
In operation, the non-illustrated fiber web is gathered by the web trumpet 10 to form a sliver 17 which is pulled through the web trumpet 10 by the calender rolls 11, 12 at a speed of, for example, 200 m/min. The sliver 17 runs in the direction A upwardly toward and over the deflecting roller 25 and then passes, essentially in a horizontal direction, through the sliver trumpet 23 into the sliver drawing unit 16 and is drawn by the roll pair 26a, 26b and 27a, 27b. Thereafter the drawn sliver 17 is, as it exits from the drawing unit 16, guided over the deflecting roller 24 vertically downwardly and is introduced into the sliver trumpet 20. The sliver 17 is pulled through the sliver trumpet 20 by pull-off rollers 21, 22 and then passes through the orbiting guide tube 19 whereupon the sliver enters into the coiler head 18 (which rotates about a vertical axis) and exits the sliver outlet opening at the underside of the coiler head 18 into the coiler can 15 where it is deposited in coils.
Turning to FIG. 3, the sliver 17 runs downwardly in the sliver drawing unit 16 in the direction B toward the coiler head plate 14a. Stated differently, the drawing unit 16 slopes downwardly towards the coiler head plate 14a. In the arrangement according to FIG. 4, the sliver 17 runs upwardly in the sliver drawing unit 16 in the direction C away from the coiler head plate 14a. Stated differently, the drawing unit 16 slopes upwardly away from the coiler head plate 14a.
FIG. 5, the direction D of the sliver run through the sliver drawing unit 16 is vertical, that is, it is oriented perpendicularly to the horizontal coiler head plate 14a. The outlet 16b of the sliver drawing unit 16 is at a short distance c from the inlet opening 20a for the coiler head 18.
Turning to FIG. 6, there is shown a microcomputer-based control and regulating device 28 to which a regulator for the sliver drawing unit 16 and a regulator for the feed roller 1 of the carding machine are connected.
The sliver trumpet 23 at the inlet 16a of the sliver drawing unit 16 includes a measuring device for measuring, for example, by mechanical contacting, the thickness of the sliver 17. The measuring trumpet 23 is connected by means of a regulator 29 with the rpm-controllable drive motor 30, for example, a d.c. motor which rotates the roll 27b. Further, the measuring trumpet 23 is connected to the electronic control and regulating device 28, for example, via a non-illustrated measuring value transducer and a measuring value amplifier 31. The feed roller 1 is associated with a measuring member 32 for measuring the thickness of the fiber lap situated between the feed roller 1 and the feed table 2. The measuring member 32 is connected via a regulator 33 with the rpm-controlled drive motor 34, for example, a d.c. motor which rotates the feed roller 1. The regulator is, in turn, connected with the electronic control and regulating apparatus 28. The roll pair 26a, 26b is rotated by a main motor 35 having a constant rpm.
Turning to FIG. 7, the sliver drawing unit 16 is formed by a "4-over-3" drawing unit, that is, it has four consecutive upper rolls 36, 37, 38, 39 and three consecutive lower rolls I (forming the lower output roll), II (forming the lower middle roll) and III (forming the lower input roll). The roll pairs 39, III and 38, II form the pre-drawing field, while the roll pairs 38, II and 36, 37, I form the main drawing field. The lower output roll I is rotated by the rpm-regulated motor 30 (controlled in the manner described in connection with FIG. 6), while the lower input and middle rolls III and II are rotated by the constant-rpm main motor 35 and thus determine the delivery speed of the sliver. A sliver guiding element 40 is disposed between the outlet end 16b of the drawing unit 16 and the inlet 20a of the sliver trumpet 20.
The 4-over-3 drawing unit 16 of FIG. 7 may be modified, for example, by omitting the upper roll 36, whereby a 3-over-3 drawing unit is obtained.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An apparatus includes a carding machine which has a web trumpet gathering a running fiber web into sliver and a calender roll pair arranged immediately downstream of the web trumpet for pulling the sliver therethrough. The apparatus further includes a sliver coiler having a rotary coiler head through which the sliver passes and a first sliver trumpet having an inlet which constitutes the inlet opening for the coiler head. A sliver drawing unit is arranged at the inlet opening for the coiler head for drawing the sliver running therethrough prior to entering the coiler head. Further, a second sliver trumpet is arranged at the inlet end of the drawing unit for guiding the sliver thereto. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 13/498,429, filed Mar. 27, 2012, which is a national stage filing under 35 U.S.C. §371 of International Application No. PCT/CA2010/001531, filed Sep. 30, 2010, which claims the benefit of the filing date under 35 U.S.C. §119(e) to U.S. provisional application No. 61/247,343, filed Sep. 30, 2009. The aforementioned, earlier-filed applications are hereby incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
This invention relates generally to networks of individuals and/or entities and network communities and, more particularly, to systems and methods for determining trust scores or connectivity within or between individuals and/or entities or networks of individuals and/or entities.
The connectivity, or relationships, of an individual or entity within a network community may be used to infer attributes of that individual or entity. For example, an individual or entity's connectivity within a network community may be used to determine the identity of the individual or entity (e.g., used to make decisions about identity claims and authentication), the trustworthiness or reputation of the individual or entity, or the membership, status, and/or influence of that individual or entity in a particular community or subset of a particular community.
An individual or entity's connectivity within a network community, however, is difficult to quantify. For example, network communities may include hundreds, thousands, millions, billions or more members. Each member may possess varying degrees of connectivity information about itself and possibly about other members of the community. Some of this information may be highly credible or objective, while other information may be less credible and subjective. In addition, connectivity information from community members may come in various forms and on various scales, making it difficult to meaningfully compare one member's “trustworthiness” or “competence” and connectivity information with another member's “trustworthiness” or “competence” and connectivity information. Also, many individuals may belong to multiple communities, further complicating the determination of a quantifiable representation of trust and connectivity within a network community. Even if a quantifiable representation of an individual's connectivity is determined, it is often difficult to use this representation in a meaningful way to make real-world decisions about the individual (e.g., whether or not to trust the individual).
Further, it may be useful for these real-world decisions to be made prospectively (i.e., in advance of an anticipated event). Such prospective analysis may be difficult as an individual or entity's connectivity within a network community may change rapidly as the connections between the individual or entity and others in the network community may change quantitatively or qualitatively. This analysis becomes increasingly complex as if applied across multiple communities.
SUMMARY OF THE INVENTION
In view of the foregoing, systems and methods are provided for determining the connectivity between nodes within a network community and inferring attributes, such as trustworthiness or competence, from the connectivity. Connectivity may be determined, at least in part, using various graph traversal and normalization techniques described in more detail below.
In an embodiment, a path counting approach may be used where processing circuitry is configured to count the number of paths between a first node n 1 and a second node n 2 within a network community. A connectivity rating R n1n2 may then be assigned to the nodes. The assigned connectivity rating may be proportional to the number of subpaths, or relationships, connecting the two nodes, among other possible measures. Using the number of subpaths as a measure, a path with one or more intermediate nodes between the first node n 1 and the second node n 2 may be scaled by an appropriate number (e.g., the number of intermediate nodes) and this scaled number may be used to calculate the connectivity rating.
In some embodiments, weighted links are used in addition or as an alternative to the subpath counting approach. Processing circuitry may be configured to assign a relative user weight to each path connecting a first node n 1 and a second node n 2 within a network community. A user connectivity value may be assigned to each link. For example, a user or entity associated with node n 1 may assign user connectivity values for all outgoing paths from node n 1 . In some embodiments, the connectivity values assigned by the user or entity may be indicative of that user or entity's trust in the user or entity associated with node n 2 . The link values assigned by a particular user or entity may then be compared to each other to determine a relative user weight for each link.
The relative user weight for each link may be determined by first computing the average of all the user connectivity values assigned by that user (i.e., the out-link values). If t i is the user connectivity value assigned to link i, then the relative user weight, w i , assigned to that link may be given in accordance with:
w i =1+( t i − t i ) 2 (1)
To determine the overall weight of a path, in some embodiments, the weights of all the links along the path may be multiplied together. The overall path weight may then be given in accordance with:
w path =Π( w i ) (2)
The connectivity value for the path may then be defined as the minimum user connectivity value of all the links in the path multiplied by the overall path weight in accordance with:
t path =w path ×t min (3)
To determine path connectivity values, in some embodiments, a parallel computational framework or distributed computational framework (or both) may be used. For example, in one embodiment, a number of core processors implement an Apache Hadoop or Google MapReduce cluster. This cluster may perform some or all of the distributed computations in connection with determining new path link values and path weights.
The processing circuitry may identify a changed node within a network community. For example, a new outgoing link may be added, a link may be removed, or a user connectivity value may have been changed. In response to identifying a changed node, in some embodiments, the processing circuitry may recompute link, path, and weight values associated with some or all nodes in the implicated network community or communities.
In some embodiments, only values associated with affected nodes in the network community are recomputed after a changed node is identified. If there exists at least one changed node in the network community, the changed node or nodes may first undergo a prepare process. The prepare process may include a “map” phase and “reduce” phase. In the map phase of the prepare process, the prepare process may be divided into smaller sub-processes which are then distributed to a core in the parallel computational framework cluster. For example, each node or link change (e.g., tail to out-link change and head to in-link change) may be mapped to a different core for parallel computation. In the reduce phase of the prepare process, each out-link's weight may be determined in accordance with equation (1). Each of the out-link weights may then be normalized by the sum of the out-link weights (or any other suitable value). The node table may then be updated for each changed node, its in-links, and its out-links.
After the changed nodes have been prepared, the paths originating from each changed node may be calculated. Once again, a “map” and “reduce” phase of this process may be defined. During this process, in some embodiments, a depth-first search may be performed of the node digraph or node tree. All affected ancestor nodes may then be identified and their paths recalculated.
In some embodiments, to improve performance, paths may be grouped by the last node in the path. For example, all paths ending with node n 1 may be grouped together, all paths ending with node n 2 may be grouped together, and so on. These path groups may then be stored separately (e.g., in different columns of a single database table). In some embodiments, the path groups may be stored in columns of a key-value store implementing an HBase cluster (or any other compressed, high performance database system, such as BigTable).
In some embodiments, one or more threshold functions may be defined. The threshold function or functions may be used to determine the maximum number of links in a path that will be analyzed in a connectivity determination or connectivity computation. Threshold factors may also be defined for minimum link weights, path weights, or both. Weights falling below a user-defined or system-defined threshold may be ignored in a connectivity determination or connectivity computation, while only weights of sufficient magnitude may be considered.
In some embodiments, a user connectivity value may represent the degree of trust between a first node and a second node. In one embodiment, node n 1 may assign a user connectivity value of l 1 to a link between it and node n 2 . Node n 2 may also assign a user connectivity value of l 2 to a reverse link between it and node n 1 . The values of l 1 and l 2 may be at least partially subjective indications of the trustworthiness of the individual or entity associated with the node connected by the link. For example, one or more of the individual or entity's reputation, status, and/or influence within the network community (or some other community), the individual or entity's alignment with the trusting party (e.g., political, social, or religious alignment), past dealings with the individual or entity, and the individual or entity's character and integrity (or any other relevant considerations) may be used to determine a partially subjective user connectivity value indicative of trust. A user (or other individual authorized by the node) may then assign this value to an outgoing link connecting the node to the individual or entity. Objective measures (e.g., data from third-party ratings agencies or credit bureaus) may also be used, in some embodiments, to form composite user connectivity values indicative of trust. The subjective, objective, or both types of measures may be automatically harvested or manually inputted for analysis.
In some embodiments, a decision-making algorithm may access the connectivity values in order to make automatic decisions (e.g., automatic network-based decisions, such as authentication or identity requests) on behalf of a user. Connectivity values may additionally or alternatively be outputted to external systems and processes located at third-parties. The external systems and processes may be configured to automatically initiate a transaction (or take some particular course of action) based, at least in part, on received connectivity values. For example, electronic or online advertising may be targeted to subgroups of members of a network community based, at least in part, on network connectivity values.
In some embodiments, a decision-making algorithm may access the connectivity values to make decisions prospectively (e.g., before an anticipated event like a request for credit). Such decisions may be made at the request of a user, or as part of an automated process (e.g., a credit bureau's periodic automated analysis of a database of customer information). This prospective analysis may allow for the initiation of a transaction (or taking of some particular action) in a fluid and/or dynamic manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, and in which:
FIG. 1 is an illustrative block diagram of a network architecture used to support connectivity within a network community in accordance with one embodiment of the invention;
FIG. 2 is another illustrative block diagram of a network architecture used to support connectivity within a network community in accordance with one embodiment of the invention;
FIGS. 3A and 3B show illustrative data tables for supporting connectivity determinations within a network community in accordance with one embodiment of the invention;
FIGS. 4A-4E show illustrative processes for supporting connectivity determinations within a network community in accordance with one embodiment of the invention; and
FIG. 5 shows an illustrative process for querying all paths to a target node and computing a network connectivity value in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
Systems and methods for determining the connectivity between nodes in a network community are provided. As defined herein, a “node” may include any user terminal, network device, computer, mobile device, access point, or any other electronic device. In some embodiments, a node may also represent an individual human being, entity (e.g., a legal entity, such as a public or private company, corporation, limited liability company (LLC), partnership, sole proprietorship, or charitable organization), concept (e.g., a social networking group), animal, or inanimate object (e.g., a car, aircraft, or tool). As also defined herein, a “network community” may include a collection of nodes and may represent any group of devices, individuals, or entities.
For example, all or some subset of the users of a social networking website or social networking service (or any other type of website or service, such as an online gaming community) may make up a single network community. Each user may be represented by a node in the network community. As another example, all the subscribers to a particular newsgroup or distribution list may make up a single network community, where each individual subscriber may be represented by a node in the network community. Any particular node may belong in zero, one, or more than one network community, or a node may be banned from all, or a subset of, the community. To facilitate network community additions, deletions, and link changes, in some embodiments a network community may be represented by a directed graph, or digraph, weighted digraph, tree, or any other suitable data structure.
FIG. 1 shows illustrative network architecture 100 used to support the connectivity determinations within a network community. A user may utilize access application 102 to access application server 106 over communications network 104 . For example, access application 102 may include a standard web browser, application server 106 may include a web server, and communication network 106 may include the Internet. Access application 102 may also include proprietary applications specifically developed for one or more platforms or devices. For example, access application 102 may include one or more instances of an Apple iOS, Android, or WebOS application or any suitable application for use in accessing application 106 over communications network 104 . Multiple users may access application service 106 via one or more instances of access application 102 . For example, a plurality of mobile devices may each have an instance of access application 102 running locally on the devices. One or more users may use an instance of access application 102 to interact with application server 106 .
Communication network 104 may include any wired or wireless network, such as the Internet, WiMax, wide area cellular, or local area wireless network. Communication network 104 may also include personal area networks, such as Bluetooth and infrared networks. Communications on communications network 104 may be encrypted or otherwise secured using any suitable security or encryption protocol.
Application server 106 , which may include any network server or virtual server, such as a file or web server, may access data sources 108 locally or over any suitable network connection. Application server 106 may also include processing circuitry (e.g., one or more microprocessors), memory (e.g., RAM, ROM, and hybrid types of memory), storage devices (e.g., hard drives, optical drives, and tape drives). The processing circuitry included in application server 106 may execute a server process for supporting the network connectivity determinations of the present invention, while access application 102 executes a corresponding client process. The processing circuitry included in application server 106 may also perform any of the calculations and computations described herein in connection with determining network connectivity. In some embodiments, a computer-readable medium with computer program logic recorded thereon is included within application server 106 . The computer program logic may determine the connectivity between two or more nodes in a network community and it may or may not output such connectivity to a display screen or data
For example, application server 106 may access data sources 108 over the Internet, a secured private LAN, or any other communications network. Data sources 108 may include one or more third-party data sources, such as data from third-party social networking services and third-party ratings bureaus. For example, data sources 108 may include user and relationship data (e.g., “friend” or “follower” data) from one or more of Facebook, MySpace, openSocial, Friendster, Bebo, hi5, Orkut, PerfSpot, Yahoo! 360, LinkedIn, Twitter, Google Buzz, Really Simple Syndication readers or any other social networking website or information service. Data sources 108 may also include data stores and databases local to application server 106 containing relationship information about users accessing application server 106 via access application 102 (e.g., databases of addresses, legal records, transportation passenger lists, gambling patterns, political and/or charity donations, political affiliations, vehicle license plate or identification numbers, universal product codes, news articles, business listings, and hospital or university affiliations).
Application server 106 may be in communication with one or more of data store 110 , key-value store 112 , and parallel computational framework 114 . Data store 110 , which may include any relational database management system (RDBMS), file server, or storage system, may store information relating to one or more network communities. For example, one or more of data tables 300 ( FIG. 3A ) may be stored on data store 110 . Data store 110 may store identity information about users and entities in the network community, an identification of the nodes in the network community, user link and path weights, user configuration settings, system configuration settings, and/or any other suitable information. There may be one instance of data store 110 per network community, or data store 110 may store information relating to a plural number of network communities. For example, data store 110 may include one database per network community, or one database may store information about all available network communities (e.g., information about one network community per database table).
Parallel computational framework 114 , which may include any parallel or distributed computational framework or cluster, may be configured to divide computational jobs into smaller jobs to be performed simultaneously, in a distributed fashion, or both. For example, parallel computational framework 114 may support data-intensive distributed applications by implementing a map/reduce computational paradigm where the applications may be divided into a plurality of small fragments of work, each of which may be executed or re-executed on any core processor in a cluster of cores. A suitable example of parallel computational framework 114 includes an Apache Hadoop cluster.
Parallel computational framework 114 may interface with key-value store 112 , which also may take the form of a cluster of cores. Key-value store 112 may hold sets of key-value pairs for use with the map/reduce computational paradigm implemented by parallel computational framework 114 . For example, parallel computational framework 114 may express a large distributed computation as a sequence of distributed operations on data sets of key-value pairs. User-defined map/reduce jobs may be executed across a plurality of nodes in the cluster. The processing and computations described herein may be performed, at least in part, by any type of processor or combination of processors. For example, various types of quantum processors (e.g., solid-state quantum processors and light-based quantum processors), artificial neural networks, and the like may be used to perform massively parallel computing and processing.
In some embodiments, parallel computational framework 114 may support two distinct phases, a “map” phase and a “reduce” phase. The input to the computation may include a data set of key-value pairs stored at key-value store 112 . In the map phase, parallel computational framework 114 may split, or divide, the input data set into a large number of fragments and assign each fragment to a map task. Parallel computational framework 114 may also distribute the map tasks across the cluster of nodes on which it operates. Each map task may consume key-value pairs from its assigned fragment and produce a set of intermediate key-value pairs. For each input key-value pair, the map task may invoke a user defined map function that transmutes the input into a different key-value pair. Following the map phase, parallel computational framework 114 may sort the intermediate data set by key and produce a collection of tuples so that all the values associated with a particular key appear together. Parallel computational framework 114 may also partition the collection of tuples into a number of fragments equal to the number of reduce tasks.
In the reduce phase, each reduce task may consume the fragment of tuples assigned to it. For each such tuple, the reduce task may invoke a user-defined reduce function that transmutes the tuple into an output key-value pair. Parallel computational framework 114 may then distribute the many reduce tasks across the cluster of nodes and provide the appropriate fragment of intermediate data to each reduce task.
Tasks in each phase may be executed in a fault-tolerant manner, so that if one or more nodes fail during a computation the tasks assigned to such failed nodes may be redistributed across the remaining nodes. This behavior may allow for load balancing and for failed tasks to be re-executed with low runtime overhead.
Key-value store 112 may implement any distributed file system capable of storing large files reliably. For example key-value store 112 may implement Hadoop's own distributed file system (DFS) or a more scalable column-oriented distributed database, such as HBase. Such file systems or databases may include BigTable-like capabilities, such as support for an arbitrary number of table columns.
Although FIG. 1 , in order to not over-complicate the drawing, only shows a single instance of access application 102 , communications network 104 , application server 106 , data source 108 , data store 110 , key-value store 112 , and parallel computational framework 114 , in practice network architecture 100 may include multiple instances of one or more of the foregoing components. In addition, key-value store 112 and parallel computational framework 114 may also be removed, in some embodiments. As shown in network architecture 200 of FIG. 2 , the parallel or distributed computations carried out by key-value store 112 and/or parallel computational framework 114 may be additionally or alternatively performed by a cluster of mobile devices 202 instead of stationary cores. In some embodiments, cluster of mobile devices 202 , key-value store 112 , and parallel computational framework 114 are all present in the network architecture. Certain application processes and computations may be performed by cluster of mobile devices 202 and certain other application processes and computations may be performed by key-value store 112 and parallel computational framework 114 . In addition, in some embodiments, communication network 104 itself may perform some or all of the application processes and computations. For example, specially-configured routers or satellites may include processing circuitry adapted to carry out some or all of the application processes and computations described herein.
Cluster of mobile devices 202 may include one or more mobile devices, such as PDAs, cellular telephones, mobile computers, or any other mobile computing device. Cluster of mobile devices 202 may also include any appliance (e.g., audio/video systems, microwaves, refrigerators, food processors) containing a microprocessor (e.g., with spare processing time), storage, or both. Application server 106 may instruct devices within cluster of mobile devices 202 to perform computation, storage, or both in a similar fashion as would have been distributed to multiple fixed cores by parallel computational framework 114 and the map/reduce computational paradigm. Each device in cluster of mobile devices 202 may perform a discrete computational job, storage job, or both. Application server 106 may combine the results of each distributed job and return a final result of the computation.
FIG. 3A shows illustrative data tables 300 used to support the connectivity determinations of the present invention. One or more of tables 300 may be stored in, for example, a relational database in data store 110 ( FIG. 1 ). Table 302 may store an identification of all the nodes registered in the network community. A unique identifier may be assigned to each node and stored in table 302 . In addition, a string name may be associated with each node and stored in table 302 . As described above, in some embodiments, nodes may represent individuals or entities, in which case the string name may include the individual or person's first and/or last name, nickname, handle, or entity name.
Table 304 may store user connectivity values. In some embodiments, user connectivity values may be assigned automatically by the system (e.g., by application server 106 ( FIG. 1 )). For example, application server 106 ( FIG. 1 ) may monitor all electronic interaction (e.g., electronic communication, electronic transactions, or both) between members of a network community. In some embodiments, a default user connectivity value (e.g., the link value 1) may be assigned initially to all links in the network community. After electronic interaction is identified between two or more nodes in the network community, user connectivity values may be adjusted upwards or downwards depending on the type of interaction between the nodes and the result of the interaction. For example, each simple email exchange between two nodes may automatically increase or decrease the user connectivity values connecting those two nodes by a fixed amount. More complicated interactions (e.g., product or service sales or inquires) between two nodes may increase or decrease the user connectivity values connecting those two nodes by some larger fixed amount. In some embodiments, user connectivity values between two nodes may always be increased unless a user or node indicates that the interaction was unfavorable, not successfully completed, or otherwise adverse. For example, a transaction may not have been timely executed or an email exchange may have been particularly displeasing. Adverse interactions may automatically decrease user connectivity values while all other interactions may increase user connectivity values (or have no effect). In addition, user connectivity values may be automatically harvested using outside sources. For example, third-party data sources (such as ratings agencies and credit bureaus) may be automatically queried for connectivity information. This connectivity information may include completely objective information, completely subjective information, composite information that is partially objective and partially subjective, any other suitable connectivity information, or any combination of the foregoing.
In some embodiments, user connectivity values may be manually assigned by members of the network community. These values may represent, for example, the degree or level of trust between two users or nodes or one node's assessment of another node's competence in some endeavor. As described above, user connectivity values may include a subjective component and an objective component in some embodiments. The subjective component may include a trustworthiness “score” indicative of how trustworthy a first user or node finds a second user, node, community, or subcommunity. This score or value may be entirely subjective and based on interactions between the two users, nodes, or communities. A composite user connectivity value including subjective and objective components may also be used. For example, third-party information may be consulted to form an objective component based on, for example, the number of consumer complaints, credit score, socio-economic factors (e.g., age, income, political or religions affiliations, and criminal history), or number of citations/hits in the media or in search engine searches. Third-party information may be accessed using communications network 104 ( FIG. 1 ). For example, a third-party credit bureau's database may be polled or a personal biography and background information, including criminal history information, may be accessed from a third-party database or data source (e.g., as part of data sources 108 ( FIG. 1 ) or a separate data source) or input directly by a node, user, or system administrator.
Table 304 may store an identification of a link head, link tail, and user connectivity value for the link. Links may or may not be bidirectional. For example, a user connectivity value from node n 1 to node n 2 may be different (and completely separate) than a link from node n 2 to node n 1 . Especially in the trust context described above, each user can assign his or her own user connectivity value to a link (i.e., two users need not trust each other an equal amount in some embodiments).
Table 306 may store an audit log of table 304 . Table 306 may be analyzed to determine which nodes or links have changed in the network community. In some embodiments, a database trigger is used to automatically insert an audit record into table 306 whenever a change of the data in table 304 is detected. For example, a new link may be created, a link may be removed, or a user connectivity value may be changed. This audit log may allow for decisions related to connectivity values to be made prospectively (i.e., before an anticipated event). Such decisions may be made at the request of a user, or as part of an automated process, such as the processes described below with respect to FIG. 5 . This prospective analysis may allow for the initiation of a transaction (or taking of some particular action) in a fluid and/or dynamic manner. After such a change is detected, the trigger may automatically create a new row in table 306 . Table 306 may store an identification of the changed node, and identification of the changed link head, changed link tail, and the user connectivity value to be assigned to the changed link. Table 306 may also store a timestamp indicative of the time of the change and an operation code. In some embodiments, operation codes may include “insert,” “update,” or “delete” operations, corresponding to whether a link was inserted, a user connectivity value was changed, or a link was deleted, respectively. Other operation codes may be used in other embodiments.
FIG. 3B shows illustrative data structure 310 used to support the connectivity determinations of the present invention. In some embodiments, data structure 310 may be stored using key-value store 112 ( FIG. 1 ), while tables 300 are stored in data store 110 ( FIG. 1 ). As described above, key-value store 112 ( FIG. 1 ) may implement an HBase storage system and include BigTable support. Like a traditional relational database management system, the data shown in FIG. 3B may be stored in tables. However, the BigTable support may allow for an arbitrary number of columns in each table, whereas traditional relational database management systems may require a fixed number of columns.
Data structure 310 may include node table 312 . In the example shown in FIG. 3B , node table 312 includes several columns. Node table 312 may include row identifier column 314 , which may store 64-bit, 128-bit, 256-bit, 512-bit, or 1024-bit integers and may be used to uniquely identify each row (e.g., each node) in node table 312 . Column 316 may include a list of all the incoming links for the current node. Column 318 may include a list of all the outgoing links for the current node. Column 320 may include a list of node identifiers to which the current node is connected. A first node may be connected to a second node if outgoing links may be followed to reach the second node. For example, for A→B, A is connected to B, but B may not be connected to A. As described in more detail below, column 320 may be used during the portion of process 400 ( FIG. 4A ) shown in FIG. 4B . Node table 312 may also include one or more “bucket” columns 322 . These columns may store a list of paths that connect the current node to a target node. As described above, grouping paths by the last node in the path (e.g., the target node) may facilitate connectivity computations. As shown in FIG. 3B , in some embodiments, to facilitate scanning, bucket column names may include the target node identifier appended to the end of the “bucket:” column
FIGS. 4A-4D show illustrative processes for determining the connectivity of nodes within a network community. FIG. 4A shows process 400 for updating a connectivity graph (or any other suitable data structure) associated with a network community. As described above, in some embodiments, each network community is associated with its own connectivity graph, digraph, tree, or other suitable data structure. In other embodiments, a plurality of network communities may share one or more connectivity graphs (or other data structure).
In some embodiments, the processes described with respect to FIG. 4A-4D may be executed to make decisions prospectively (i.e., before an anticipated event). Such decisions may be made at the request of a user, or as part of an automated process, such as the processes described below with respect to FIG. 5 . This prospective analysis may allow for the initiation of a transaction (or taking of some particular action) in a fluid and/or dynamic manner.
At step 402 , a determination is made whether at least one node has changed in the network community. As described above, an audit record may be inserted into table 306 ( FIG. 3 ) after a node has changed. By analyzing table 306 ( FIG. 3 ), a determination may be made (e.g., by application server 106 of FIG. 1 ) that a new link has been added, an existing link has been removed, or a user connectivity value has changed. If, at step 404 , it is determined that a node has changed, then process 400 continues to step 410 (shown in FIG. 4B ) to prepare the changed nodes, step 412 (shown in FIG. 4C ) to calculate paths originating from the changed nodes, step 414 (shown in FIG. 4D ) to remove paths that go through a changed node, and step 416 (shown in FIG. 4E ) to calculate paths that go through a changed node. It should be noted that more than one step or task shown in FIGS. 4B, 4C, 4D, and 4E may be performed in parallel using, for example, a cluster of cores. For example, multiple steps or tasks shown in FIG. 4B may be executed in parallel or in a distributed fashion, then multiple steps or tasks shown in FIG. 4C may be executed in parallel or in a distributed fashion, then multiple steps or tasks shown in FIG. 4D may be executed in parallel or in a distributed fashion, and then multiple steps or tasks shown in FIG. 4E may be executed in parallel or in a distributed fashion. In this way, overall latency associated with process 400 may be reduced.
If a node change is not detected at step 404 , then process 400 enters a sleep mode at step 406 . For example, in some embodiments, an application thread or process may continuously check to determine if at least one node or link has changed in the network community. In other embodiments, the application thread or process may periodically check for changed links and nodes every n seconds, where n is any positive number. After the paths are calculated that go through a changed node at step 416 or after a period of sleep at step 406 , process 400 may determine whether or not to loop at step 408 . For example, if all changed nodes have been updated, then process 400 may stop at step 418 . If, however, there are more changed nodes or links to process, then process 400 may loop at step 408 and return to step 404 .
In practice, one or more steps shown in process 400 may be combined with other steps, performed in any suitable order, performed in parallel (e.g., simultaneously or substantially simultaneously), or removed.
FIGS. 4B-4E each include processes with a “map” phase and “reduce” phase. As described above, these phases may form part of a map/reduce computational paradigm carried out by parallel computational framework 114 ( FIG. 1 ), key-value store 112 ( FIG. 1 ), or both. As shown in FIG. 4B , in order to prepare any changed nodes, map phase 420 may include determining if there are any more link changes at step 422 , retrieving the next link change at step 440 , mapping the tail to out-link change at step 442 , and mapping the head to in-link change at step 444 .
If there are no more link changes at step 422 , then, in reduce phase 424 , a determination may be made at step 426 that there are more nodes and link changes to process. If so, then the next node and its link changes may be retrieved at step 428 . The most recent link changes may be preserved at step 430 while any intermediate link changes are replaced by more recent changes. For example, the timestamp stored in table 306 ( FIG. 3 ) may be used to determine the time of every link or node change. At step 432 , the average out-link user connectivity value may be calculated. For example, if node n 1 has eight out-links with assigned user connectivity values, these eight user connectivity values may be averaged at step 432 . At step 434 , each out-link's weight may be calculated in accordance with equation (1) above. All the out-link weights may then be summed and used to normalize each out-link weight at step 436 . For example, each out-link weight may be divided by the sum of all out-link weights. This may yield a weight between 0 and 1 for each out-link. At step 438 , the existing buckets for the changed node, in-links, and out-links may be saved. For example, the buckets may be saved in key-value store 112 ( FIG. 1 ) or data store 110 ( FIG. 1 ). If there are no more nodes and link changes to process at step 426 , the process may stop at step 446 .
As shown in FIG. 4C , in order to calculate paths originating from changed nodes, map phase 448 may include determining if there are any more changed nodes at step 450 , retrieving the next changed node at step 466 , marking existing buckets for deletion by mapping changed nodes to the NULL path at step 468 , recursively generating paths by following out-links at step 470 , and if the path is a qualified path, mapping the tail to the path. Qualified paths may include paths that satisfy one or more predefined threshold functions. For example, a threshold function may specify a minimum path weight. Paths with path weights greater than the minimum path weight may be designated as qualified paths.
If there are no more changed nodes at step 450 , then, in reduce phase 452 , a determination may be made at step 454 that there are more nodes and paths to process. If so, then the next node and its paths may be retrieved at step 456 . At step 458 , buckets may be created by grouping paths by their head. If a bucket contains only the NULL path at step 460 , then the corresponding cell in the node table may be deleted at step 462 . If the bucket contains more than the NULL path, then at step 464 the bucket is saved to the corresponding cell in the node table. If there are no more nodes and paths to process at step 456 , the process may stop at step 474 .
As shown in FIG. 4D , in order to remove paths that go through a changed node, map phase 476 may include determining if there are any more changed nodes at step 478 and retrieving the next changed node at step 488 . At step 490 , the “bucket:” column in the node table (e.g., column 322 of node table 312 (both of FIG. 3B )) corresponding to the changed node may be scanned. For example, as described above, the target node identifier may be appended to the end of the “bucket:” column name. Each bucket may include a list of paths that connect the current node to the target node (e.g., the changed node). At step 492 , for each matching node found by the scan and the changed node's old buckets, the matching node may be matched to a (changed node, old bucket) deletion pair.
If there are no more changed nodes at step 478 , then, in reduce phase 480 , a determination may be made at step 484 that there are more node and deletion pairs to process. If so, then the next node and its deletion pairs may be retrieved at step 484 . At step 486 , for each deletion pair, any paths that go through the changed node in the old bucket may be deleted. If there are no more nodes and deletion pairs to process at step 482 , the process may stop at step 494 .
As shown in FIG. 4E , in order to calculate paths that go through a changed node, map phase 496 may include determining if there are any more changed nodes at step 498 and retrieving the next changed node at step 508 . At step 510 , the “bucket:” column in the node table (e.g., column 322 of node table 312 (both of FIG. 3B )) corresponding to the changed node may be scanned. At step 512 , for each matching node found in the scan and the changed node's paths, all paths in the scanned bucket may be joined with all paths of the changed bucket. At step 514 , each matching node may be mapped to each qualified joined
If there are no more changed nodes at step 498 , then, in reduce phase 500 , a determination may be made at step 502 that there are more node and paths to process. If so, then the next node and its paths may be retrieved at step 504 . Each path may then be added to the appropriate node bucket at step 506 . If there are no more nodes and paths to process at step 502 , the process may stop at step 516 .
FIG. 5 shows illustrative process 520 for supporting a user query for all paths from a first node to a target node. For example, a first node (representing, for example, a first individual or entity) may wish to know how connected the first node is to some second node (representing, for example, a second individual or entity) in the network community. In the context of trust described above (and where the user connectivity values represent, for example, at least partially subjective user trust values), this query may return an indication of how much the first node may trust the second node. In general, the more paths connecting the two nodes may yield a greater (or lesser if, for example, adverse ratings are used) network connectivity value (or network trust amount).
At step 522 , the node table cell where the row identifier equals the first node identifier and the column equals the target node identifier appended to the “bucket:” column name prefix is accessed. All paths may be read from this cell at step 524 . The path weights assigned to the paths read at step 524 may then be summed at step 526 . At step 528 , the path weights may be normalized by dividing each path weight by the computed sum of the path weights. A network connectivity value may then be computed at step 530 . For example, each path's user connectivity value may be multiplied by its normalized path weight. The network connectivity value may then be computed in some embodiments in accordance with:
t network =Σt path ×w path (4)
where t path is the user connectivity value for a path (given in accordance with equation (3)) and w path is the normalized weight for that path. The network connectivity value may then be held or outputted (e.g., displayed on a display device, output by processing circuitry of application server 106 , and/or stored on data store 110 ( FIG. 1 )). In addition, a decision-making algorithm may access the network connectivity value in order to make automatic decisions (e.g., automatic network-based decisions, such as authentication or identity requests) on behalf of the user. Network connectivity values may additionally or alternatively be outputted to external systems and processes located at third-parties. The external systems and processes may be configured to automatically initiate a transaction (or take some particular course of action) based, at least in part, on the received network connectivity values. Process 520 may stop at step 532 .
In practice, one or more steps shown in process 520 may be combined with other steps, performed in any suitable order, performed in parallel (e.g., simultaneously or substantially simultaneously), or removed. In addition, as described above, various threshold functions may be used in order to reduce computational complexity. For example, a threshold function defining the maximum number of links to traverse may be defined. Paths containing more than the threshold specified by the threshold function may not be considered in the network connectivity determination. In addition, various threshold functions relating to link and path weights may be defined. Links or paths below the threshold weight specified by the threshold function may not be considered in the network connectivity determination.
Although process 520 describes a single user query for all paths from a first node to a target node, in actual implementations groups of nodes may initiate a single query for all the paths from each node in the group to a particular target node. For example, multiple members of a network community may all initiate a group query to a target node. Process 520 may return an individual network connectivity value for each querying node in the group or a single composite network connectivity value taking into account all the nodes in the querying group. For example, the individual network connectivity values may be averaged to form a composite value or some weighted average may be used. The weights assigned to each individual network connectivity value may be based on, for example, seniority in the community (e.g., how long each node has been a member in the community), rank, or social stature. In addition, in some embodiments, a user may initiate a request for network connectivity values for multiple target nodes in a single query. For example, node n 1 may wish to determine network connectivity values between it and multiple other nodes. For example, the multiple other nodes may represent several candidates for initiating a particular transaction with node n 1 . By querying for all the network connectivity values in a single query, the computations may be distributed in a parallel fashion to multiple cores so that some or all of the results are computed substantially simultaneously.
In addition, queries may be initiated in a number of ways. For example, a user (represented by a source node) may identify another user (represented by a target node) in order to automatically initiate process 520 . A user may identify the target node in any suitable way, for example, by selecting the target node from a visual display, graph, or tree, by inputting or selecting a username, handle, network address, email address, telephone number, geographic coordinates, or unique identifier associated with the target node, or by speaking a predetermined command (e.g., “query node 1 ” or “query node group 1 , 5 , 9 ” where 1 , 5 , and 9 represent unique node identifiers). After an identification of the target node or nodes is received, process 520 may be automatically executed. The results of the process (e.g., the individual or composite network connectivity values) may then be automatically sent to one or more third-party services or processes as described above.
In an embodiment, a user may utilize access application 102 to generate a user query that is sent to access application server 106 over communications network 104 (see also, FIG. 1 ) and automatically initiate process 520 . For example, a user may access an Apple iOS, Android, or WebOS application or any suitable application for use in accessing application 106 over communications network 104 . The application may display a searchable list of relationship data related to that user (e.g., “friend” or “follower” data) from one or more of Facebook, MySpace, openSocial, Friendster, Bebo, hi5, Orkut, PerfSpot, Yahoo! 360, LinkedIn, Twitter, Google Buzz, Really Simple Syndication readers or any other social networking website or information service. In some embodiments, a user may search for relationship data that is not readily listed—i.e., search Facebook, Twitter, or any suitable database of information for target nodes that are not displayed in the searchable list of relationship data. A user may select a target node as described above (e.g., select an item from a list of usernames representing a “friend” or “follower”) to request a measure of how connected the user is to the target node. Using the processes described with respect to FIGS. 3 and 4A -D, this query may return an indication of how much the user may trust the target node. The returned indication may be displayed to the user using any suitable indicator. In some embodiments, indicator may be a percentage that indicates how trustworthy the target node is to the user.
In some embodiments, a user may utilize access application 102 to provide manual assignments of at least partially subjective indications of how trustworthy the target node is. For example, the user may specify that he or she trusts a selected target node (e.g., a selected “friend” or “follower”) to a particular degree. The particular degree may be in the form of a percentage that represents the user's perception of how trustworthy the target node is. The user may provide this indication before, after, or during process 520 described above. The indication provided by the user (e.g., the at least partially subjective indications of trustworthiness) may then be automatically sent to one or more third-party services or processes as described above. In some embodiments, the indications provided by the user may cause a node and/or link to change in a network community. This change may cause a determination to be made that at least one node and/or link has changed in the network community, which in turn triggers various processes as described with respect to FIGS. 3 and 4A-4D .
In some embodiments, a path counting approach may be used in addition to or in place of the weighted link approach described above. Processing circuitry (e.g., of application server 106 ) may be configured to count the number of paths between a first node n 1 and a second node n 2 within a network community. A connectivity rating R n1n2 may then be assigned to the nodes. The assigned connectivity rating may be proportional to the number of paths, or relationships, connecting the two nodes. A path with one or more intermediate nodes between the first node n 1 and the second node n 2 may be scaled by an appropriate number (e.g., the number of intermediate nodes) and this scaled number may be used to calculate the connectivity rating.
Each equation presented above should be construed as a class of equations of a similar kind, with the actual equation presented being one representative example of the class. For example, the equations presented above include all mathematically equivalent versions of those equations, reductions, simplifications, normalizations, and other equations of the same degree.
The above described embodiments of the invention are presented for purposes of illustration and not of limitation. The following numbered paragraphs give additional embodiments of the present invention. | Systems and methods to determine trust scores and/or trustworthiness levels and/or connectivity are described herein. Trust and/or Trustworthiness and/or connectivity may be determined within, among or between entities and/or individuals. Social analytics and network calculations described herein may be based on user-assigned links or ratings and/or objective measures, such as data from third-party ratings agencies. The trust score may provide guidance about the trustworthiness, alignment, reputation, status, membership status and/or influence about an individual, entity, or group. The systems and methods described herein may be used to make prospective real-world decisions, such as whether or not to initiate a transaction or relationship with another person, or whether to grant a request for credit. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to speed control of vehicles and has particular application to the speed control of vehicles, such as forklifts, that are often used in indoor areas having speed restrictions.
BACKGROUND OF THE INVENTION
[0002] In most workplaces today there is considerable emphasis on safety in the workplace. One area for improvement is the operation of machinery and vehicles in indoor speed restricted areas.
[0003] Speed controlling devices for vehicles, particularly cars and trucks, are well known. Many of these known speed controlling devices act to permanently limit the maximum speed of the vehicle usually in response to a preset speed limit or in response to external stimuli such as road markings.
[0004] Vehicles such as forklifts are typically operated in workplaces where there are safety zones e.g. inside a factory where pedestrians share the pathways. These safety zones are typically restricted vehicle speed areas so as to reduce the risk of accidents and injury.
[0005] One system of controlling the speed of a forklift includes a built-in speed limiter which controls the maximum speed of the forklift to a single predetermined fixed value. A system of this type limits the speed of the forklift wherever the forklift may be, even when the forklift is outside in the open where speed restrictions may not exist. A further disadvantage of this existing system is that it is not suitable for use on electric vehicles. The speed limiter is typically mounted in the differential and measures the speed of the vehicle. The measured speed is converted by an electronic control unit into a control signal which controls a stepping motor.
[0006] Other known types of speed controllers automatically set the speed of the vehicle depending on the location of the vehicle. These types of speed controllers suffer the disadvantage that they do not allow any manual control of the speed of the vehicle.
[0007] There is therefore a need to regulate the speed of vehicles or machinery to suit the prevailing speed restrictions.
[0008] It is therefore an object of the invention to provide a speed controller for vehicles which selectively limits the speed of the vehicle.
SUMMARY OF THE INVENTION
[0009] The invention accordingly provides a system for selectively limiting the speed of a vehicle, wherein said system includes a sensor device located on the vehicle, the sensor being directed away from the vehicle so as to detect a structure nearby the vehicle, and a controller which, in response to the sensor detecting the structure, imposes a speed limit on the vehicle.
[0010] Advantageously, the sensor is located on an upper surface of the vehicle, the sensor being directed upwardly so as to detect a structure above the vehicle.
[0011] The system may also incorporate a colour sensor mounted on the vehicle to detect different speed zones indicated by different colour markings or other electronic sensing on the floor or walls of a factory, for example.
[0012] Advantageously, the vehicle is a forklift, or other load-moving vehicle commonly used indoors.
[0013] Preferably, the controller adjusts the vehicles speed with the use of an electronic device which is powered by the vehicle's power supply. The electronic device adjusts an actuator which is connected to the vehicle's throttle. The controller responds to the vehicle's speed via a speed detector and, via the electronic device, corrects the accelerator to enforce a maximum speed depending on the location of the vehicle.
[0014] Preferably, the structure is the roof of a building. Speed restricted areas are typically located inside factories where the confined floor space is shared with pedestrians. Alternatively, the structure may be one or more bridge-like structures passing over a road or pathway. The structure may also take the form of a transmitting device, which sends a signal to the sensor on the vehicle identifying the vehicle's location and the relevant speed limit.
[0015] The vehicle preferably has at least one predetermined speed, and more preferably has two maximum speeds—one for inside a building, for example, and one for outside a building. Alternatively, the vehicle may have multiple speeds available.
BRIEF DESCRIPTION OF DRAWINGS
[0016] The invention will now be described by way of example with reference to the accompanying drawings in which:
[0017] [0017]FIG. 1 is a schematic side view of a forklift truck equipped with a speed controller in accordance with the present invention; and
[0018] [0018]FIG. 2 is a flow chart illustrating a preferred control sequence.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] To refer to the drawings, there is shown a forklift truck of known design and construction. The forklift truck has a battery 10 which forms the power supply for the present invention. The battery 10 powers a central control unit 12 and accelerator control unit 22 . Control unit 12 signals accelerator control unit 22 when it is necessary to adjust the speed of the vehicle, as described below. The sequence of operation of the control unit 12 is illustrated in FIG. 2.
[0020] An indoor/outdoor sensor 14 is mounted on the roof 16 of the truck. The sensor 14 is directed upwardly so that, when the truck is inside, the sensor 14 is able to receive a reflected signal from the roof or ceiling of the building (not shown) and will provide a signal to the control unit 12 . The sensor 14 may be of any suitable type such as, for example, microwave, infrared, laser, or radar.
[0021] When the truck is outdoors there may be provided one or more bridge-like structures passing over a road or pathway, which the sensor 14 can detect as the truck passes underneath. Alternatively, the sensor 14 may detect a transmitting device (not shown), which sends a signal to the sensor 14 identifying the vehicle's location, whether indoors or outdoors, and the relevant speed limit.
[0022] The speed of the truck is preferably measured by means of a speed sensor 18 which can determine the speed of the truck by, for example, measuring the rotational speed of the adjacent wheel 20 . Alternatively, the speed of the truck may be determined using a sensor which detects the ground speed of the vehicle. The speed sensor may be of any suitable type such as, for example, microwave, infrared, laser, or radar. The speed of the truck is passed to the control unit 12 .
[0023] If the speed of the truck is above the preset inside maximum speed, and if the sensor 14 receives a return signal, the control unit 12 will signal the accelerator control unit 22 to reduce the speed of the truck until sensor 14 determines that it is at or below the preset speed. The accelerator control unit 22 adjusts an actuator (not shown) which is connected to the vehicle's throttle (not shown), so as to correct the accelerator and impose a maximum speed on the vehicle.
[0024] Naturally, if the speed of the truck is at the preset limit, the control unit 12 does nothing.
[0025] If the speed is below the preset limit, the control unit 12 will allow the truck driver to increase the truck speed, but will not automatically increase the truck speed as the truck driver may have a valid reason for driving at less than the preset speed limit.
[0026] The accelerator control unit 22 serves to control the rate of acceleration of the truck depending on how close the truck speed is to the relevant speed limit. For example, if the truck is travelling at a speed just below the allowed speed limit, the accelerator control until 22 will permit the truck to accelerate slowly up to the speed limit so that the speed limit is not passed.
[0027] When the sensor 14 does not receive a return signal, thus signifying there is no roof and the truck is outdoors, the control unit 12 will allow the speed of the truck to be increased (if the driver so desires) to either an upper limited speed, or an unlimited (within the confines of the truck's capabilities) speed.
[0028] A further sensor 24 , being a ground surface sensor, may be provided in addition to sensor 14 , or in place of sensor 14 . The sensor 22 can detect certain floor characteristics to thus determine if the truck is in a region requiring the lower, or higher, speed limit. The characteristics may include painted surfaces, bar codes, reflectors, or any other suitable, indicia.
[0029] Alternatively, either or both sensors 14 , 24 may be able to detect the change from one zone to another, for example, from a higher speed limit zone to a lower speed limit zone—and to maintain the present maximum speed limit for that zone while still remaining in that zone. This may be achieved by use of appropriate signal generators at zone boundaries, or use of indicia devices such as, for example, painted surfaces, bar codes, or the like.
[0030] The painted floor characteristics described above may involve the use of different colours and/or patterns in the paint, if desired. Where different coloured painted surfaces are used, the sensors 14 , 24 are preferably colour sensors mounted on the vehicle to detect different speed zones indicated by different colour markings.
[0031] There may also be more than two predetermined speed limits so that there may be a lowest speed limit, a highest speed limit, and a required number of intermediate speed limits therebetween.
[0032] It will be appreciated that the present invention provides a speed controller for a vehicle, particularly vehicles such as forklifts commonly used indoors, that enables the speed of the vehicle to be selectively limited depending on the location of the vehicle. Using the speed controller of the present invention enables the vehicle to travel at multiple speeds, and retains manual control of the speed of the vehicle provided that speed is below a predetermined speed limit imposed by the speed controller. It will also be appreciated that the present invention can be used to control the speed of other load-moving vehicles commonly used indoors.
[0033] It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. | A system for selectively limiting the speed of a vehicle, wherein said system includes a sensor device ( 14 ) located on the vehicle, the sensor ( 14 ) being directed away from the vehicle so as to detect a structure nearby the vehicle, and a controller ( 12 ) which, in response to the sensor ( 14 ) detecting the structure imposes a predetermined speed limit on the vehicle. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to collision avoidance systems and methods and, in particular, discloses a system and method for a collision avoidance frame work for human commanded systems such as mining shovels or the like.
REFERENCES
[0002] Barraquand, J., Langlois, B. & Latombe, J. (1992), ‘Numerical potential-field techniques for robot path planning’, IEEE Transactions On Systems Man And Cybernetics 22(2), 224-241.
[0003] Bellingham, J., Richards, A. & How, J. (2002), Receding horizon control of autonomous vehicles, in ‘Proc. of the American Control Conf’.
[0004] Bemporad, A. & Moran, M. (1999), ‘Control of systems integrating logic, dynamics, and constraints’, Automatica 35(3), 407-427.
[0005] Blanchini, F. (1999), ‘Set invariance in control [survey paper]’, Automatica 35, 1747-1767.
[0006] Blanchini, F. & Miani, S. (2008), Set-Theoretic Methods in Control, Systems & Control: Foundations & Applications, Birkhauser, Boston, Basel, Berlin.
[0007] Blanchini, F., Pellegrino, F. A. & Visentini, L. (2004), ‘Control of manipulators in a constrained workspace by the means of linked invariant sets’, International Journal of Robust and Nonlinear Control 14, 1185-1205.
[0008] Cohen, J., Lin, M. C., Manocha, D. & Ponamgi, K. (1995), I-collide: Am interactive and exact collision detection system for large-scaled environments, in ‘Proceedings of ACM Int. 3D Graphics Conference’, ACM Press, pp. 189-196.
[0009] Culligan, K. (2006), Online trajectory planning for uays using mixed integer programming, Master's thesis, MIT, Aerospace Control Lab.
[0010] Daniel, R. & McAree, P. (1998), ‘Fundamental limits of performance for force reflecting teleoperation’, International Journal Of Robotics Research 17(8), 811-830.
[0011] Daniel, R. & McAree, P. (2000), ‘Multivariable stability of force-reflecting teleoperation: Structures of finite and infinite zeros’, International Journal Of Robotics Research 19(3), 203-224.
[0012] Floudas, C. (1995), Non-linear and Mixed Integer Optimization: Fundamentals and Applications, Topics in Chemical Engineering, Oxford University Press, New York.
[0013] Gottschalk, A. S., Lin, M. C. & Mancha, D. (1996), Obbtree: a hierarchical structure for rapid interference detection, in ‘Proceedings of the 23rd annual conference on Computer graphics and interactive techniques’, ACM Press, pp. 171-180.
[0014] ILOG (2007), ILOG CPLEX SYSTEM Version 10.2 Users Guide. 49
[0015] Kearney, M., Raković, S. & McAree, P. (2009), Optimal cost control correction: A set-theoretic approach, in ‘Proc. European Control Conference [accepted]’.
[0016] Khatib, O. (1986), ‘Real-time obstacle avoidance for manipulators and mobile robots’, International Journal of Robotics Research 5(1), 90-98.
[0017] Kuwata, Y. (2003), Real-time Trajectory Design for Unmanned Aerial Vehicles using Receding Horizon Control, Masters, MIT.
[0018] Kuwata, Y. (2007), Trajectory planning for unmanned vehicles using robust receding horizon control, Phd, MIT.
[0019] Kuwata, Y. & How, J. P. (2004), Three dimensional receding horizon control for uays, in ‘AIAA Guidance, Navigation, and Control Conference’, Providence, R.I., USA.
[0020] Kuwata, Y., Richards, A., Schouwenaars, T. & How, J. (2007), ‘Distributed robust receding horizon control for multi-vehicle guidance’, IEEE Transactions on Control Systems Technology 15(4), 627-641.
[0021] Latombe, J.-C. (1991), Robot motion planning, Kluwer Academic, Boston, Mass.
[0022] LaValle, S. M. (2006), Planning Algorithms, Cambridge University Press, Cambridge, U.K. available at http://planning cs uiuc.edu/.
[0023] Maciejowski, J. (2002), Predictive control: with constraints, Pearson Education Limited, Harlow, England.
[0024] Mayne, D. Q., Rawlings, J. B., Rao, C. V. & Scokaert, P. O. M. (2000), ‘Constrained model predictive control: Stability and optimality’, Automatica 36(6), 789-814.
[0025] McAree, P. & Daniel, R. (2000), ‘Stabilizing impacts in force-reflecting teleoperation using distance-to-impact estimates’, International Journal Of Robotics Research 19(4), 349-364.
[0026] Mignone, D. (2001), The REALLY BIG Collection of Logic Propositions and Linear Inequalities, Technical report, Automatic Control Lab, ETH Zurich.
[0027] Rakovi¶c, S. & Mayne, D. Q. (2005), Robust time optimal obstacle avoidance problem for constrained discrete time systems, in ‘44th IEEE conference on Decision and Control’, IEEE, Seville, Spain, pp. 981-986.
[0028] Raković, S. V., Blanchini, F., E. Cruck & Moran, M. (2007), Robust Obstacle Avoidance for Constrained Linear Discrete Time Systems: A Set-theoretic Approach, in ‘IEEE Conference on Decision and Control’.
[0029] Raković, S. V. & Mayne, D. Q. (2007), ‘Robust Model Predictive Control for Obstacle Avoidance: Discrete Time Case’, Lecture Notes in Control and Information Sciences (LNCIS) 358, 617-627.
[0030] Ren, J., McIsaac, K. & Patel, R. (2006), ‘Modified Newton's method applied to potential field-based navigation for mobile robots’, IEEE Transactions On Robotics 22(2), 384-391.
[0031] Richards, A. G. (2002), Trajectory Optimization using Mixed-Integer Linear Programming, Masters, MIT.
[0032] Richards, A. G. (2005), Robust Constrained Model Predictive Control, Phd, MIT.
[0033] Richards, A., Kuwata, Y. & How, J. (2003), Experimental demonstration of real-time milp control, in ‘AIAA Guidance, Navigation and Control Conference’, Austin, Tex.
[0034] Rossiter, J. (2003), Model-based predictive control: a practical approach, CRC Press, Boca Raton, Fla.
[0035] Schouwenaars, T. (2006), Safe Trajectory Planning of Autonomous Vehicles, Phd, MIT.
[0036] Sheridan, T. (1993), ‘Space teleoperation through time-delay - review and prognosis’, IEEE Transactions On Robotics And Automation 9(5), 592-606.
[0037] Slutski, L. (1998), Remote manipulation systems: quality evaluation and improvement, International series on microprocessor-based and intelligent systems engineering, Kluwer Academic, Dordrecht, the Netherlands.
[0038] Smith, Z. V. (2008), Algorithms for Collision Hulls and their Applications to Path Planning in Open-Cut Mining, PhD thesis, University of Queensland, Mechanical Engineering [submitted].
[0039] Thompson, R., McAree, P., Daniel, R. & Murray, D. (2005), ‘Operator matching during visually aided teleoperation’, Robotics And Autonomous Systems 50(1), 69-80.
BACKGROUND
[0040] In any part human operated machinery environment, in industrial and other environments, it is important for the machinery to avoid collisions with other objects. One important example of such an environment is in an open cut mining excavation environment.
[0041] FIG. 1 depicts a mining shovel loading a haul truck. This is a common activity in open-cut mining, but one which carries the significant risk of collision between the shovel and the truck. It would be desirable to have a technology that assists operators of earth-moving equipment to avoid such collisions. However, the need for such a technology arises in more or less the same form in several teleoperation contexts including nuclear decommissioning (Thompson et al. 2005, McAree & Daniel 2000, Daniel & McAree 2000, 1998) and space applications (Sheridan 1993). The aim is to filter the operator command so that the operator's intent is realized while avoiding collisions between the slave and obstacles in its workspace. The problem is characterized by (i) the presence of a human-in-the-loop who provides a command reference to the slave manipulator to achieve some defined task; (ii) significant energy associated with motion of the slave, with a high likelihood for damage-causing impacts between it and obstacles within its workspace; (iii) rate and saturation constraints on inputs states and outputs which limit the rate at which energy can be removed from and injected into the slave; (iv) the slave and workspace obstacles having non-convex geometries; and (v) a requirement for the slave to manoeuvre within concavities of obstacles.
[0042] Previous relevant work includes potential-field avoidance methods (Khatib 1986), motion planning (Latombe 1991, LaValle 2006), receding horizon trajectory planning (denoted RHTP) (Bellingham et al. 2002, Richards et al. 2003, Kuwata 2007, Kuwata et al. 2007) and set-theoretic control methods (Raković & Mayne 2005, Blanchini et al. 2004, Raković & Mayne 2007, Raković et al. 2007). Potential field obstacle avoidance methods were first explored in Khatib (1986) and have been applied frequently to obstacle avoidance problems, see for example (Latombe 1991, LaValle 2006, Ren et al. 2006, Barraquand et al. 1992). These methods use potential fields around each obstacle to determine planning or control laws that repel the manipulator. The approach, while conceptually attractive, suffers from the drawback that the potential field does not explicitly take account of the dynamics and performance limitations of the manipulator. Careful crafting of the potential field is required to guarantee avoidance and ensure that no alteration occurs in situations where collisions will not occur, such as moving parallel to an obstacle face. Motion planning methods, by way of contrast, seek to find a path from an initial configuration of a robot to a desired configuration avoiding all obstacles en route. These methods are most commonly used in autonomous robotics (Latombe 1991, LaValle 2006). The main differences between the motion planning and avoidance filtering problems is the objective and the available information: the final goal of the robot is known in the motion planning problem, hence the problem is fully specified, while for the avoidance filtering problem future commands are not known, and the objective is to minimize the alteration from the operator's command.
[0043] RHTP, for example, calculates the path to the goal configuration using a receding horizon control framework with the property that each time step, the minimum-cost trajectory to the goal configuration is computed and the first action is taken. This control structure allows for changes to the environment and the goal configuration to occur during the operation. RHTP can be implemented for polytopal obstacles, polytopal system constraints and linear (or piecewise afine) dynamics using MIP, see for example (Bellingham et al. 2002, Richards et al. 2003, Kuwata 2007, Kuwata et al. 2007). Set-theoretic control methods (Blanchini & Miani 2008) have also been applied to obstacle avoidance problems. Dynamic programming-based set iterates, for instance, have been used to robustly drive the state to the origin while avoiding obstacles (Rakovic & Mayne 2005), and linked invariant sets have been used to solve the obstacle avoidance with tracking problem (Blanchini et al. 2004). Both of these methods solve variations of the motion planning problem and, as such, are applicable to the avoidance filtering problem (Kearney et al. 2009). Set-theoretic methods were not considered because any change to the environment requires the re-computation of the sets which define the avoidance control laws, restricting these methods to a static environment. This attribute of set theoretic methods are not compatible with the level of detail strategy necessary to represent non-convex obstacle sets.
SUMMARY
[0044] It is an object of the present invention to provide an improved collision avoidance framework for human commanded systems.
[0045] In accordance with a first aspect of the present invention, there is provided a method of implementing an optimal avoidance filter for interposing between a human operator issued movement commands and a corresponding machine control system of a movable machine, for the avoidance of collisions with objects, the method comprising: (a) inputting a detailed representation of objects in the vicinity of the movable machine; (b) formulating a hierarchical set of bounding boxes around the objects, the hierarchical set including refinement details depending on the current positional state of the movable machine, with objects closer to the machine having higher levels of refinement details; (c) utilising the resultant hierarchical set as a set of constraints for an optimisation problem to determine any alterations to the issued movement commands so as to avoid collisions with any objects.
[0046] Preferably the method also includes the steps of: (d) utilising the predicted future motion to update the hierarchical set off bounding boxes. In some embodiments, the step (c) further can comprise the step of: (i) determining a series of alternative alterations to the issued movement commands, and costing the series in term of magnitude of alteration, and utlising a lower cost alternative alteration. The set of bounding boxes are preferably axially aligned.
[0047] The steps (a) to (c) are preferably applied in a continuous iterative manner
[0048] The hierarchical set of bounding boxes preferably can include representation of non convex objects, in the form of convexities in the hierarchical set.
[0049] The step (b) further can preferably comprise, for any particular time step, culling members of the set that are not reachable in the current time step.
[0050] In accordance with a further aspect of the present invention, there is provided an optimal avoidance filter for interposing between a human operator issued movement commands and a corresponding machine control system of a movable machine, for the avoidance of collisions with objects, the optimal avoidance filter comprising: First input means for inputting a detailed representation of objects in the vicinity of the movable machine; Hierarchical bounding box determination means for formulating a hierarchical set of bounding boxes around the objects, the hierarchical set including refinement details depending on the current positional state of the movable machine, with objects closer to the machine having higher levels of refinement details; Optimisation means utilising the resultant hierarchical set as a set of constraints for a mixed integer optimisation problem to determine any alterations to the issued movement commands so as to avoid collisions with any objects, and outputting the alterations to the movement commands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] Benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of exemplary embodiments and the appended claims, taken in conjunction with the accompanying drawings, in which:
[0052] FIG. 1 illustrates an Electric mining shovel loading a haul truck;
[0053] FIG. 2 illustrates a Teleoperated system with the Optimal Avoidance Filter (OAF) interposed between master and slave devices. The OAF calculates an additive modification to the operator command, dependant on the state, and the obstacle set;
[0054] FIG. 3 illustrates a convex polytopal obstacle (black), made up from intersection of half spaces. The shaded area indicates the feasible region when a bold obstacle avoidance constraint is active (its corresponding =0). The state (black dot), x, is shown to be in the feasible region;
[0055] FIG. 4 illustrates a different level of detail representation for a haul truck tray;
[0056] FIG. 5 illustrates the construction of an axially-aligned bounding box hierarchy of a 2D non-convex object;
[0057] FIG. 6 illustrates an axial-aligned bounding box BVH—based on the example in FIG. 5 ;
[0058] FIG. 7 illustrates examples of minimum covers generated using the nominal trajectory for different state, command input pairs. The nominal trajectory is given by circles and current position by the square;
[0059] FIG. 8 illustrates a comparison of implicit and leaf boxes OAF algorithms from four different starting points and constant commands. The trajectories starting at points 1,2 and 3 stop within concavities of the obstacle in the direction commanded by the operator, while the trajectory from point 4 moves along the side of the obstacles before resuming following the command provided by the operator. In all four of these simulations, the trajectories produced by the leaf node OAF and the implicit OAF correspond.
[0060] FIG. 9 illustrates nominal trajectory OAF compared to root box and leaf boxes OAFs from four different starting points and constant commands. Trajectories determined using nominal trajectory and leaf nodes OAF, starting from points 1,2 and 3, correspond. The trajectories starting at point 4 diverge due to the ordering of the branching in the MIP solution;
[0061] FIG. 10 illustrates the nominal trajectory OAF and leaf boxes OAF trajectories can be seen diverging. The dashed line, indicating the nominal path, shows that at the point of divergence the cost of diverting to the left and right were equal;
[0062] FIG. 11 illustrates a comparison of simulation times for the different OAF algorithms and BVH complexities.
[0063] FIG. 12 illustrates the simplification of a BVH using Propositions 5.1 and 5.2.
[0064] FIG. 13 illustrates three different intersection situations for reachable constraints. Bold lines indicate reachable constraints, while dashed lines represent unreachable constraints.
[0065] FIG. 14 illustrates comparison between trajectories generated by unmodified OAF algorithms, and those that use the reachable constraint method to determine constraints. With the exception of situation 4 in (a), which is due to the order of branching in the MIQP solver (as in FIG. 10 ), all of the trajectories correspond.
[0066] FIG. 15 illustrates a Truck tray (left) and dipper (right).
[0067] FIG. 16 illustrates a Leaf boxes approximation to the truck tray-dipper obstacle set (256 boxes).
[0068] FIG. 17 illustrates a simulation of loading pass using an OAF in the state space.
[0069] FIG. 18 illustrates a simulation of loading pass using an OAF.
DETAILED DESCRIPTION
[0070] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings.
[0071] The preferred embodiment utilises an optimal avoidance filter (or OAF) and it is synthesized using a receding horizon control (RHC) framework in which the control action is determined by predicting the future evolution of the system over a given horizon, optimizing the control sequence over the horizon to obtain the most desirable future system evolution, and applying the first control action in the optimized control sequence (Rossiter 2003, Maciejowski 2002). RHC has two attributes that are advantageous when applied to the avoidance filtering problem. First, the predictive nature of receding horizon control allows the constraints associated with the slave manipulator, e.g. actuator torque and speed constraints, to be explicitly taken into account when determining the control action. Second, the future avoidance of obstacles can be guaranteed, even when the operator's future commands are not known, provided the avoidance filter is recursively feasible (Rossiter 2003). A significant challenge is the representation of obstacles. Abstractly, there exists a collision set C obs in the configuration space of the slave that is to be manoeuvred around, defined as the set of configurations where the slave intersects with workspace obstacles (or itself). C obs is well defined mathematically, but difficult to compute. We utilize recent work by Smith (2008) who has presented algorithms for representing C obs in a form that is suitable for incorporation into a receding horizon control framework. In particular, these algorithms approximate C obs as a hierarchy of axially-aligned bounding-boxes. The OAF formulation draws an appropriate representation from this hierarchy and expresses the resulting constraints as a family of mixed integer linear inequalities to be satisfied. The OAF is synthesized as a mixed integer program (MIP) using the approximation of C obs , denoted Ĉ obs drawn by the OAF from the hierarchy of axially-aligned bounding boxes. The requirement to run in real-time places restrictions on the level and apportioning of geometric detail in Ĉ obs . Intuitively, higher detail is desired in regions where the slave manipulator currently is and is likely to go within the prediction horizon, while the remainder of Ĉ obs can be represented more coarsely.
[0072] The preferred embodiment is directed to the complimentary questions of (i) how to draw an efficient representation of C obs from a level of detail representation, at each time step given the current state of the slave manipulator and operator command and (ii) how to embed this level-of-detail within the OAF MIP. Two strategies are examined. The first looks to determine the most appropriate Ĉ obs as part of the OAF MIP. The second looks to use a prediction of future motion to determine a level-of-detail approximation that is fit-for-purpose and provide this to the OAF MIP. Both strategies produce similar solutions, but the second is shown to have a significantly lower computational cost. Further reduction in computational cost is achieved by removing those obstacle avoidance constraints than cannot be active on the prediction horizon from the OAF MIP. Restrictions are identified on how Ĉ obs can change between samples to ensure that the OAF remains recursively feasible. A simplified simulation example, based on the shovel-truck avoidance problem, is presented to show the applicability of the methods presented to the motivating problem.
[0073] The proposed OAF follows a similar structure to RHTP: a framework based on receding horizon control with avoidance constraints represented using mixed integer inequalities, but will differ in that it will calculate an additive modification to the operator's current command (along the lines of the potential field avoidance method), rather than the command to drive the state to a defined goal configuration.
2 Structure of the OAF
[0074] FIG. 2 shows schematically a human-operated system made up of
A slave manipulator which receives an input to perform a desired task. This slave manipulator may include a pre-existing control system. The inputs and states are subject to constraints. The input is often, though not always, a rate command. An input device, through which a human operator provides a command input to the slave manipulator. Joysticks are a common form of input device and can be quite sophisticated, e.g. in force reaction applications (Slutski 1998) The environment, which contain obstacles whose location and geometry are known. In general, the obstacles have non-convex geometry. It is desired that the slave device does not collide with any of the obstacles in the environment.
[0078] The OAF is interposed between the input device and the slave manipulator (as shown in FIG. 2 ) and computes and additive alteration to the operator reference so that the slave avoids collision with obstacles. The OAF also ensures that the constraints of the slave manipulator are satisfied. The OAF objective function is chosen to ensure that the alteration from the operator command is minimal, although alternative objectives could be chosen within this framework.
2.1 Notation and Definitions
[0000]
Variables are represented using the following convention: spaces (state and input) are represented using capital letters, e.g. X;U. Sets are represented using upper case letter, e.g. P;O. Members of sets and spaces are represented using lower case italics, e.g. x; u; v. Convex polytopes are represented as uppercase characters, e.g. P;O. Problem descriptions (mathematical programs) will use uppercase characters, e.g. P.
The slave dynamics are represented using a non-linear, time-invariant discrete-time System:
[0000] χ + =f ( χ,u ). (2.1)
[0000] where χε is the current state of the system, uεR m is the current input and χ + is the successor state. The state at time-step k is denoted χ k .
The slave manipulator has constraints on the states and the inputs, which, in general, are mixed. The admissible set of inputs and states satisfy:
[0000] (χ,u)ε ⊂ × (2.2)
[0000] where X⊂ n is the set of admissible states and U⊂ m is the set of admissible inputs. The obstacle set ⊂X is a mapping from C obs to the state space, in which it is desired that the state evolution never enters:
[0000] χ k ∉ , ∀k=1, 2, . . . (2.3)
[0082] A formal definition of is
[0000] :={χ∉ :C p (χ)εC obs }, (2.4)
[0000] where C p ( . ) maps the state space into a configuration of the slave manipulator. Correspondingly, the representation of obstacle C j within the state space is:
[0000] j ={χε :C p (χ)ε j }, (2.5)
[0000] and the approximation of each set is given respectively by Ĉ j and Ô j . For the examples in this description, several of the states make up the configuration space, hence C p (χ)=C p χ where C p is an appropriately sized matrix. i is used to represent part of the obstacles set the is represented by a convex polytope, such that ∪ i i
[0083] X T is a positively invariant set and κ(:) an associated feedback control law that must meet the following invariance and admissibility conditions (Blanchini 1999):
[0000] ∀χεX T , f(χ,κ(χ))εX T ,
[0000] ∀χεX T , (χ,κ(χ))ε .
[0084] The sequence of inputs generated by the operator, {ũ 0 , ũ 1 , . . . ũ n } is denoted by ũ N . The infinite sequence of future inputs {ũ 0 , ũ 1 , . . . } is denoted by ũ ∞ . -The OAF algorithm computes a sequence of alterations {v 0 , v 1 . . . v n } is denoted by v n . The infinite sequence, {v 0 , v 1 . . . } is denoted by v ∞ .
2.2 The Optimal Avoidance Filter Algorithm
[0085] The OAF algorithm calculates an additive alteration v i , to the command provided by the operator ũ k , to determine the filtered system input
[0000] u k =ũ k +v k , (2.6)
[0000] such that (i) collisions with obstacles are avoided (χ k+I ∉ ), and (ii) the system constraints are satisfied ((χ k+i ; u k+i )ε ), now and for all future time steps (i>=0). Additionally, the OAF algorithm minimizes the alterations to the operator command by costing the alterations using an appropriate norm. As posed, this problem is acausal, since the future operator input sequence {ũ 0 , ũ 1 , . . . } is unknown.
[0086] The OAF mathematical program P N (χ, ũ), which is solved online in a receding horizon fashion, accounts for constraints as it is derived from an N-step constrained optimal control problem, and causality is obtained by using an appropriate model to predict future operator inputs. The terminal state of the OAF mathematical program is constrained to enter a collision-free positively invariant set, χ T .
[0000] χ N εX T , (2.7)
[0000] to obtain, using standard results in receding horizon control literature (Mayne et al. 2000, Rossiter 2003), a guaranteed stable (Mayne et al. 2000), and recursively feasible (Rossiter 2003) receding horizon controller. The obstacle avoidance constraints incorporated into the OAF mathematical program are
[0000] χ k ∉ , ∀k=0, . . . , N, (2.8)
[0000] X T ∩ =. (2.9)
[0087] The operator command prediction model used holds the current operator's command constant over the planning horizon, and sets the command input to be zero for k>N:
[0000] ũ k+i =ũ k , i= 1, . . . N− 1, (2.10)
[0000] ũ k+i =0, i≧N. (2.11)
[0088] The invariant set feedback control law is then considered to be an alteration:
[0000] v k =κ(χ k ), ∀ k>N. (2.12)
[0089] In this prediction model, the likelihood that the prediction is correct decreases into the future. This attribute can be included in the formulation of P N by discounting the cost function:
[0000]
v
N
-
1
=
arg
min
v
∑
k
=
0
N
-
1
γ
k
v
k
,
(
2.13
)
[0000] where 0≦γ>1 is the discount factor. The resulting OAF mathematical program P N (χ, ũ), can be posed as:
[0000]
v
N
-
1
=
arg
min
v
∑
k
=
0
N
-
1
γ
k
v
k
(
2.14
)
x
k
+
1
=
f
(
x
k
,
u
~
+
v
k
)
,
∀
k
=
0
,
…
,
N
-
1
(
2.15
)
(
x
k
,
u
~
+
v
k
)
∈
,
∀
k
=
0
,
…
,
N
-
1
(
2.16
)
x
k
∉
,
∀
k
=
1
,
…
,
N
-
1
(
2.17
)
x
N
∈
χ
T
,
(
2.18
)
χ
T
⋂
=
∅
.
(
2.19
)
[0090] The OAF algorithm is implemented by at each time step by:
1. Measuring the current state, χ k , and the current operator command input, ũ k . 2. Solving the OAF mathematical program P x (χ, ũ), to obtain the sequence of alterations, v N−1 . 3. Setting the first element of v N−1 , to be v k . 4. Sending the filtered input command, u k =ũ k .+v k , to the slave device.
3 The OAF for Convex Polytopal Obstacles
[0095] Let the obstacle set, O, be composed of N O convex polytopes:
[0000]
=
⋃
N
o
j
=
1
O
j
.
(
3.1
)
[0096] Each j can be described as the intersection of N h (finite) open half-spaces as shown in FIG. 3 . That is
[0000]
O
j
=
⋂
N
h
(
O
j
)
j
=
1
{
x
∈
:
a
i
,
j
T
x
<
b
i
,
j
}
.
(
3.2
)
[0097] Noting that {χ:−a i,j T χ≦−b ij } is the complement of {χ: −a i,j T χ<b ij }, the obstacle avoidance constraint χ∉O j , can can be represented as:
[0000]
x
∈
⋂
N
h
(
O
j
)
i
=
1
{
x
∈
:
-
a
i
,
j
T
x
≤
-
b
i
,
j
}
.
(
3.3
)
[0098] Equation 3.3 is non-convex and can also be expressed as a collection of OR (written ) constraints:
[0000] [− a 1j χ≦−b 1j ] [−a 2j χ≦−b 2j ] . . . [−a N h (O j )jx ≦−b N k (O j ) j ]. (3.4)
[0099] This structure is exploited in (Richards 2002, Kuwata 2003) where Eqn. 3.4 is transformed into a set of mixed-integer linear inequalities using the so-called big-M method (Bemporad & Moran 1999, Mignone 2001) by introducing a scalar M, such that
[0000] { xε n :−a i,j T χ≦−b i,j +M}, ∀i,j, (3.5)
[0000] and a binary decision variable (a ijk ) for each of the half-spaces in O j . The resulting mixed-integer linear inequalities are:
[0000]
-
a
i
,
j
T
x
≤
-
b
i
,
j
+
M
α
i
,
j
,
k
,
∀
i
=
1
,
…
,
N
h
(
O
j
)
,
(
3.6
)
∑
j
=
1
N
h
(
O
j
)
α
i
,
j
,
k
≤
N
h
(
O
j
)
-
1
,
(
3.7
)
α
i
,
j
,
k
∈
{
0
,
1
}
,
∀
1
,
…
,
N
h
(
O
j
)
.
(
3.8
)
[0000] where k represents the prediction time step in P N . When a constraint is active a=0; when inactive α=1. Equation 3.5 ensures that when a constraint is inactive, is a subset of the half-space induced by the constraint. Equation 3.7 ensures that the obstacle avoidance constraints for O j (Eqns. 3.6 to 3.8) are satisfied by forcing at least one of the avoidance constraints of O j to be active. If the slave dynamics are linear, its system constraints polytopal, and the obstacle set, O, made up of polytopal obstacles, then the OAF can be posed as the following MIP:
[0000]
v
N
-
1
=
arg
min
v
∑
k
=
0
N
-
1
γ
k
v
k
(
3.9
)
x
k
+
1
=
Ax
k
+
B
(
u
~
k
+
v
k
)
,
∀
k
=
0
,
…
,
N
-
1
(
3.10
)
(
x
k
,
u
~
k
+
v
k
)
∈
,
∀
k
=
0
,
…
,
N
-
1
(
3.11
)
a
ij
x
k
≤
b
i
,
j
+
M
α
i
,
j
,
k
,
∀
i
=
1
,
…
,
N
h
(
O
j
)
,
∀
j
=
1
,
…
,
N
o
,
∀
k
=
1
,
…
,
N
-
1
(
3.12
)
∑
i
=
1
N
h
(
O
j
)
α
i
,
j
,
k
≤
N
h
(
O
j
)
-
1
,
∀
j
=
1
,
…
,
N
o
,
∀
k
=
1
,
…
,
N
-
1
(
3.13
)
x
N
∈
χ
T
,
(
3.14
)
χ
T
⋂
=
∅
,
(
3.15
)
[0000] given that an appropriate norm is chosen for Eqn. 3.9. The solution of Eqns. 3.9 to 3.15 is NP-hard (Floudas 1995), with a worst-case bound on the computational cost that is exponential in the number of binary decision variables:
[0000]
(
N
-
1
)
∑
j
=
1
N
o
N
h
(
O
i
)
.
(
3.16
)
[0100] Equation 3.16 does not include the additional binary variables required to represent the invariant set obstacle avoidance constraint (Eqn. 3.15), as this depends on the choice of invariant set. This additional number may range from zero, for a fixed invariant set (X T ⊂ / ), to a number that is arbitrarily large for an invariant set parameterized by χ N .
3.1 Using Axial-Aligned Bounding Boxes to Represent Obstacles
[0101] In previous work, Kuwata & How (2004), Richards (2005), Richards et al. (2003) have used axially-aligned bounding boxes (abbreviated as ABBs) to represent (or bound) obstacles, or parts thereof. An ABB is represented by the maximum and minimum bounds in each axis of the obstacle:
[0000] B j :=[χ min,j , χ max,j ]×[ min,j , max,j ]× . . . (3.17)
[0102] The mixed-integer inequalities for the avoidance of an ABB obstacle are given by:
[0000]
x
≤
x
min
,
j
+
M
α
1
,
j
,
k
(
3.18
)
-
x
≤
-
x
max
,
j
+
M
α
2
,
j
,
k
(
3.19
)
y
≤
y
min
,
j
+
M
α
3
,
j
,
k
(
3.20
)
-
y
≤
-
y
max
,
j
+
M
α
4
,
j
,
k
…
(
3.21
)
∑
i
=
1
2
N
D
α
i
,
j
,
k
≤
2
N
D
-
1
(
3.22
)
[0000] where N D is the number of dimensions in which the obstacle is defined (usually 2D or 3D). 2N D binary variables are required for each ABB-obstacle.
Extension to Non-Convex Obstacles Using Bounding Volume Hierarchies
[0103] One strategy that extends the OAF to avoid non-convex obstacles is to convexify them, and avoid the resulting convex representation. The two most common convex representations for non-convex obstacles are the convex decomposition and the convex hull. The convex decomposition represents a non-convex obstacle as a number of convex regions P i;j , such that j =∪P ij , ∀j, and the convex hull of an obstacle is the smallest convex set that contains the obstacle. A major downside of using a convex decomposition of the object is that it contains a lot of detail, hence it is computationally expensive representation, while the convex hull representation, although computationally less expensive, does not allow the slave to move within concavities of the non-convex obstacle. Schouwenaars (2006) has modified the convex hull representation to include convex polytopal safe zones within the convex hull that allow movement into the concavities, but this increases the complexity of the representation. Furthermore each of these representations are static, and consequently may not be the most efficient representation in a given situation (as represented by the state, command input pair).
[0104] The preferred embodiment utilises a level-of-detail approach for avoiding non-convex obstacles which utilizes representations drawn from bounding volume hierarchies of each obstacle. FIG. 4 illustrates this idea showing several different level of detail representations of a haul truck tray, from coarsest to finest. The appropriate level-of-detail representation of the obstacle set is chosen such that the cost of computing the alteration vk is reduced when compared to using the highest detail representation available, while not significantly changing the resulting alteration. It is necessary to ‘trade-off’ between these two objectives.
4.1 Representation of Non-Convex Obstacles Using Bounding Volume Hierarchies
[0105] In prior work, BVH's have been used to determine whether arbitrary geometric models of objects intersect (Gottschalk et al. 1996, Cohen et al. 1995). A BVH is constructed by recursively bounding and partitioning the geometry of an obstacle and storing the resulting bounding volumes in a binary tree (Gottschalk et al. 1996). This construction is initiated by determining an ABB (or another chosen volume) that bounds the entire obstacle. This box is the root box (ABB) of the obstacle. The geometry of the obstacle is then subdivided along the centre of the longest side of the root ABB into two sub-geometries, which are in turn bounded with an ABB and stored in the binary tree. This ‘bound-and-split’ process is recursively applied to the leaf boxes of the BVH until either a minimum geometry size is achieved or further recursion does not improve precision. FIGS. 5 and 6 shows the construction of a BVH for an arbitrary closed 2D obstacle. ABBs are chosen because they are simple and lead to efficient Minkowski sum operations (Smith 2008). BVHs composed of oriented bounding boxes (Gottschalk et al. 1996) could also be used as an alternative level-of-detail representation. A union the ABBs selected from the BVH of a specific obstacle ( j ) must be a superset of that obstacle, specifically a cover.
[0106] Definition A cover j is a collection of boxes, B, from the BVH of j , such that:
[0000]
j
=
⋃
(
l
,
m
)
∈
I
j
B
l
,
m
⊇
j
,
(
4.1
)
[0107] where l indicates the level of detail (starting with 1 for the root node), and m indicates the node within the level. B l;m is a particular box within the BVH. The index set, I j , indicates which boxes from the BVH are included in the cover representing j . A further requirement is that no superfluous boxes should be included in the cover, i.e. boxes that can be removed where the remnant remains a cover. If this requirement holds, the cover is minimal. A minimal cover of an obstacle is a cover such that if any of the boxes (ABBs) are removed, it is no longer a cover. The non-convex OAF algorithm will choose a minimal cover as the representation for each obstacle, based upon the current state and operator command. The following proposition allows for the synthesis of minimal cover selection algorithms that recurse down the BVH:
[0108] Proposition 4.1 There is a single member of the minimal cover on each branch of the tree (path from root box to a particular leaf box).
[0109] The leaf boxes of the BVH form a partition of the obstacle:
[0000]
j
=
⋃
m
=
1
2
N
L
-
1
(
B
N
L
,
m
)
[0000] where (.), is the geometry that is bounded by a given box, and (B NL; m1 )∩ (B NL;m2 )=, ∀m 1 ≠m 2 . The geometry in each of the leaf boxes is only bounded by its ancestor boxes, i.e. (B NL;m ) B l , ∀l=1, . . . , N L −1 only, where (.) indicates the appropriate ancestor box for each level. These boxes are found on the branch of the tree that goes from the root box to the given leaf box. Hence, to cover the entire obstacle, it is necessary for boxes on each branch of the tree to be included in the cover. If there is more than one box on a branch, then the box that is a descendant of the other box is superfluous and can be removed. The minimal cover can be chosen in two ways: implicitly as part of the optimization solution or explicitly using a static or adaptive rule. Approaches to each are now considered.
4.2 Implicit Non-Convex OAF
[0110] In the implicit non-convex OAF algorithm, the entire BVH is included in the OAF MIP and the coarsest minimal cover that is feasible with respect to the optimal trajectory is selected during the optimization. The selection of the minimal cover is incorporated into the OAF MIP by allocating minimal cover-selection binary decision variables δ l,m,k ε{0,1}, to each box in the BVH that has children, and by adding a minimal cover selection function (logic) for each box, β l,m (δ l,m,k ) to the right-hand side of the constraint relaxation inequality (3.22),
[0000]
∑
i
=
1
2
N
D
α
i
,
j
,
k
≤
2
N
D
-
1
+
β
l
,
m
(
δ
k
)
,
(
4.2
)
[0000] where δ k is the vector of minimal cover selection binary variables for time k. The minimum cover selection function determines whether the box is in the minimal cover based on δ k : If β l,m (δ k )=0, the box is a member of the minimal cover; if β l,m (δ k )≧1, it is not. For β l,m (δ k )=1, the constraint relaxation inequality becomes:
[0000]
∑
i
=
1
2
N
D
α
i
,
j
,
k
≤
2
N
D
,
(
4.3
)
[0000] allowing all of the avoidance constraints for the box to be relaxed to the entire constraint set. The OAF objective function is modified by placing a small cost on the minimal cover binary decision variables such that finer detail will only be selected if a reduction of the trajectory cost (the unmodified objective function) results. The minimal cover selection function for each box is composed of an ancestor minimal cover selection function, β l,m (δ k )≧0 and a descendent minimal cover selection function, β l,m (δ k )≧0, both of which must equal zero if the box is in the minimal cover. The minimal cover selection function becomes:
[0000] β l,m (δ k )= β l,m (δ k )+{tilde over (β)} l,m (δ k ) (4.4)
[0111] The ancestor component ensures that the box can only be a member of the minimal cover if none of its ancestors are in the minimal cover (by Proposition 4.1). The descendent component determines whether the box, or some of its descendants are part of the minimal cover, given that β l,m (δ k )=0. The descendant minimal cover selection algorithm for boxes with children is given by:
[0000] {tilde over (β)} l,m (δ k )=δ l,m,k . (4.5)
[0112] The box may be selected for the minimal cover (dependant on the ancestor part of the selection function) if δ l,m,k =0, and if δ l,m,k =1, B l,m will be relaxed in favor of its descendants. By Proposition 4.1, β NL,m (δ k )=0 for the leaf boxes of the BVH, since if none of the ancestors of a leaf box are in the minimal cover, then the leaf box must be in the minimal cover. The ancestor minimal cover selection function is given by:
[0000]
β
_
l
,
m
(
δ
k
)
=
∑
p
=
1
l
-
1
(
1
-
δ
p
,
·
,
k
)
,
(
4.6
)
[0000] where (.) indicates the appropriate ancestor box (which can be determined by recursing up the BVH via the parent relationship) of B l,m . If all of the ancestor boxes of B l,m are not in the minimal cover (i.e. δ p,.k =1; ∀p)=0. and B l,m may be in the minimal cover. If one of the ancestors of B l,m is in the minimal cover, β l,m (δ k )≧1 and B l,m cannot be in the minimal cover. Note β l,m (δ k )=0 for the root box as it has no ancestors. The minimum cover selection functions for the boxes in a BVH with N L detail levels are given by:
[0000]
β
1
,
1
(
δ
k
)
=
δ
1
,
1
,
k
,
(
4.7
)
β
l
,
m
(
δ
k
)
=
δ
l
,
m
,
k
+
∑
p
=
1
l
-
1
(
1
-
δ
p
,
·
,
k
)
,
∀
m
=
1
,
…
,
2
l
-
1
,
∀
l
=
2
,
…
,
N
L
-
1
,
(
4.8
)
β
N
L
,
m
(
δ
k
)
=
∑
p
=
1
N
L
-
2
(
1
-
δ
p
,
·
,
k
)
,
∀
m
=
1
,
…
,
2
N
L
-
1
(
4.9
)
[0113] The OAF objective function (Eqn. 3.9) is modified so that it selects the coarsest minimal cover that is feasible with respect to the minimum cost trajectory. This is achieved by costing the relaxation of a box in favor of its descendants, which is implemented by placing a small cost ε>0, on each of the minimum cover selection binary decision variables. This causes the MIP solver to choose finer detail only if the trajectory cost will be reduced as a result. The modified objective function is:
[0000]
v
N
-
1
=
arg
min
v
∑
k
=
0
N
-
1
(
γ
k
v
k
+
ε
1
T
δ
k
)
,
(
4.10
)
[0000] where 1 is a column vector of ones of an appropriate size, and 0<γ≦1 is the discounted rate.
[0114] The implicit version of the finite horizon obstacle avoidance problem (P imp (x 0 ; , ũ N−1 .)) is:
[0000]
v
N
-
1
=
arg
min
v
∑
k
=
0
N
-
1
(
γ
k
v
k
+
ε
1
T
δ
k
)
,
(
4.11
)
x
k
+
1
=
Ax
k
+
B
(
u
~
k
+
v
k
)
,
∀
k
=
0
,
…
,
N
-
1
(
4.12
)
(
x
k
,
u
~
k
+
v
k
)
∈
,
∀
k
=
0
,
…
,
N
-
1
(
4.13
)
a
i
,
l
,
m
x
k
≤
b
i
,
l
,
m
+
M
α
i
,
l
,
m
,
k
,
∀
i
=
1
,
…
,
2
N
D
,
∀
m
=
1
,
…
,
2
l
-
1
,
∀
l
=
1
,
…
,
N
L
,
∀
k
=
1
,
…
,
N
-
1
(
4.14
)
∑
i
=
1
2
N
D
α
i
,
l
,
m
,
k
≤
2
N
D
-
1
+
β
l
,
m
(
δ
k
)
,
∀
m
=
1
,
…
,
2
l
-
1
,
∀
l
=
1
,
…
,
N
L
,
∀
k
=
1
,
…
,
N
1
(
4.15
)
x
N
∈
χ
T
,
(
4.16
)
χ
T
⋂
=
∅
,
(
4.17
)
[0000] where β l,m (δ k ) is given by the appropriate selection function in Eqns. 4.7-4.9. The implicit non-convex OAF algorithm, given by solving Eqns. 4.11-4.17 in a receding horizon fashion, is recursively feasible (Rossiter 2003), as the same minimal cover can always be chosen by the MIP solver at the next time step. A single minimal cover for the entire prediction horizon can be chosen by using only one set of minimal cover selection decision variables and using these for the minimal cover selection functions at each prediction step.
4.3 Explicit Non-Convex OAF
[0115] The explicit non-convex OAF algorithm operates by:
1. selecting an appropriate minimal cover from the BVH for each obstacle using a static rule or a adaptive algorithm based on the current state and/or operator command, then 2. solving the OAF for convex polytonal obstacles (Section 3),treating the boxes in the minimal cover(s) as convex obstacles.
[0118] A static minimal cover selection rule could be to choose either the finest minimal cover, which is made up of all the leaf boxes in the BVH (denoted leaf boxes OAF), or the minimal cover that requires the least number of binary variables to represent it, i.e. the root box only (denoted root box OAF). A simple adaptive minimal cover selection algorithm would be to switch between the leaf boxes and root box minimal cover representations for an obstacle depending on the current distance to the obstacle. A more sophisticated adaptive minimal cover selection algorithm can be synthesized by examining the structure of the solution of PN. The optimizer selects the minimum-cost feasible trajectory over the prediction horizon as the solution of PN. As the objective function costs deviations from the operator command, the minimum-cost feasible trajectory is likely to be spatially close to the nominal trajectory:
[0119] Definition The nominal trajectory {tilde over (T)} N (xk; ũ k ), is defined as the predicted trajectory over an N-step horizon that will occur if the operator's command is held constant over the N-step horizon (vN-1=0, hence zero-cost):
[0000] {tilde over (T)} N (χ k , ũ k )={{tilde over (χ)} k , {tilde over (χ)} k+1 , . . . , {tilde over (χ)} k+N },
[0000] where ˜{tilde over (χ)}k=xk and {tilde over (χ)}j+1=f({tilde over (χ)} j; ũk).
[0120] Hence, an appropriate minimal cover selection rule may be to choose fine detail for the parts of the obstacles that are close to the nominal trajectory and coarse detail for parts of the obstacles far away from the nominal trajectory. As the nominal trajectory is defined for the horizon, a single minimal cover will be used over the prediction horizon. A minimal cover selection rule that apportions fine detail near the nominal trajectory and coarse detail elsewhere can be implemented efficiently by recursing down the BVH of each obstacle. The desired minimal cover (i) will contain the smallest number of ABBs such that any leaf boxes that intersect with the nominal trajectory are included, or (ii) if the trajectory does not intersect with any of the leaf boxes, the coarsest minimal cover that does not intersect with the nominal trajectory will be chosen. The implementation of the minimal cover selection rule involves recursing down each branch of the BVH until a leaf box or a box that does not intersect with the nominal trajectory is found and added to the minimal cover. Further recursion to such a box's children (if any) is halted due to Proposition 4.1. This approach is hereafter called the nominal trajectory minimal cover selection algorithm, see Alg. 1, and the OAF algorithm utilizing this selection rule to select minimal covers for each obstacle is called the nominal cover OAF algorithm.
[0000]
Algorithm 1: recurseNomTraj(B l,m, {tilde over (T)} N (x k ,ũ k ))
Data: ABB: B l,m ; nominal trajectory: {tilde over (T)} N (x k , ũ k )
Result: Nominal Trajectory Minimal Cover,
if B l,m is a leaf node then
| append B l,m to
| = + B l,m ;
else
| if B l,m ∩ {tilde over (T)} N (x k , ũ k ) = then
| | append B l,m to
| | = + B l,m ;
| else
| | recurse to Children
└ └ ∀ children to B l,m : B l+1,p , recurseNomTraj( {tilde over (T)} N (x k , ũ k ));
[0121] FIG. 7 presents minimal covers for the obstacle given in FIGS. 5 and 6 that are generated by four different state, operator command pairs using Alg. 1. Each nominal trajectory is represented by the joined circles and the current position is shown by the square. FIG. 7( a ) shows the minimal cover when the current position is external to the root box and the nominal trajectory does not intersect with any leaf boxes, i.e. the coarsest minimal cover that does not intersect with the nominal trajectory. The minimal cover produced in FIG. 7( b ) includes leaf boxes that the nominal trajectory intersects with, and the minimum amount of boxes required to cover the remainder of the object. FIG. 7( c ) shows that the minimal cover is the root box when the slave state is outside the root box and the nominal trajectory does not intersect with the root box. FIG. 7( d ) shows a potential drawback to the nominal trajectory minimal cover selection algorithm.
[0122] Here the nominal trajectory crosses the centerline of the object and includes fine detail on the opposite side of the obstacle in the minimal cover. The inclusion of finer detail on the opposite side of the obstacle in the minimal cover is unlikely to improve the trajectory, or in particular, reduce the magnitude of the first alteration, compared to a minimal cover that has a coarser representation for the far side of the obstacle. This additional detail will increase the computational cost of solving the resulting MIP.
[0123] Algorithm 2 shows the operation of the explicit non-convex OAF algorithm. getMinimalCover( )calls the appropriate static or adaptive rule that chooses the minimal cover for each object at each time step, e.g. all leaf nodes, or the nominal trajectory minimal cover (Alg. 1).
[0000]
ALGORITHM 2
Explicit non-convex OAF
Data: current state , current operator command , obstacle ABB-Tree
root node B 1.1
Result: operator modification
= get MinimalCover( )
Set up standard OAF problem with as obstacles
Add to P N as obstacles
solve OAF problem
v N−1 ← solution of P N
select first input modification
return
indicates data missing or illegible when filed
4.3.1 Recursive Feasibility of Nominal Trajectory Explicit OAF
[0124] The constraint set of the nominal trajectory non-convex OAF potentially changes at each time step. As a result, standard recursive feasibility conditions as set down, for example in (Rossiter 2003), do not hold. We now provide conditions under which recursive feasibility holds for changing obstacle constraint sets. The obstacle representation at time k is denoted, k , and is a superset of the obstacle set . It is assumed that there is a feasible trajectory at time step k,
[0000] T k ={χ k ,χ k+1 , . . . , χ k+N }∪X T .
[0125] A trajectory at time k+1 can be constructed that is a subset of T k (assuming the deterministic case),
[0000] T k+1 ={χ k+1 , χ k+2 , . . . , χ k+N , f (χ k+N , k (χ k+N ))}∪χ T .
[0126] A limited recursive feasibility condition is presented in the following proposition:
[0127] Proposition 4.2 Recursive feasibility holds for a changing obstacle set when the obstacle set is monotonically decreasing, i.e. k+1 k .
[0128] Proof: It is given that T k is feasible with respect to k , i.e. T k ∩ k =. Since T k+1 T k and k+1 k then T k+1 is feasible with respect to k+1 .
[0129] The downside of Proposition 4.2 is that it only allows for the obstacle representation set to be refined; it does not allow for the obstacle representation set to become coarser if the slave moves away from it. This limitation is addressed in Corollary 4.3.
[0130] Definition The a posteriorix obstacle set, O(T k ), is defined as the coarsest level of detail obstacle representation set such that (T k )∩T k =.
[0131] Corollary 4.3 Recursive feasibility holds for a changing obstacle set if the obstacle set at time k+1, k+1 , is a subset of (T k ).
[0132] Proof: Follows directly from the proof of Proposition 4.2. It is possible to incorporate the recursive feasibility conditions for k+1 from Corollary 4.3 into the nominal trajectory minimal cover selection algorithm (Alg. 1) by enforcing recursion to the box's children when a box intersects with the solution trajectory from P N at the previous time step. This modification to Alg. 1, restricts the minimal cover at time k+1 to be a subset of k (T k ).
4.4 Evaluation of Explicit and Implicit Non-Convex OAF Algorithms
[0133] The alternative OAF algorithms are evaluated by comparing their performance in terms of computational cost and deviation from the nominal trajectory. The implicit OAF algorithm is evaluated against the leaf boxes OAF algorithm, and the nominal trajectory OAF algorithm is compared to both the leaf boxes and the root box OAF algorithms. The dynamic model used for the comparison simulations is that of a proportionally velocity-controlled point mass in two dimensions. The discretized dynamics (T s =0.2 s) and constraints for each degree of freedom (chosen along x and y axes) are:
[0000]
[
q
k
+
1
v
q
,
k
+
1
]
=
[
1
0.0865
0
0.135
]
[
q
k
v
q
,
k
]
+
[
0.1135
0.865
]
u
q
,
k
.
(
4.18
)
q
∈
[
-
10
,
10
]
,
v
q
∈
[
-
1
,
1
]
,
u
q
∈
[
-
1
,
1
]
,
10
(
u
q
-
v
q
)
∈
[
-
1
,
1
]
.
(
4.19
)
[0134] The invariant set used in this simulation is the zero-velocity invariant set, which is given, along with its associated terminal feedback control by:
[0000] X T ={[x,y,v x ,v y ] T ε / :v x =0, v y =0}, (4.20)
[0000] u x,T =0, u y,T =0. (4.21)
[0135] This invariant set is incorporated in the MIP OAF using the following constraints:
[0000] x k+N ∉ . (4.22)
[0000] v x,k+N =0, v y,k+N =0, u x,k′N =0, u y,k+N =0. (4.23)
[0136] Note that Eqn 4.22 will require obstacle avoidance constraints, analogous to those in remainder of the horizon, to be imposed for the terminal state, e.g. nominal trajectory or implicit avoidance constraints. The obstacle set and BVH for these simulations is the obstacle and BVH given, respectively, in FIGS. 5 and 6 . The prediction horizon length is set to 1 sec (N=5). and a 2-norm cost will be placed on the deviation, and the discount rate γ=1. The resulting MIP formulation is a Mixed Integer Quadratic Program (MIQP), which can be solved using CPLEX (ILOG 2007).
[0137] FIG. 8 shows that the trajectory produced by the implicit OAF corresponds to the trajectory produced by the leaf box OAF. Since all minimal covers are supersets of leaf box minimal cover, and that the MIQP solver determines the global optimal solution to the MIP, the trajectories correspond due to Proposition 4.4:
[0138] Proposition 4.4 Consider two minimal covers: 1 and 2 . If 1 2 , then cost of the optimal trajectory that is feasible with respect to 1 is less than, or equal to the cost of the optimal trajectory that is feasible with respect to 2 .
[0139] Proof: Consider the set of all trajectories from a given state, χ, that are feasible with respect to the constraints and the minimal cover .
[0000] T N (χ, )={ T N ( χ,u N−1 ): ∀ u N−1 ε N , subject to T N ( χ,u N−1 )∩ =}
[0140] Since 1 2 , all of the trajectories that are feasible with respect to 2 , are also feasible with respect to 1 , hence T N (χ, 2 ) T N (χ, 1 ), ∀χε . So the cost for the minimum cost trajectory in T N (χ, 1 ) is less than, or equal to the cost for the minimum cost trajectory in T N (χ, 2 ).
[0141] This result is dependant on the appropriate choice of ε in Eqn. 4.11. If ε is larger than the cost difference between the leaf node trajectory and one for another minimal cover, then the implicit and leaf node trajectories will not correspond. The least computationally efficient algorithm of either the leaf boxes OAF or the implicit OAF is redundant, as they produce the same trajectory.
[0142] The table below shows simulation times (in seconds) for the different forms of the OAF for the different starting points. These simulations were run on an Intel Core 2 Duo E6300 (single core only) with 4 GB of RAM, where the OAF MIQP is solved using CPLEX10.2 (ILOG 2007).
[0000]
1
2
3
4
Binary Variables
Root Box
0.56
0.53
0.66
0.56
20
Leaf Boxes
15.09
15.13
14.44
12.66
320
Nominal Trajectory
3.67
2.86
3.16
3.37
20-320
Implicit
59
52.71
52.2
55.35
695
[0143] The table shows that for the four trajectories considered in FIG. 8 , the computation of the leaf boxes trajectory takes approximately 30% of the time taken to compute the implicit OAF trajectory. This comparison renders the implicit OAF formulation redundant. Two reasons for the poor performance of the implicit OAF are that (i) it is computing the best minimal cover in addition to the optimal trajectory, and (ii) the leaf node OAF is a subproblem of the implicit OAF. The nominal trajectory explicit OAF is to be verified by comparing its trajectories against those produced by the leaf boxes OAF and the root box OAF. The nominal trajectory OAF is formulated to produce a lower deviation trajectory than the root node
[0144] OAF, and (ii) be more computationally efficient on average than the leaf boxes OAF. The simulations verify this supposition. In three of the four simulations shown in FIG. 9 , the trajectories produced by the leaf boxes OAF and the nominal trajectory OAF correspond, while in the fourth, the leaf boxes OAF and the nominal trajectory OAF diverges due to the order of branching in the MIQP solver when the minimum-cost trajectory is not unique (see FIG. 10 ). Additionally, divergences will generally occur due to a difference between the leaf boxes minimal cover and the nominal trajectory minimal cover, particularly if perturbations to the nominal trajectory would result in an alternate minimal cover. The simulation times in the above Table show that the nominal trajectory OAF is more computationally efficient than the leaf boxes OAF, with simulations taking approximately 20-25% of the computation time for the leaf boxes OAF.
[0145] The number of binary variables for the different OAF algorithms is given by the following table:
[0000]
Number of Binary Variables
Root Boxes
2N D N
Leaf Boxes
2N D N × 2 N L −1
Implicit
N [2N D (2 N L − 1) + (2 N L −1 − 1)]
[0146] FIG. 11 shows how the simulation times of the four different OAF algorithms change with respect to the complexity of the BVH, which is given by the number of levels (N L ) within the BVH binary tree. The simulation times of the implicit and leaf boxes OAF increase significantly due to the increase in the number of binary variables. This increase occurs because the number of binary variables required for both formulations are exponential with respect to N L (see Table 2), and the worst case computation cost of an MIP is exponential with respect to the number of binary variables. FIG. 11 also shows that the nominal trajectory OAF does increase, although not by as much as the leaf boxes OAF, and is less costly than the leaf boxes OAF. The root box algorithm is constant as N L has no affect on its runtime.
5 Reducing Computational Cost Using Reachable Sets
[0147] The computational cost of the OAF can be further reduced by removing obstacles or parts thereof that are not reachable at a given time-step in the prediction horizon from the MIP. Within the context of the OAF formulations presented in Sections 2 and 4, reachability can be used to (i) simplify the BVH for a given obstacle by removing ABBs and branches of the tree that are not reachable, and (ii) remove polytopal obstacles and constraints that are not reachable at a given prediction step from the OAF MIP. Reachability is defined in terms of the region in the state space X that can be reached in a given time period: the reachable set.
[0148] Definition: The one-step reachable set is defined as the set containing all possible successor states for a given state or set of states , i.e.
[0000] ( )={χ + ε n :∀uε , ∀χε , χ + =f ( χ,u )}. (5.1)
[0149] Definition The i-step reachable set is recursively defined as the repeated application of the one-step reachable set:
[0000] x ( )= ( x−1 ( )), (5.2)
[0000] with 0 ( )= .
5.1 Simplification of Bounding Volume Hierarchies Using Reachable Sets
[0150] The number of ABBs within a BVH that are considered in a computation can be reduced using reachability. This reduction is performed by (i) culling boxes and branches of the BVH that are not reachable, and (ii) replacing a box with one of its children within the BVH, when only that child is reachable. This BVH simplification strategy relies on the following propositions:
[0151] Proposition 5.1 If an ABB within the BVH is not reachable (i.e. it does not intersect with the reachable set), then none of its descendants are reachable.
[0152] Proof Let B be a descendant box of B,B∩ =, and (B) is defined as the geometry that is bounded by B ( (b)⊂B). Since B is a descendant of B, then (B) (B). By the transitive property of ⊂, (B)∩ =, hence if B is culled due to being non-reachable, its descendants should also be culled.
[0153] Proposition 5.2 If reachable set R intersects a box B lm , and only one of the box's children B l+1,q1 , then box B l;m can be replaced by its child B l+1;q within the BVH.
[0154] Proof Let B l+1,q1 and B l+1;q2 be the two child boxes of B l;m . Also B l;m and B l+1;q1 intersect with reach set, R, while B l+1;q2 does not. ∩ (B lm )= ∩ (B l+1,q1 ) since (B l,m )= (B l+1,q1 )∪ (B l+1,q2 ) and ∩ (B l+1,q2 )=. Hence, ∩ (B lm ) B l+1,q1 .
[0155] Propositions 5.1 and 5.2 can be used together to synthesize an algorithm that simplifies a BVH for a given reachable set by traversing the tree. This recursive algorithm first determines whether the children of a candidate box are reachable, and removes all the non-reachable children and their descendants from the BVH. If only one child remains, it replaces the candidate box in the BVH, and has the recursive algorithm run on it. If more than one child is reachable, the candidate box remains in the tree and recursion proceeds to its reachable children. FIG. 12 shows how this recursive algorithm can be used to simplify a BVH, where the colored-in dots represent the boxes that intersect with reachable set . FIG. 12( a ) shows the entire BVH, and FIG. 12( b ) shows the simplified BVH. The simplification of the BVH will result in either a reduction in the number of binary variables required to represent an obstacle or an increase in the detail of the representation.
5.2 Reduction of Polytopal Obstacle Constraints Using Reachability
[0156] The number of binary variables required to represent at a given prediction time-step can be reduced by culling the obstacles and constraints that cannot be reached from the OAF MIP. This idea is analogous to that set out previously by Kuwata (2003) and Richards et al. (2003), both of whom use approximations of the reachable set of the entire prediction horizon to cull constraints representing obstacles outside this set from the OAF MIP. Culligan (2006) further reduced the number of binary variables in the MIP by including, for each time step in the planning horizon, only the obstacles that could be reached at that time step.
[0157] A further new reduction is achieved by including only the constraints that are necessary to represent the part of the obstacle set that intersects with the reach set. Specifically, it reduces the number of constraints (hence, binary variables) required to represent a convex polytopal obstacle, O j , that is not completely inside the reach set, k Only constraints that are active for some state within k /O j are selected. The constraint, {χ:a ij χ≦b ij }, is selected if.
[0000] k ∩{χ:a i,j χ≦b i,j }≠. (5.3)
[0158] The reachable constraints are then represented by the index set, and the induced obstacle is given by
[0000] I j,k ={iε{ 1,2, . . . , N h ( O j )}: k ∩{χ: −a i,j χ≦−b i,j }≠}, (5.4)
[0000] and the induced obstacle is given by
[0000]
j
,
k
=
⋂
i
∈
X
j
,
k
{
x
∈
k
:
-
a
i
,
j
x
≤
-
b
i
,
j
}
.
(
5.5
)
[0159] The induced obstacle is a subset of the reach set, k , and can also be expressed as the intersection of the O j with k .
[0160] Three possible situations occur if an obstacle O j intersects with reach set k :
1. O j k (see FIG. 13( a )): Here, all of the half-spaces will be required to represent the obstacle. The formulation of Eqns. 3.6 and 3.7 are used to determine the constraints for O j . The induced obstacle for time k is given by O jk =O j . 2. O j k with two or more constraints reachable, i.e. |I jk ≧2 (see FIG. 13( b )).
[0163] The mixed integer linear inequalities for O j at time k are:
[0000]
-
a
i
,
j
T
x
≤
-
b
i
,
j
+
M
α
i
,
j
,
k
,
∀
i
∈
ℐ
j
,
k
.
(
5.6
)
∑
x
∈
ℐ
j
,
k
α
i
,
j
,
k
≤
ℐ
j
,
k
-
1
,
(
5.7
)
[0164] where |.| indicates the number of elements in the index set.
3. O j k with only a single constraint reachable, i.e. |I jk |=1 (see FIG. 13( c )). No binary variables are required as only a single linear inequality is required to represent O j in k . The constraint is
[0000] − i,j T χ≦−b i,j , for iεI j,k . (5.8)
[0166] The number of binary variables that can be removed from the OAF MIP using the reachable constraint method, will depend on the dynamics of the slave, the closeness of the reachable set approximation to the true reachable set, and the geometry of the obstacles. Note that when O k ∀k=1, . . . , N, there will be no reduction in the number of binary variables; in this situation other OAF algorithms, such as those presented in Sections 2 and 4, can be used.
5.3 Reachable Constraint Method for Axially-Aligned Bounding Boxes
[0167] Reachable constraints can be efficiently determined for the case where the obstacle O j and the reachable set (or its approximation) k are ABBs, by modifying the standard algorithm for testing whether a pair of ABBs intersect (Cohen et al. 1995). This algorithm determines whether two ABBs intersect involves by projecting the boxes onto each axis, and determining whether the projections overlap. If the projections overlap on all axes, then the ABBs overlap. The modified algorithm stores whether the bounds of the obstacle overlap as boolean variables, I i:j:k , and, if the obstacle intersects with the reach set, these variables are used to determine the reachable constraint index set I j,k directly.
[0168] Since the only modifications to the standard algorithm are (i) the storage of the I i,j,k variables, and (ii) the construction of set I j,k , the modified algorithm requires only a minor increase in computational resources over the standard ABB intersection test algorithm. The operation of the modified intersection algorithm in 2D is presented in
[0000]
Algorithm 3: Pairwise ABB-intersection algorithm - reachable constraint
method
Data: ABB reach box or ABB approximation to reach set:
R k = [x min,R k , x max,R k ] × [y min,R k , y max,R k ]
Data: ABB obstacle O j = [x min,j , x max,j ] × [y min,j , y max,j ]
Result: Active constraint index set,
begin
| =
| Test projections onto axes for overlap (True/False):
| r x,min = x min,R k ε [x min,j , x max,j ] , r x,max = x max,R k ε [x min,j , x max,j ]
| I 1,j,k = x min,j ε [x min,R k , x max,R k ] , I 2,j,k =x max,j ε [x min,R k , x max,R k ]
| r y,min = y min,R k ε [y min,j , y max,j ] , r y,max = y max,R k ε [y min,j , y max,j ]
| I 3,j,k = y min,j ε [y min,R k , y max,R k ] , I 4,j,k = y max,j ε [y min,R k , y max,R k ]
| Test for intersection (Do the boxes overlap on boh axes?):
| if (r x,min r x,max I 1,j,k I 2,j,k ) (r y,min r y,max I 3,j,k I 4,j,k ) then
| | ABB's collide
| | for i = 1 to do
| | | if I i,j,k = true then
| └ └ └ append i to
end
Algorithm 3.
[0169] This algorithm can be extended to higher dimensions with only minimal modifications (projecting to the new axis/axes and requiring the additional projections to overlap also for intersection of the ABB).
5.4 Recursive Feasibility for Reachable Constraints
[0170] We now show that the reachable constraint method is recursively feasible when applied to (i) a constant obstacle set , and (ii) an obstacle set that can change at each time step according to Corollary 4.3, k :
[0171] Proposition 5.3 Recursive feasibility holds for (i) a constant obstacle set, and (ii) an obstacle set that can change at each time step according to Corollary 4.3, with constraints determined using the reachable constraint method.
[0172] Proof Part (ii) is considered first. It is assumed there is a feasible trajectory at time k,
[0000] T k ={χ k , χ k+1 , . . . , χ k+N }∪χ T , (5.9)
[0000] satisfying the following constraints
[0000] χ k+p+1 =f (χ k+p , u k+p ), ∀ p =0, . . . , ( N− 1), (5.10)
[0000] (χ k+p , u k+p )ε , ∀ p =0, . . . , ( N− 1) (5.11)
[0000] χ k+p ∉ k,p (χ k ), ∀ k= 1, . . . , ( N− 1), (5.12)
[0000] χ k+N εX T , (5.13)
[0000] X T ∩ k,p =. (5.14)
[0000] where k,p (χ k )= k ∩ p (χ k ). Assuming that T k can be exactly implemented in the future, it is possible to construct a trajectory at the next time step,
[0000] T k+1 ={χ k+1 , χ k+2 , . . . , χ k+N , f (χ k+N , k (χ k+N ))}∪ X T , (5.15)
[0000] which is a subset of the trajectory at the previous time step (T k ). In order for recursive feasibility to be established, it is necessary to show that T k+1 is feasible if T k is feasible. The dynamic and system constraints (Eqn. 5.10 and 5.11) for T k+1 are satisfied as it is a subset of the T k . The constraints in Eqns. 5.13 and 5.14 are satisfied for the T k+1 due to the invariance of X T .
[0173] It remains necessary to show that this trajectory will satisfy the obstacle avoidance constraints induced by the reachable sets from χ k+1 , that is:
[0000] χ k+p ∉ k+1,p−1 (χ k+1 ), ∀ p =2, . . . , N (5.16)
[0174] Since −1 (χ k+1 ) p (χ k ) (as p−1 (χ k+1 ) is a restriction of p (χ k ), with the additional constraint that the state at time k+1 is χ k+1 ) and k+1 (T k ), where (T k ) is the a posteriori obstacle set for time k (by the condition of Corollary 4.3). The induced obstacle sets are related by:
[0000] k+1,p−1 (χ k+1 ) p (χ k )∩ ( T k ). (5.17)
[0175] It follows from Eqn. 5.17, and the fact that k (T k ):
[0000] χ k+p ∉ k,p (χ k )→χ k+p ∉ k+1, p−1 (χ k+1 ), ∀p.
[0176] Hence, all constraints are satisfied for T k+1 , if the constraints, Eqn 5.10 to 5.14, are satisfied for T k . The recursive feasibility condition given in Eqn. 5.17 also holds trivially when the obstacle set is constant, since T k is feasible with respect to , so (i) is also satisfied.
5.5 Evaluation of OAF Algorithms Using the Reachable Constraint Method
[0177] The leaf boxes and nominal trajectory OAF algorithms, using the reachable constraint method, are evaluated against the corresponding unmodified OAF algorithm. The OAF algorithms uses the reachable constraint method should produce the same trajectory, more computationally efficiently than the corresponding unmodified OAF method. The dynamic model and OAF formulation presented in Section 4.4 are used, again, for these simulations.
[0178] The reachable constraint method utilizing ABBs, requires an ABB approximations to the reachable sets can be calculated. These ABBs are calculated using a method similar to the one presented in Culligan (2006). The approximate reachable sets,
[0000] p (χ k )=[χ k+p,min ,χ k+p,max ]+[ k+p,min , k+p,max ], ∀p=1, . . . , N (5.18)
[0000] are calculated by solving the following models:
[0000] χ k+p,min =f (χ k+p−1, min , u min ), ∀p=1, . . . , N, (5.19)
[0000] χ k+p,max =f (χ k+p−1,max , u max ), ∀p=1, . . . , N, (5.20)
[0000] χ k,max =χ k,min =χ k . (5.21)
[0000] where the maximal and minimal inputs are given by:
[0000]
u
m
i
n
=
arg
min
u
{
1
T
u
:
u
∈
}
,
(
5.22
)
u
m
ax
=
arg
max
u
{
1
T
u
:
u
∈
}
.
(
5.23
)
[0179] This formulation will produce outer approximation to reach sets for linear systems with system matrices having all positive or zero elements, such as the model presented in Section 4.4.
[0180] FIG. 14 and the table below show the comparisons between OAF algorithms using the reachable constraint method and unmodified OAF algorithms FIG. 14 shows that the trajectories for each starting point correspond for both the leaf node OAF and the nominal trajectory OAF, except for Trajectory 4 of the Leaf boxes OAF. This behaviour is due to the ordering of the branching in the MIQP when the minimal-cost trajectory is not unique. Table 3 shows that OAF algorithm using the reachable constraint method to have significantly shorter run times than the corresponding unmodified OAF algorithm. Hence, the reachable constraint method should be used where reachable sets and the resulting reachable constraints can be determined efficiently, e.g. when the reach set and obstacles are represented using ABBs.
[0181] The table below shows a simulation time comparison between unmodified OAF algorithms and OAF algorithms using the reachable constraint method. These simulations were run on an Intel Core 2 Duo E6300 (single core only) with 4 GB of RAM, where the OAF MIQP is solved using CPLEX10.2 (ILOG 2007). Times in seconds.
[0000]
1
2
3
4
Leaf Boxes
Unmodified
15.09
15.13
14.44
12.66
Reachable constraints only
3.33
2.75
2.51
3.42
Nominal
Unmodified
3.67
2.86
3.16
3.37
Trajectory
Reachable constraints only
1.49
1.31
1.38
1.65
6. Simulation Example Based on Simplified Mining Shovel-Truck Avoidance Problem
[0182] The example considered in this section is that of a simplified cartesian excavator, where an operator loads material into a truck tray ( FIG. 15 , left) by commanding the velocity of the dipper ( FIG. 15 , right).
[0183] The scenario that is simulated in this section is of an operator making his first loading pass of an empty truck tray with the dipper, but failing to lift out or stop the dipper inside the truck tray. This is modeled as a constant operator command input over the simulation. The nominal trajectory OAF algorithm, using the reachable constraint method, and a lookahead of 1 second (or 5 samples) will be used to avoid collisions. The dynamics and kinematics in this example have been simplified: the motion is pure translation, and each degree of freedom (DOF) has double integrator dynamics with proportional rate feedback. Each DOF is aligned to a cartesian axis. The x DOF has twice the effective inertia, and can travel at twice the velocity of the y DOF and z DOF.
[0184] The discrete time model for the system (Δt=0:2s) is
[0000]
[
x
k
+
1
u
x
,
k
+
1
y
k
+
1
u
y
,
k
+
1
z
k
+
1
u
z
,
k
+
1
]
=
[
1
0
0
0.1264
0
0
0
1
0
0
0.08647
0
0
0
1
0
0
0.08647
0
0
0
0.3679
0
0
0
0
0
0
0.1353
0
0
0
0
0
0
0.1353
]
[
x
k
v
x
,
k
y
k
v
y
,
k
z
k
v
z
,
k
]
+
[
0.07358
0
0
0
0.1135
0
0
0
0.1135
0.6321
0
0
0
0.8647
0
0
0
0.8647
]
[
u
x
,
k
u
y
,
k
u
z
,
k
]
.
(
6.1
)
[0185] The corresponding velocity, command and actuator constraints for this system are
[0000] v x ε[−2,2], v y , v z ε[−1,1], (6.2)
[0000] u x ε[−2,2], u y , u z ε[−1,1], (6.3)
[0000] 10( u q −v q )ε[−1,1], q=x,y,z. (6.4)
[0186] Again, the zero-velocity, collision-free invariant set is utilized as the OAF terminal invariant set:
[0000] X T ={χε /O:v x =0, v y =0, v z =0}, (6.5)
[0000] and the associated terminal feedback control is
[0000] u x,T =0, u y,T =0, u z,T =0. (6.6)
[0187] The invariant set and associated control law is included in the OAF MIQP using the following constraints:
[0000] χ k+N ∉ , (6.7)
[0000] v x,k+N =0, v y,k+N =0, v z,k+N =0, (6.8)
[0000] u x,k+N =0, u y,k+N =0, u z,k+N =0. (6.9)
[0188] Object-object avoidance constraints can be represented using the Minkowski Sum, as the motion of the dipper is pure translation. The Minkowski Sum is defined as the exhaustive sum of two sets, A and B:
[0000] ⊕ ={ a+b:∀aε , ∀bε }
[0189] The set representing the geometry of the dipper for a given state χ (since the dipper's motion is pure translation) is:
[0000] X D (χ)= C p χ⊕X D (6.10)
[0000] where Cp: → 3 is the projection matrix from the state to the position space (Note that in general, the relationship between the state and position spaces may not be linear, particularly if rotation states are involved), and χ D ⊂ 3 is the set representing the geometry of the dipper when the state is at the origin. Hence, the object-object obstacle avoidance constraint for the cartesian excavator is given by:
[0000] ( C p χ⊕χ D )∩ x =. (6.11)
[0000] where T ⊂ 3 represents the geometry of the truck tray. Equation 6.11 can be transformed into a point-object constraint using the Minkowski sum:
[0000] C p χε[ ⊕(−χ D )] (6.12)
[0000] where −χ={−χ, ∀χεχ}.
[0190] The level-of-detail point-polytope avoidance constraints are calculated using a method based on the method to determine Minkowski bounding trees, presented in Smith (2008): A BVH of ABBs for the tray is constructed, and the BVH of the obstacle set is found by taking Minkowski sum of the truck tray BVH box-wise with an ABB of the dipper (effectively the root box of the BVH of the dipper). FIG. 16 shows the leaf boxes of the Minkowski Bounding Tree of the dipper-truck tray obstacle set.
[0191] FIG. 17 shows the leaf boxes of the BVH representing the state space obstacle and the resulting trajectory (white spheres), while FIG. 18 , shows corresponding snapshots of the relative motion of the dipper to the truck tray. Both figures show that the dipper successfully avoids colliding with the shovel.
7 Conclusions
[0192] The preferred embodiment provides for an effective OAF, which is interposed between a human operator and the slave manipulator, to assist the operator in avoiding collisions by minimally altering the operator's command. The OAF formulation addresses the challenges inherent in assisting human operators in avoiding obstacles, namely it deals with the non-causal structure of the problem, and accounts for that the dynamics and performance limitations of the system when determining the alteration to the operator's command. The main contribution of the paper though is in incorporating geometric level of detail into the OAF framework to produce a computationally efficient algorithm for avoiding non-convex obstacles. The present results, while simulation-based only, are sufficiently promising to suggest that the OAF can work in practice for a suitable application.
Interpretation
[0193] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
[0194] Similarly it should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.
[0195] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.
[0196] Furthermore, some of the embodiments are described herein as a method or combination of elements of a method that can be implemented by a processor of a computer system or by other means of carrying out the function. Thus, a processor with the necessary instructions for carrying out such a method or element of a method forms a means for carrying out the method or element of a method. Furthermore, an element described herein of an apparatus embodiment is an example of a means for carrying out the function performed by the element for the purpose of carrying out the invention.
[0197] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
[0198] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner
[0199] In the claims below and the description herein, any one of the terms comprising, comprised of or which comprises is an open term that means including at least the elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed thereafter. For example, the scope of the expression a device comprising A and B should not be limited to devices consisting only of elements A and B. Any one of the terms including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.
[0200] Similarly, it is to be noticed that the term coupled, when used in the claims, should not be interpreted as being limitative to direct connections only. The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Thus, the scope of the expression a device A coupled to a device B should not be limited to devices or systems wherein an output of device A is directly connected to an input of device B. It means that there exists a path between an output of A and an input of B which may be a path including other devices or means. “Coupled” may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other but yet still co-operate or interact with each other.
[0201] Although the present invention has been described with particular reference to certain preferred embodiments thereof, variations and modifications of the present invention can be effected within the spirit and scope of the following claims. | A method of implementing an optimal avoidance filter for interposing between a human operator issued movement commands and a corresponding machine control system of a movable machine, for the avoidance of collisions with objects. The method: includes inputting a detailed representation of objects in the vicinity of the movable machine; and formulating a hierarchical set of bounding boxes around the objects. The hierarchical set including refinement details depending on the current positional state of the movable machine, with objects closer to the machine having higher levels of refinement details. The method further includes utilizing the resultant hierarchical set as a set of constraints for a mixed integer optimisation problem to determine any alterations to the issued movement commands so as to avoid collisions with any objects. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
The applicants hereby claim the benefit of the earlier filing date of Apr. 25, 2002, of Provisional Application Ser. No. 60/375,541, under 35 U.S.C.§ 119 (e).
TECHNICAL FIELD OF THE INVENTION
This invention relates to a rod puller apparatus and method. In particular, the invention relates to a rod puller apparatus and method for removing rods, posts and the like from the ground without bending or breaking the rods or posts.
BACKGROUND OF THE INVENTION
Many situations exist wherein rods, posts, pilings and the like are driven into the ground to serve a temporary purpose. By way of example only, and not limitation, in the construction industry it is necessary for steel rods, many feet in length, to be sunk into the ground at the construction site. The rods can serve any purpose, but, for example again, often are used as electrical grounding devices. Certainly, many other needs are served by such temporary rods, such as for surveying purposes, locating cement car stops in parking lots, metal, wood, and cement fence and sign posts and the like.
In any event, once installed, it is often necessary to remove these “rods”. This has proven to be a difficult, time-consuming, and destructive process. That is, for example only, heretofore, the removal of long, metal, rods which have been driven deep into the earth, often results in the rods being bent beyond reusable form. One prior art method is to tie a chain to the rod and use a back hoe, or the like, to yank the rod out of the ground. Even if this is successful, the rod is generally so bent and deformed as to be of no possible further use.
In some cases, the rod has been driven into ground so hard and to such a depth that removal is, for all practical purposes, impossible. In this case, the prior art solution is to cut the rod off as close to the ground level as possible and then drive the stub below grade and leave the rest of the rod forever buried at the construction site.
By way of further example, these metal rods are generally made of steel, are eight to ten feet long, and vary in diameter from one-half to three-quarter inches. Additionally, utility companies, construction firms, and the like, invest a large amount of money in maintaining a supply of such rods. Companies use other rods as well such as four foot long curb pins and two to four foot long grading stakes. Any rods, whether metal, wood, cement, or the like, that can be reclaimed and reused helps reduce the costs to such companies.
Thus, there is a need in the art for providing an apparatus and method for pulling sunken rods or posts that leaves the rods and posts intact and reusable.
SUMMARY OF THE INVENTION
Accordingly, the rod puller apparatus and method of the present invention includes an extended lever. A roller pad is connected to the extended lever. A releasable grab attachment is movably connected to the roller pad. In a preferred embodiment, the releasable grab attachment is removable and adjustable for various sized rods. In another preferred embodiment, the roller pad includes a foot leverage platform. In another preferred embodiment, the roller pad includes an attachment for a replacement guide roller.
In yet another preferred embodiment, a method of pulling rods includes the step of providing an extended lever. A roller pad is attached to one end of the extended lever. A releasable grab attachment is connected to the roller pad. A portable support is placed next to a rod which has previously been driven into the ground. The roller pad is placed on the portable support. The extended lever is moved toward the rod and the releasable grab attachment is placed over the rod. The lever arm is moved away from the rod resulting in the rod being pulled a small distance out of the ground. The steps are repeated until the rod is completely removed from the ground.
In another aspect of this embodiment, the releasable grab attachment includes a replacement guide roller conformed to fit rods with different diameters. In another aspect of this embodiment, a foot leverage platform is provided on the roller pad and a user's foot is used to assist in the movement of the roller pad by means of the extended lever formed by the foot leverage platform.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features, and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment and the accompanying drawings in which:
FIG. 1 is a side view illustration of the rod puller apparatus according to one embodiment at the start of the first pull cycle;
FIG. 2 is a side view illustration of the apparatus of FIG. 1 near the middle of the first pull cycle;
FIG. 3 is a side view illustration of the apparatus of FIG. 1 at the end of the first pull cycle;
FIG. 4 is a side view illustration of the apparatus of FIG. 1 at the start of the second pull cycle;
FIG. 5 is a side view illustration of the apparatus of FIG. 1 near the middle of the second pull cycle;
FIG. 6 is a side view illustration of the apparatus of FIG. 1 at the end of the second pull cycle;
FIG. 7 is a side view illustration of the detail of the apparatus of FIG. 1 ;
FIG. 8 is an enlarged side view illustration of the detail of the releasable grab attachment and replaceable guide roller according to one embodiment of the apparatus of FIG. 1 ;
FIG. 9 is a top view of the apparatus of FIGS. 1 and 8 ;
FIG. 10 is an enlarged side view of the apparatus of FIG. 1 illustrating the placement of the reserve replaceable guide roller;
FIG. 11 is an exploded view of the apparatus of FIG. 1 showing the replaceable guide roller and a replacement guide roller;
FIG. 12 is a bottom view of another embodiment of the releasable grab attachment of the apparatus of FIG. 1 ;
FIG. 13 is a top view of the grab attachment of FIG. 12 ;
FIG. 14 is a side view of the apparatus with the grab attachment of FIGS. 12 and 13 ; and
FIG. 15 is a top view of another embodiment of the releasable grab attachment of the apparatus of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention are illustrated by way of example FIGS. 1–15 . With specific reference to FIG. 1 , the rod puller apparatus 10 of the present invention includes extended lever 12 . Roller pad 14 is connected to one end 16 of extended lever 12 . A releasable grab attachment 18 is connected to the front 20 of roller pad 14 .
In a preferred embodiment, releasable grab attachment 18 moves slightly so as to allow parallel alignment of the grab attachment 18 with, and in relation to, rod 22 . In a preferred embodiment, a replaceable guide roller 24 is connected to the front of roller pad 14 as more fully disclosed and described hereafter. In another preferred embodiment, roller pad 14 includes foot leverage platform 26 . FIG. 1 also illustrates the use of portable support 28 located close to rod 22 and utilized to provide a supporting surface 30 for roller pad 14 above ground 32 .
In operation, portable support 28 is placed on the ground 32 in close proximity to rod 22 . Extended lever 12 is grasped by a user's hand 34 and roller pad 14 is placed on supporting surface 30 and rotated in the direction of dotted arrow 36 which is in the direction of rod 22 . At that point, releasable grab attachment 18 fits snugly over rod 22 . The user then places his/her foot 38 on foot leverage platform 26 and pulls extended lever 12 with his/her hand 34 away from rod 22 in the direction of solid arrow 40 as shown in FIG. 2 and pushing down on foot leverage platform 26 with his/her foot 28 . This pinches rod 22 between grab attachment 18 and the front 20 of roller pad 14 or, in a preferred embodiment, replaceable guide roller 24 . When roller pad 14 reaches the limit of its travel in the direction of solid arrow 40 as shown in FIG. 3 , the process is repeated again as illustrated in FIGS. 4 , 5 , and 6 until the rod 22 is pulled completely from the ground 32 .
Rod puller apparatus 10 accomplishes the extraction of rod 22 from ground 32 by a series of cycles. The “first” cycle is illustrated by way of example in FIGS. 1–3 . The “second” cycle is illustrated by way of example in FIGS. 4–6 . Importantly, however many cycles are required to fully extract rod 22 from the ground, rod 22 is extracted essentially without damage, bending, or deformation of any kind.
By way of further explanation, with reference to FIGS. 1–6 , roller pad 14 is comprised of a curved, “curvate”, lower section 42 and a top section 44 . As illustrated, extended lever 12 , in a preferred embodiment, extends through top section 44 such that end 16 of extended lever 12 is connected to curved lower section 42 of roller pad 14 . Certainly, any appropriate confirmation for the connection of extended lever 12 with roller pad 14 is suitable for purposes of the invention.
Again, by way of additional explanation, releasable grab attachment 18 is connected to the front 20 of roller pad 14 . Releasable grab attachment 18 , in a preferred embodiment consists of stationery extension 46 and rotatable section 48 . Rotatable section 48 is rotatably connected to stationery extension 46 by any means known in the art such as pin 50 . As clearly shown in FIGS. 1 and 4 , this configuration enables releasable grab attachment 18 to connect with rod 22 in a manner approximately perpendicular to rod 22 . Additionally, as illustrated in FIGS. 2 , 3 , 5 , and 6 , the ability of rotatable section 48 to rotate ensures, in combination with the short cycles of the invention, that rod 22 is not bent or deformed as it is being pulled from ground 32 .
FIG. 7 is a further illustration of the basic elements of the invention including the releasable grab attachment 18 of the present invention. Grab attachment 18 includes teeth 52 for a better purchase on rod 22 . Grab attachment is moveably connected to rotatable section 48 by a pin 50 and is prevented from full rotation by another pin 50 at the end 54 of rotatable section 48 .
Referring now to FIGS. 8 and 9 , the replaceable guide roller 24 of the present invention is illustrated. In FIG. 8 , no rotatable extension 48 is used and only stationary extension 46 is provided. Even if rotatable extension is used the function is the same. That is, for purposes of example only and not by limitation, as shown in FIG. 9 , a pair of support arms 51 with a first end 53 and a second end 55 are attached by pin 50 at the first end 53 to the front 20 of top section 44 of roller pad 14 . The tubular shaped replaceable guide roller 24 is attached by pin 50 in between support arms 51 closer to front 20 of top section 44 than is grab attachment 18 such that a rod receiving space 57 is formed by the rectangular shaped grab attachment 18 , guide roller 24 and support arms 51 for rod 22 . In use, rod 22 is slipped in-between them into space 57 for pulling as described above. The applicants have found that a snug fit is preferable. As a result, different sizes of rods may be accommodated by removing and replacing the guide roller 24 with one with a smaller or larger diameter as required. FIG. 9 also shows support 56 in top section 44 for supporting a replacement guide roller 24 of a different diameter while another guide roller 24 is in use as more clearly illustrated in FIG. 10 .
FIG. 10 shows support 56 in the form of a pin of a diameter smaller than the inside diameter of guide roller 24 such that guide roller slips over support 56 and is retained in position on support 56 by use of a cotter pin 58 (see FIG. 11 ) in hole 60 . Support 56 has a larger head 62 than the body of support 56 that prevent support 56 from slipping through the hole 64 in the top section 44 . In this manner, extra roller guides are on hand, and out of harms way in operation, whenever a different size of rod is encountered.
FIG. 11 illustrates the connection of reserve guide roller 24 by means of support 56 and also the use of pin 50 , also with large head 62 , and cotter pin 58 to rotatably secure guide roller 24 to stationary extension 46 and rotatable extension 48 . This same pin 50 and cotter pin 58 combination is used to secure grab attachment 18 (not shown) to rotatable extension 48 .
FIGS. 12 and 13 illustrate the bottom and top, respectively of another preferred embodiment of the grab attachment 18 of the present invention. In situations where the top of the item to be pulled is too large for the grab attachment 18 to slip over it, as described above, side loading jaw 66 is used. For example, when the head of a rod 22 is mushroomed out by repeated blows of a sledge hammer, side loading jaw 66 is attached to the front 20 of the invention for use as described above. FIG. 14 shows the attachment of side loading jaw 66 to rotatable extension 48 which is in turn connected to stationary extension 46 by pins 50 as discussed above. In this embodiment, however, side loading jaw 66 is attached to the pin 50 nearest the end 54 of rotatable extension 48 .
Referring now to FIG. 15 , a grab attachment 18 that is conformed to pull posts and other non-round objects is disclosed. The grab attachment 18 in this embodiment includes a stationary arm 68 and slidable arm 70 . Slidable arm 70 is moved toward stationary arm 68 so as to snug up against the post to be removed (not shown) on three of the four sides of the post. Thereafter the operation of the invention is as previously described. This grab attachment 18 is also useful in pulling metal fence posts.
The description of the present embodiments of the invention have been presented for purposes of illustration but are not intended to be exhaustive or to limit the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. As such, while the present invention has been disclosed in connection with the preferred embodiments thereof, it should be understood that there may be other embodiments which fall within the spirit and scope of the invention as disclosed herein and as defined by the following claims. | A rod puller apparatus and method includes an extended lever. A roller pad is connected to the extended lever. A releasable grab attachment is connected to the roller pad. In a preferred embodiment, a foot leverage platform is connected to the roller pad. In a further preferred embodiment, a replaceable guide roller is provided so as to accommodate rods of various diameters. Other grab attachments are provided for rods with mushroomed heads and for square posts and/or metal fence posts. | 4 |
FIELD OF THE INVENTION
The present invention relates to throttle bodies that are employed to regulate the flow of intake air into an internal combustion engine, and more particularly to the throttle shafts that support and actuate the valve within the throttle body.
BACKGROUND OF THE INVENTION
Conventional throttle bodies are mounted within the intake air stream of an internal combustion engine. Typically, a butterfly valve is employed to control the amount of air flow though the throttle body. The butterfly valve is mounted on a throttle shaft, which is in turn coupled to the vehicle accelerator pedal, and possibly other actuating mechanisms.
The air intake system operates most accurately when there is no air leakage in the system. With minimal leakage, mass air flow sensors, which are also mounted in the air intake stream, will obtain more accurate readings of the air flowing into the engine, which, in turn, allows an on-board computer to operate the engine at peak efficiency.
One potential source of leakage is around the throttle shaft where it mounts to the throttle body housing. In order to maintain smooth rotation of the throttle shaft, bearings are typically employed that mount to the shaft and are fixed to the housing. But the need to seal around the throttle shaft still exists. Some designs do not do anything about the leakage and just allow the resultant inaccuracy to occur. Other designs employ rubber seals that mount adjacent to the bearings around the surface of the throttle shaft, but these seals can wear and create a drag on the shaft causing resistance to smooth rotation of the shaft. Although, having seals avoids the problems with leakage, especially the inconsistency of leakage from one car to another.
Still other designs employ O-rings mounted within a circumferential groove formed in the shaft at the locations of the bearings with the O-rings mounting between the shaft and bearings to seal between the two. The design maintains ease of assembly and also keeps costs to a minimum. However, the groove in the throttle shaft also weakens the shaft itself, requiring a slightly larger diameter for the same applied forces. A minimum throttle shaft diameter is desirable to save weight and cost. Therefore, a desire exists to allow for easy and cost efficient assembly of a throttle shaft to bearings in a throttle body while sealing the space between the throttle shaft and the bearings, but not weakening the throttle shafts or interfering with smooth rotation of the shaft.
A further concern that arises with throttle shafts is that they typically mount, at one end, to a throttle position sensor. Since the throttle shafts must be free to rotate relative to the throttle body housing, they typically have play in an end-to-end (axial) direction. In order to account for this play, the throttle position sensor must be more complex and expensive because it generally needs additional bushings, springs and seals to account for this. Thus a desire exists to limit the end-to-end free play, allowing for the employment of a less expensive sensor, while still allowing for free rotation and good sealing around the throttle shaft.
SUMMARY OF THE INVENTION
In its embodiments, the present invention contemplates a throttle body for use in an air intake system of an internal combustion engine. The throttle body includes a throttle body housing having an air flow bore and a throttle shaft mounting bore therethrough. Bearings are mounted within the throttle shaft mounting bore, and a throttle shaft, having a mounting surface thereabout, is aligned with at least one of the bearings. Sealing means are located between the mounting surface and the at least one of the bearings, for filling any gap that may exist between the mounting surface and the corresponding bearing and for substantially eliminating axial movement between them.
Accordingly, an object of the present invention is to use sealing compound to seal the throttle shaft to bearings mounted to the throttle body housing to allow for smooth rotation of a throttle shaft relative to a throttle body while providing for sealing around the throttle shaft where it mounts to the housing, without substantially reducing the strength of the throttle shaft.
An advantage of the present invention is that the intersection of the throttle shaft to the bearings in the throttle body housing is sealed, to prevent leakage, allowing for a more accurate sensing of the volume of air entering the engine.
A further advantage of the present invention is that the axial play of the throttle shaft relative to the housing is substantially eliminated, allowing for the use of a throttle position sensor that does not have to be designed to account for this play.
An additional advantage of the present invention is that the sealing compound can be applied accurately at a high rate of production speed and automated, thus reducing manufacturing costs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general perspective view of a throttle body for an internal combustion engine in accordance with the present invention;
FIG. 2 is an exploded perspective view of the throttle body of FIG. 1, shown without sealant on the throttle shafts;
FIG. 3 is a perspective view, on an enlarged scale, of one of the throttle shafts, with one of the surfaces illustrating the coating of sealing compound;
FIG. 4 is a section cut, on an enlarged scale, taken along line 4--4 in FIG. 3; and
FIG. 5 is a perspective view similar to FIG. 3 illustrating an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A throttle body assembly 10 includes a throttle body housing 12, which assembles into an air intake system for an internal combustion engine, not shown. The throttle body housing 12 disclosed in this preferred embodiment includes two air flow bores, a primary air flow bore 14 and a secondary air flow bore 16 through which intake air is directed during operation of the internal combustion engine. The throttle body housing 12 also includes a pair of throttle shaft bores, a primary throttle shaft bore 18 and a secondary throttle shaft bore 20. The primary throttle shaft bore 18 intersects and is generally normal to the axis of the primary air flow bore 14, and the secondary throttle shaft bore 20 intersects and is generally normal to the axis of the secondary air flow bore 16.
Within the primary throttle shaft bore 18 are mounted a pair of throttle shaft bearings 22, one on each side of the primary air flow bore 14. Within the secondary throttle shaft bore 20 are mounted a second pair of throttle shaft bearings 24, one on each side of the secondary air flow bore 16. A throttle position sensor 26 and gasket 28 are mounted, by screws 30, to throttle body housing 12 adjacent to one of the throttle shaft bearings 22 mounted in primary throttle shaft bore 18. An expansion plug 32 is mounted to throttle body housing 12 adjacent to one of the throttle shaft bearings 24 mounted in the secondary throttle shaft bore 20.
A primary throttle shaft 34 is sized to fit within the pair of bearings 22, with one end of the shaft mating with the throttle position sensor 26. The primary throttle shaft 34 includes a central slotted portion for receiving a primary throttle plate 36, affixed with screws 38. The primary throttle shaft 34 also includes a pair of mounting surfaces 40, each one aligned to mount within a corresponding one of the bearings 22. The mounting surfaces 40 are shown with knurls on them, although splines or a rough ground surface can also be used for this surface that mounts within the throttle shaft bearings 22. The other end of the primary throttle shaft 34 is coupled to a primary throttle spring 46, a primary throttle control lever 48 and attachment hardware 62 in a conventional fashion, forming a primary throttle shaft assembly 44.
A sealing compound 42 is applied on the mounting surfaces 40 and hardens between the primary throttle shaft 34 and throttle shaft bearings 22, filling in any gap between the two. This seals the throttle shaft 34 to the bearings 22. The knurls on the mounting surface 40 give the sealing compound 42 a better grip on the throttle shaft 34, than if it were a smooth surface, as is the case with conventional throttle shafts.
The sealing compound 42 is one which will provide sealing and locking properties while being used in a vehicle engine compartment environment. An example of a typical primary throttle shaft 34 might have a width of knurled area of about 7 mm, with the knurl being a diamond knurl at a 96 diametrical pitch and a minimum depth of 0.1 mm after finish grinding and plating the main surface of the throttle shaft 34; the shaft 34 being between about 6 and 10 mm in diameter. Examples of sealing compounds that can be used are DRI-LOC 204 ™ manufactured by Locktite Corporation, or Scotch-Grip 2510™ by 3M Company of St. Paul Minn.
The sealing compound 42 will also keep the throttle shaft 34 from moving in an axial direction. By holding the throttle shaft 34 from axial movement, in addition to preventing leakage, a less complex, and thus, less expensive throttle position sensor 26 can be used that does not need to be able to account for axial play. For example, a throttle position sensor such as a 526 SERIES model by CTS Corporation of Elkhart, Ind. can be used.
In the exemplary embodiment disclosed in FIGS. 1 and 2, the throttle body 10 includes a secondary air bore 16 as disclosed above, and thus includes a secondary throttle shaft 50. The secondary throttle shaft 50 mounts within the throttle shaft bearings 24 and includes mounting surfaces 52 that align with bearings 24 and will also be coated with a sealant. A secondary throttle plate 54 is secured in a slot in secondary throttle shaft 50 by screws 56. A conventional secondary throttle lever 58 and secondary throttle return spring 60 are coupled to the secondary throttle shaft 50 and secured thereto with conventional mounting hardware 62, forming a secondary throttle shaft assembly 64.
Of course, one skilled in the art would understand that a throttle shaft as disclosed in the present example of the best mode can also be used in a typical throttle body with just one air bore, and one corresponding throttle plate and shaft.
An alternate embodiment is illustrated in FIG. 5. This embodiment is the same as the first embodiment as illustrated in FIGS. 1-4, except for a change to the primary throttle shaft. The elements that have been modified from the first embodiment are given an added prime. In this embodiment, the primary throttle shaft 34' mounts within throttle shaft bearings 22 and couples to the throttle position sensor 26 the same as in the first embodiment. However, the throttle shaft 34' only includes a mounting surface 40 at the bearing location that will mount closest to the primary throttle control lever 48.
The other mounting surface location is replaced with a circumferential groove 68 formed in the shaft with an O-ring 70 mounted within the groove 68. This O-ring will align with the ocher throttle shaft bearing 22. In this way, the throttle shaft 34' can still be reduced in diameter without weakening the throttle shaft 34' too much. This is because most of the bending stress in the throttle shaft 34' is caused by a conventional throttle cable, not shown, that engages the primary throttle control lever 48 and pulls on it. The stress is thus higher in the throttle shaft 34' at the bearing 22 that is closer to the control lever 48 than it is at the other bearing. Therefore, the groove 68 is not at the location of peak stress and the diameter of the throttle shaft 34' can be reduced without becoming to weak. Further, the sealant 42 at the one bearing 22 will still limit the axial movement of the throttle shaft 34'.
While certain embodiments of the present invention have been described in detail, those Familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A throttle body (10) for use in the air intake system of an internal combustion engine. The throttle body (10) includes a throttle body housing (12) having throttle shaft bearings (22) mounted within it for receiving a throttle shaft (34). The throttle shaft (34) is mounted within the bearings (22) and coupled to a throttle position sensor (26), which is mounted to the throttle body (10). The throttle shaft (34) includes mounting surfaces (40) aligned with the bearings (22) and a sealant (42) applied between the mounting surfaces (40) and the bearings (22) to both seal the intersection between the two and to substantially eliminate axial movement of the throttle shaft (34) relative to the throttle shaft bearings (22). | 5 |
FIELD OF THE INVENTION
This invention relates generally to the mixing of particulate and/or other forms of material, including the mixing of dry particles or granules with one another and with liquids and paste-like plastic masses. More particularly, the invention relates to apparatus for accomplishing such mixing, and in particular to new and novel agitator structures for use in such mixing apparatus, especially mixers such as those used in the baking arts. Notwithstanding this, it should be understood that the apparatus and technology provided in accordance herewith is not limited to the field of baking and on the contrary is useful and advantageous in many other specific applications where generally analogous mixing tasks are required.
BACKGROUND OF THE INVENTION
To a considerable extent, the various requirements which are involved in the mixing operations of commercial bakeries are also encountered in other food-processing and/or commercial and industrial activities, although the difficulties and obstacles present in the baking art often exceed those present in other fields.
For example, in the mixing of different baking doughs the requirement for achieving complete and substantially uniform dispersion of different materials, such as dry particulate matter, throughout the mix is more apt to be merely the beginning requirement rather than the ultimate one. For example, the recipes for different baked products often call for specific sequences of ingredient addition, with continuous mixing being carried out so that the addition of each different component technically produces a different mixture at a different point in time, and each such mixture is a prerequisite for the addition of the next ensuing ingredient. At the same time, baking doughs involve the physical chemistry of hydration, since they typically combine dry ingredients with various different liquid ingredients of widely-varying viscosities (e.g. from water to various oils, etc.), as well as utilizing various pastelike materials such as solid shortenings and the like, all of whose mixing characteristics differ very substantially from one another. Furthermore, baking often involves other requirements such as the need to "cream" ingredient mixtures by uniformly dispersing wet and dry ingredients and then working the resulting mix so as to incorporate air into it, as well as the requirement for "developing" dough, which involves plastic deformation of a hydrated dough mass, frequently including the need for substantial amounts of shearing or kneading of the dough mass by the mixer blades.
Generally speaking, food mixers are predominantly of the "horizontal" type, i.e., having agitators which rotate about a horizontally-disposed axis, although there are also various vertical mixers and special purpose devices. As will be understood, commercial food and/or bakery-product mixers operate on dough masses of the same general type as those encountered in home baking where mixers are usually of the vertical type, but the need for quantity and speed are substantially different in commercial operations, and this substantially exacerbates the degree of difficulty in meeting functional requirements as well as the significance of power consumption and the importance of speed. Thus, a mixer which performs well in the home environment may very well not do so in the commercial environment, but a mixer which performs well in the commercial environment is practically assured of functional acceptability, and probably of functional superiority, in other environments.
In the past, the predominating type of horizontal commercial mixer utilized one or more agitator elements having long, thin mixer blades which were bent into a helically-curving, longitudinally twisted shape. Typically, such prior agitator structures had a pair of such helical blades, each extending longitudinally along approximately half the length of the agitator but disposed on opposite sides thereof and located along different axial portions, i.e., each blade extending generally from an opposite end of the agitator and toward its midsection. In such agitators, a radially-extending cross arm located generally centrally of the structure is used to interconnect and reinforce the two opposite helically-curved mixing blades because the latter must of necessity have thin cross sections and are comparatively weak. Because of this structural weakness, such agitators had to have a rigid center drive shaft disposed along the axis of rotation, which supported and rotatably drove the twisted, helical mixer blade sections during mixing activity.
Agitators of the type just described have become an industry standard over the many, many years in which they have been used, even to the extent of being taken for granted and thus foreclosing objective evaluation of their performance. In fact, while it has to a large extent been presumed that mixers utilizing such agitators provided desirable or even optimum results, the present inventors have determined that such is not always, or even usually, the actual result, and that on the contrary such agitators provide a great many areas of defective performance, depending upon the specifics of the mixing task involved, such as the type of media to be mixed, amount of development required, desired speed of the performance, etc. In addition, it is not unusual to experience torsional failure in such agitators, due to the inherent structural weakness noted above, at which time the helical blades become twisted and bent, in effect destroying the agitator.
In addition, the previously predominating type of agitator structure, as described above, also inevitably involves the very serious disadvantage of having a high degree of manufacturing difficulty, resulting in the near impossibility of precise duplication. That is, in order to obtain the helically-curving shape, the mixing blades of such agitators had to be formed from comparatively thin elongated sections of metallic plate stock, which could be bent into generally helical configuration by complex processes, usually involving hammering and forging, etc. In fact, this type of blade actually involved a double curvature, which incorporates a twisting moment. Such a structure inevitably requires substantial individual shaping steps and considerable custom work, machining, etc. Furthermore, while such a complex shape is producible by casting processes, this involves very substantial expense and, furthermore, also requires considerable finishing machining, in order to obtain the required final dimensions and shaping. Of course, manufacturing of such agitators also involve the requirement for mounting the curving, twisting, helical mixing blades upon the center support shaft, and rigidly securing the same thereto so that they may withstand the demanding structural requirements encountered in actual use.
Due to these extensive fabrication difficulties, agitators of the type described above could never be produced as efficiently and economically as desired, and each such twisted helical blade is not likely to be identical to the next, resulting in substantial difficulty in producing operationally-satisfactory mixers having multiple agitators. Additionally, these fabrication and design problems kept the manufacturers involved from developing an agitator structure which was sufficiently strong to eliminate the center support shaft, even though such shafts present substantial operational disadvantage because they inherently interfere with desirable mixing flow patterns and introduce "dead zones" in the mixer interior. Also, such center shafts tend to promote build-up of the mix media along them, and thus introduce cleaning problems.
THE PRESENT INVENTION
The present invention provides significant and extensive improvements for mixers of the general type described above, by way of a new concept in agitator structures for use in such mixers. In so doing, the invention provides for substantially improved results in mixing performance, as well as providing substantial improvements in manufacturability, thereby yielding commensurate advantages in both such areas. From the standpoint of mixing performance, improvements are provided in mixing speed as well as in the completeness and efficiency of achieving uniform component dispersion within the mix, including the substantial elimination of "dead zones," such as have virtually always been present in prior mixers, where little or no true mixing occurs and lack of homogeneity and uniformity in the resulting mix is therefore characteristically an inseparable adjunct of mixer performance.
From the standpoint of structural design and manufacturability, the novel agitator structure of the present invention may, and preferably does, comprise an assemblage of component parts which are individually manufactured by much more standardized processes from much more standardized stock than has been true heretofore, thereby eliminating both the attendant structural weakness and manufacturing expense which characterized prior agitators of the twisted helix type. At the same time, the novel agitator structure in accordance herewith provides the very desirable attribute of enhanced applications flexibility; i.e., agitators in accordance with the present invention have a high degree of scaleability and may readily be manufactured with various differing dimensions to satisfy particular applications and requirements. This desirable result may be achieved, in essence, simply by changing the dimensions of selected component parts without necessarily changing others, manufacture (assembly) of components into the operative agitator structure proceeding in substantially the same way and by the same procedure in each such instance, without extensive and costly special machining or assembly processes.
The foregoing objectives and advantages of the invention are provided by an agitator structure which is open and "shaftless" along its axis of rotation, and which incorporates straight and flat (i.e., planar) mixing blades rather than twisted or otherwise complexly-curved blades. This structure improves strength and performance as well as enhancing manufacture, since it may be accomplished by use of flat stock (e.g., metal plate) and does not require forging or hammering operations, or any need for complex castings. Furthermore, preferred embodiments of the new and novel agitator structure eliminate and/or change the basic componentry of known agitators, incorporating (for example) elements whose shape and location are different than those which have become the norm in the past. Such new and different structures not only improve mixing performance, as noted above, but also provide the manufacturing and applications advantages and economies which have also been noted.
The foregoing attributes and characteristics of the invention will become more apparent and better understood by reference to the ensuing description of certain preferred embodiments of the underlying concepts, particularly in contemplation of the appended drawings depicting such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an overhead plan view of a first preferred agitator structure embodiment;
FIG. 2 is an end elevational view of the apparatus illustrated in FIG. 1;
FIG. 3 is a cross-sectional elevational view taken along the compound plane III--III of FIG. 1;
FIG. 4 is an overhead plan view of a second preferred embodiment for an agitator structure in accordance herewith;
FIG. 5 is an end elevational view of the agitator structure shown in FIG. 4;
FIG. 6 is a front perspective view of the agitator structure shown in FIGS. 4 and 5; and
FIGS. 7-11 inclusive are a series of overhead perspective views showing a pair of the agitator structures in accordance with FIGS. 1-3 operatively mounted in double-agitator configuration within a mixer body, i.e. "bowl," showing various relative positions of rotation for the two such agitators which occur during normal operation of such a mixer.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in more detail to the drawings, FIGS. 1-3 inclusive illustrate a first embodiment of an agitator structure 10 in accordance with the invention. As there illustrated, it will be seen that the agitator structure 10 embodies an open, shaftless design, having axially-aligned hub portions 12 and 14 at each opposite end, by which the agitator may be rotatively mounted upon appropriate trunnion shafts within a mixer housing. More particularly, each of the hubs 12 and 14 comprises a generally circular support boss 12a which is welded or otherwise secured to the inside face of a crank arm 16, 18, respectively, the resulting assembly being bored, and machined and assembled, to produce a pair of aligned mounting and driving apertures 20 having keyways 21, as illustrated (FIG. 2).
The crank arms, or drive arms, 16 and 18 extend in generally opposite radial directions from the axis of rotation, and each is secured to, and supports, one or the other of a pair of mixing blades 22, 24 respectively, which are preferably disposed generally parallel to one another and oriented at an acute angle "A" (FIG. 1) with respect to the drive axis (which is labeled "B" in FIG. 1). As further illustrated in FIGS. 1 and 2, the inboard portions of mixing blades 22 and 24 located centrally of the agitator 10 are interconnected by a center blade, or connector blade, 26, which extends generally transversely across the rotational axis B and is rigidly secured to each of the two respective mixing blades 22 and 24 to reinforce and support them.
Accordingly, it will be seen that the customary axial support shaft which has for so long been considered an inseparable part of conventional mixer agitators has been entirely eliminated, and a much different structural arrangement provided. Furthermore, it will be noted that the geometry of each of the mixing blades 22 and 24 is not of twisted-helix configuration, or even of helical configuration, but is instead generally planar. Thus, the mixing blades may advantageously be made from flat-sided plate-like stock which is cut into an arcuate overall shape and chamferred, or angled, along the top and bottom sides 22a, 22b and 24a, 24b, respectively. As may be seen in FIG. 3, these chamferred sides are disposed such that they converge toward one another (preferably, with a sharper angle on the top, or outer sides 22a, 24a), thereby giving the mixing blades a polygonal cross section, in particular, a trapezoidal cross section. As illustrated, arcuate or other slots 28 may be cut through the mixing blades to provide additional shearing effects where this is desired, although in many instances such slots will not be necessary.
Those who are skilled in the art and familiar with horizontal-axis mixers as have come to be known heretofore will immediately recognize the structural unconventionality of the mixing blades 22 and 24, both with respect to shape and size. That is, the thickness and massiveness of such mixing blades are striking in comparison to the typical twisted-helix type of mixer blade, as is the use of the flat blade configuration employed in accordance herewith, by which the relative high strength and rigidity are obtained. A further feature of this configuration should also be noted, however; i.e., the sweep angle, or mixing angle, "A" is continuous and uniform along the entire length of each mixing blade 22 and 24, and this feature provides substantially different and more desirable mixing action than that obtainable from known prior agitator structures. That is, the mixing action afforded by agitators in accordance herewith (whether employed in single or double-agitator mixers) is much more uniform and consistent, and may be optimized for a particular type of operation by selection of a particular desired mixing angle (different operations such as dispersion and development optimally requiring different mixing angles); moreover, the selected optimal mixing angle is maintained consistently and continuously along the entire length of each mixing blade. The continuous and consistent mixing action so produced is dramatically different, and superior, to that obtained from prior types of agitator structures, especially those of the twisted helix type, which provide differing mixing angles all along the length of their mixing blades.
It will further be noted that mixing blades 22 and 24 are positioned such that their respective leading edges move in the same rotational direction, but the angularity of the mixing blades is such that the mixing operation which they provide is, in effect, to continuously move a swept stream of the mix from opposite ends (actually, from opposite corners) of the mixer (viewed as an envelope which approximates the surface of revolution defined by agitator rotation) toward the center portion thereof, thus continuously combining and intermixing the particles or other media within the mixing chamber. In this respect, the silhouette presented by the outer periphery of each of the mixing blades 22 and 24 defines a circle, viewed from the end of the agitator Thus, upon rotation, the mixing blades define a uniform, right-circular cylinder of revolution, such that the edges of the blades continuously sweep along and closely adjacent to the inside periphery of the mixer housing over the length of the mixer blades The outer surfaces or faces 22a and 24a taper back somewhat more angularly than the corresponding inner surfaces 22b and 24b (note FIG. 3), to minimize cohesive build-up of the mix media along the outer such surfaces, where the maximum relative movement of the mix media occurs, thus keeping the agitator blades clear and clean, and enhancing thorough and complete mixing of the media.
Further with respect to the mixing pattern and mix media movement provided by the novel agitator structure in accordance herewith, it should be noted that the inboard end extremity of each of the mixing blades 22 and 24 preferably has an extension portion 23, 25, respectively (FIGS. 1 and 2), which protrudes beyond the intersection of the corresponding mixing blade with the center blade, or connector, 26. These extension portions, which as illustrated extend substantially beyond the midpoint of the agitator, provide very desirable additional mixing action in the center area of the agitator. Although not well appreciated heretofore, this center area has in fact long been the site of very imperfect, and incomplete, mixing performance, as is amply demonstrated by the development of observable lines of striation in the mix media (where multi-colored mix components are utilized) extending generally orthogonally to, and around the center area of, the agitator. Of course, such lines show that the media is simply being inadequately mixed in this area, leading to lack of homogeneity and, in many instances, incomplete development of baking dough. The presence of the extension portions 23 and 25, and the substantially enhanced mixing effects provided thereby, together with the results achieved by the center blade 26 (as described hereinafter), substantially eliminate this problem by achieving much more extensive and complete mixing throughout the central area of the agitator.
Due to the relative geometry of the agitators and the mixer housing, which is typically a uniform and continuous right circular cylinder, it is desirable that the outermost faces 23a and 25a (FIG. 1) of the corresponding mixing blade extension portions 23 and 25 be machined to have a cylindrical surface configuration which closely complements that of the inside of the mixer housing. This establishes and maintains the desired clearance between the mixer blade and the inside surface of the mixer housing (which is preferably on the order of about one-eighth inch). This, in turn, establishes and maintains an important parameter of the desired mixing operation, since if this clearance is too wide it will substantially diminish proper mixing action, whereas if it is too narrow it will damage and degrade the mixture in the affected area, even to the extent of causing localized burning of the mix due to friction. Thus, this clearance should be accurately established, and it should also be consistently maintained throughout the length of the blade. This has been a significant failure of prior agitators, but is a significant achievement obtained by the present invention.
In addition to the mixing blade extension portions 23 and 25, discussed above, mixing operation at the center area of the agitator 10 is also affected by the shape and position of the center blade, or connector, 26. That is, the shape and orientation of connector blade 26 (FIGS. 2 and 3) are preferably selected to enhance mixing operation, as well as to structurally support the mixing blades 22 and 24. Thus, while the connector blade 26 may advantageously be comprised simply of a section of bar or plate stock, having a rectangular cross section which is disposed with its longitudinal axis lying generally orthogonally across the axis of agitator rotation, the connector blade 26 is preferably canted laterally somewhat with respect to the longitudinal axis "B" (FIGS. 2 and 3), and also is preferably positioned to intersect the plane of each mixing blade 22 and 24 at an acute angle. Thus, connector blade 26 preferably rotates through the center area of the mixer in an angular disposition, having leading and trailing edges 26a and 26b, respectively, as well as leading and trailing surfaces 28a and 28b, respectively, which shear and impel the mix media as the agitator rotates, helping to move the media outwardly from the center area of the mixer in cooperation with the mixing blades themselves and, in particular, in cooperation with the extension portions 23 and 25 of the mixing blades. At the same time, cohesive build-up of the mix media upon the connector blade 26 is substantially reduced by the angulated structure just described.
As previously indicated, FIGS. 4, 5 and 6 illustrate an alternative preferred embodiment 110 of agitators in accordance with the invention, which also have highly advantageous attributes while at the same time embodying structural variations which further illustrate certain of the underlying concepts of the invention.
With further reference to FIGS. 4, 5 and 6, it will be noted that the agitator 110 shown there includes a pair of spaced end hubs 112 and 114, which are essentially like the hubs 12 and 14 described above in conjunction with the embodiment of FIGS. 1-3, and in the same analogous manner the agitator 110 includes a pair of mutually-spaced mixing blades 122, 124 which are connected by respective crank arms 116 and 118 to the aforementioned end hubs. While these components of the agitator 110 are quite similar to the corresponding structures of agitator 10, it will be noted that the agitator 110 does not have a center or connector blade such as the blade 26 of the first embodiment and, on the contrary, the mixing blades 122, 124 are 20 connected to strut-like support bars 126, 126', respectively, which extend from each respective mixing blade to the opposite end hub. This arrangement, of course, also provides a "shaftless" agitator structure which, as a result of the structural features just noted, is entirely open throughout its middle area. Nonetheless, the mixing action provided by the agitator 110 throughout the center area (as well as other areas) is vigorous and active, with little or no of the "dead zone" effect exhibited by most prior art horizontal agitators.
One reason underlying the highly effective iixing performance of the agitator 110 just noted is the structure embodied in the mixing blades 122, 124 (which are, as already indicated, essentially like blades 22 and 24 of agitator 10); however, the other structural attributes of agitator 110 are also significantly involved in the highly effective mixing performance of this embodiment. For example, the angular disposition of the struts, or connector bars 126, 126', together with the cross-sectional shape and the basic orientation of these bars with respect to the sweep motion of the associated mixer blades, also contributes substantially to the desirable mixing performance of this agitator. Thus, the angular position of rectangular cross section bars 126, 126' with respect to their associated mixing blades 122 and 124 provides a strong stirring, or mixing, action which is of a different nature than that provided by the mixing blades themselves, as well as being different from that provided by the center blade 26 which is present in the agitator 10 of FIGS. 1, 2 and 3. Furthermore, the relative angulation between the connecting bars 126, 126' and their associated mixing blades 122 and 124 provides, in effect, a plow-shaped structure on each opposite side of the agitator 110 which strongly moves the mix material away from the center area. In this regard, it should be noted that the two angularly-shaped such "plows" are preferably not directly aligned with one another across the axis of rotation, i.e., the mixing blades 122 and 124 are preferably longer than the struts or bars 126, 126'.
The novel type of agitator structures in accordance with the concepts of the present invention, as discussed above, are not only advantageous when used singly in an appropriate mixer housing but, in addition, may readily be used conjointly in pairs; in particular, both embodiments of such agitators may be used in pairs, to provide coordinated, interleaved, operation in which the outer surface of revolution defined by each mixing blade element enters into and passes through that of the corresponding mixing blade in the adjacent agitator. Such a combined, paired-agitator mixer is illustrated in FIGS. 7-11 inclusive, in which the two separate agitators of the type shown in FIGS. 1-3 inclusive (designated 10 and 10', respectively) are shown cooperatively mounted within a mixer housing 30.
As illustrated in FIGS. 7-11, the mixer housing 30 basically comprises an open-topped, laterally-enclosed vessel (often called a "bowl" even though not generally spherical, or semi-spherical in shape), defined by oppositely-spaced sidewalls 32 and 34 and end walls 38 and 40. The lower extremities of sidewalls 32 and 34 curve under and partially around the agitators 10, 10' and extend toward one another to form a ridge or peak 36 inside the mixer housing; i.e., the lower extremities of the sidewalls 32 and 34 comprise complementary longitudinal segments of a cylinder whose inner periphery approximates the lower part of the surface of revolution defined by the two agitators. These cylindrically-configured sidewalls are closed at each opposite end by flat end walls 38 and 40, to form an enclosing vessel around the sides and bottom of the agitators.
Within the mixer housing 30, the two agitators 10, 10' are disposed in side-by-side relation, with their corresponding hubs 12 and 14 mounted upon drive shafts or pivot axles extending through the end walls 38 and 40. As will be understood, the two such agitators may be rotatably driven by such axle members, either from one or both ends as the occasion may demand. Agitator structures in accordance with the present invention will typically have ample structural strength and rigidity to permit application of drive force from only one end, and a typical form of drive may utilize a drive gear (not specifically shown) which is secured to a drive shaft (not specifically shown) that extends from the hub portion of each of the two agitators outward through the adjacent end wall 38, either or both such drive gears being suitably engaged with another such gear (not specifically shown) for transmittal of the required drive forces. As will be appreciated, mutual engagement of such drive gears will establish and maintain the desired coordinated positioning of the two agitators relative one another as they are rotatably driven, although of course other types of engagement or drive structure may also be utilized to the same effect.
The various positions of coordinated rotation of the two agitators 10, 10' may be understood by considering FIG. 7 to represent the end of one complete revolution, and by considering FIGS. 8-11 as representing the sequential positions leading to that of FIG. 7. More particularly, in FIG. 8 it will be noted that the agitators 10, 10' are in essence reversed from the relative positions shown in FIG. 7; that is, in FIG. 8 mixing blades 24, 24', located at the right-hand side of the mixer, are disposed closely adjacent and generally parallel to one another, whereas the other two such mixing blades 24, 24' are spaced widely apart. In this relative position of the two agitator structures, the center blades 26, 26' thereof are disposed generally crosswise of one another, in a somewhat T-shaped arrangement.
As the two adjacent agitators 10, 10' rotate during normal operation of the mixer, they progress from the positional relationship shown in FIG. 8 through that of the succeeding FIGS. 9-11 inclusive, and from the position of FIG. 11 to that of FIG. 7. During this movement, the leading edges 21, 21' of mixing blades 24, 24' initially move downward toward the upraised central edge 36 extending along the bottom of the mixer housing, and away from one another, while the leading edges 27, 27' of mixing blades 24, 24' initially move upwardly within the housing and rotate toward one another. During this relative rotation, the inward end portions of mixer blades 22, 22' sweep across and approach reasonably closely to the oppositely-disposed center blades 26, 26' of the adjacent agitator, and as the agitators continue rotational movement from the positions generally shown in FIG. 7 back to those generally shown in FIG. 8, the inward end portions of mixing blades 24, 24' carry out an analogous sweeping movement with respect to the opposite side of the respective center blade 26, 26' of the adjacent agitator.
During the agitator motion just described, the inboard extension end portions 23 and 25 (and 23', 25') of each mixing blade sweep through that portion of the interior of the mixer housing, or bowl, which is located generally opposite the main (outboard) part of the other mixing blade of both agitators, in a counter-mixing motion. Also, the canted center blades 26, 26' are at the same time sweeping through and stirring the center area of the mixer, and the end result is a strong and vigorous composite mixing action in the center part of the housing. Additionally, it should be understood that during rotational movement of the two agitator structures 10, 10', the crank arms 16 and 18, and 16', 18', also perform a sweeping and mixing function in the area closely adjacent each of the end walls 38 and 40, and it should be further understood that in accordance with further aspects of the invention the leading edges and side surfaces of the crank arms may be angled and configured in a manner somewhat analogous to the center blades 26, 26', in order to bring about a specific mixing and media movement where that is desired.
It is to be understood that the above detailed description is merely that of certain exemplary preferred embodiments of the invention, and that numerous changes, alterations and variations may be made without departing from the underlying concepts and broader aspects of the invention. In particular, it should be understood that the component parts from which agitators in accordance with the invention are assembled are in the nature of standardized-type parts, and that any or all of these parts may be varied in size and shape from one specific agitator to another, to make the particular resulting agitator useful in a particular mixer arrangement or environment, even including those of the type known as "Steffan" mixers, and those known as "vertical mixers," which customarily utilize a somewhat spherically dished, bowl-like, mixer housing. Of course, as already stated hereinabove, the agitators themselves may be used either singly or in paired groupings, such as is illustrated, and the concept underlying the agitator will produce superior and desirable results in either such instance. Accordingly, the scope of the invention is to be understood as the same as set forth in the appended claims, which should be interpreted in accordance with the established principles of patent law, including the doctrine of equivalents. | An improved agitator structure for use in mixers for baking dough and other such food products and the like providing for improved mixing performance and speed, and useable in single-agitator or multiple-agitator embodiments, comprises an open, "shaftless" structure which incorporates straight and flat (i.e. planar) mixing blades as opposed to twisted or other complexly-curved blades, and incorporates a pair of mutually-spaced hubs aligned with one another along an axis of rotation, a pair of mutually-spaced mixer blades located generally on opposite sides of the rotational axis and extending generally longitudinally thereof along a different portion of such axis, with each such mixer blade disposed at a longitudinal angle with respect to such axis and each being connected to at least one of the hubs for rotation therewith about said axis. Each of the mixer blades comprises a generally planar member having a curved outer edge which lies substantially within the plane of its associated mixer blade, with the curved outer edge of the mixer blades defining a cylindrical service of revolution upon rotation of the blades about said axis. | 1 |
[0001] The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
BACKGROUND
[0002] 1. Field of Endeavor
[0003] The present invention relates to biological assays and more particularly to an immunoassay magnetic trapping device.
[0004] 2. State of Technology
[0005] U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005 provides the following state of technology information, “The most commonly employed portable pathogen detection is strip-type tests, such as those used in handheld glucose diagnostics or the Joint Biological Point Detection System (JBPDS), a system used for detection of biowarfare agents. These tests are held or ‘smart ticket’ assay, and are currently the smallest embodiment of a viable pathogen detection technology. In the JBPDS, for example, a membrane strip is printed with three lines: a mobile line of colored latex particles coated with an antibody to the bioagent being detected, a fixed line of a second antibody to the same bioagent, and a fixed line of antibody directed to the antibody on blue latex particles. To perform an assay, a liquid sample is added to the device that hydrates the latex spheres (which are located in the sample well). If the targeted bioagent is present, a complex is formed between the latex sphere and bioagent. This complex wicks through the strip and is captured by the fixed line of antibody to the bioagent forming a visible line of color. A line will also appear at the next fixed line due to capture of free latex spheres. Thus a negative assay will only have a single line at the control line and a positive assay will have two lines. The JBPDS obtains multiplex capability by delivering multiple ‘tickets’ (printed membrane strips) to the assay by means of a mechanical carousel. Currently, nine different ‘tickets,’ each sensitive to a different bioagent, share the sample and perform the analysis with fluidic automation and photonic inspection of the test lines. This technology represents a credible solution for military use since the number of target pathogens is limited. For civilian use, however, the scaling of the device to 30 or more pathogens is quite problematic. The carousel becomes increasingly complicated and large, while dividing the sample between the different assays creates an unacceptable reduction in sensitivity.”
[0006] In an article titled, “U.S. Is Deploying a Monitor System for Germ Attacks,” by Judith Miller in The New York Times on Jan. 22, 2003, it was reported, “To help protect against the threat of bioterrorism, the Bush administration on Wednesday will start deploying a national system of environmental monitors that is intended to tell within 24 hours whether anthrax, smallpox and other deadly germs have been released into the air, senior administration officials said today. The system uses advanced data analysis that officials said had been quietly adapted since the September 11 attacks and tested over the past nine months. It will adapt many of the Environmental Protection Agency's 3,000 air quality monitoring stations throughout the country to register unusual quantities of a wide range of pathogens that cause diseases that incapacitate and kill . . . . The new environmental surveillance system uses monitoring technology and methods developed in part by the Department of Energy's national laboratories. Samples of DNA are analyzed using polymerase chain reaction techniques, which examine the genetic signatures of the organisms in a sample, and make rapid and accurate evaluations of that organism . . . . Officials who helped develop the system said that tests performed at Dugway Proving Ground in Utah and national laboratories showed that the system would almost certainly detect the deliberate release of several of the most dangerous pathogens. ‘Obviously, the larger the release, the greater the probability that the agent will be detected,’ an official said. ‘But given the coverage provided by the E.P.A. system, even a small release, depending on which way the wind was blowing and other meteorological conditions, is likely to be picked up.’”
[0007] In an article titled, “Biodetectors Evolving, Monitoring U.S. Cities,” by Sally Cole in the May 2003 issue of Homeland Security Solutions, it was reported, “The anthrax letter attacks of 2001, and subsequent deaths of five people, brought home the reality of bioterrorism to Americans and provided a wake-up call for the U.S. government about the need for a method to detect and mitigate the impact of any such future attacks. Long before the anthrax letter attacks, scientists at two of the U.S. Department of Energy's national laboratories, Lawrence Livermore National Laboratory (LLNL) and Los Alamos National Laboratory (LANL), were busy pioneering a ‘biodetector’ akin to a smoke detector to rapidly detect the criminal use of biological agents. This technology is now expected to play a large role in the U.S. government's recently unveiled homeland security counter-terrorism initiative, Bio-Watch, which is designed to detect airborne bioterrorist attacks on major U.S. cities within hours. Announced back in January, Bio-Watch is a multi-faceted, multi-agency program that involves the U.S. Department of Energy, the Environmental Protection Agency (EPA), and the U.S. Department of Health and Human Services' Centers for Disease Control and Prevention (CDC). Many of the EPA's 3,000 air-quality monitoring stations throughout the country are being adapted with biodetectors to register unusual quantities of a wide range of pathogens that cause diseases that incapacitate and kill, according to the EPA. The nationwide network of environmental monitors and biodetectors, which reportedly will eventually monitor more than 120 U.S. cities, is expected to detect and report a biological attack within 24 hours. Citing security reasons, the EPA declined to disclose further details about the program at this time . . . . The Autonomous Pathogen Detection System (APDS) is a file-cabinet-sized machine that sucks in air, runs tests, and reports the results itself. APDS integrates a flow cytometer and real-time PCR detector with sample collection, sample preparation, and fluidics to provide a compact, autonomously operating instrument capable of simultaneously detecting multiple pathogens and/or toxins. ‘The system is designed for fixed locations,’ says Langlois, ‘where it continuously monitors air samples and automatically reports the presence of specific biological agents. APDS is targeted for domestic applications in which the public is at high risk of exposure to covert releases of bioagents—subway systems, transportation terminals, large office complexes, and convention centers . . . . APDS provides the ability to measure up to 100 different agents and controls in a single sample,’ Langlois says. ‘It's being used in public buildings right now.’ The latest evolution of the biodetector, APDS-II, uses bead-capture immunoassays and a compact flow cytometer for the simultaneous identification of multiple biological simulants. Laboratory tests have demonstrated the fully autonomous operation of APDS-II for as long as 24 hours.”
SUMMARY
[0008] Features and advantages of the present invention will become apparent from the following description. Applicants are providing this description, which includes drawings and examples of specific embodiments, to give a broad representation of the invention. Various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this description and by practice of the invention. The scope of the invention is not intended to be limited to the particular forms disclosed and the invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims.
[0009] The present invention provides a system for immunoassaying a sample. The system comprises providing magnetic beads, connecting signal molecules to the beads, connecting the sample to the magnetic beads with the connected signal molecules, magnetically trapping the magnetic beads with the connected signal molecules and the sample, lysising the sample, and analyzing the sample. In one embodiment, the present invention provides an immunoassay apparatus for assaying a sample comprising a channel, magnetic beads, signal molecules connected to the beads, a magnetic bead based reagent delivery unit connected to the channel that delivers the magnetic beads and the signal molecules to the channel, a magnet operatively connected to the channel, a lysis unit connected to the channel, a sample delivery unit connected to the channel, at least one reagent delivery unit connected to the channel, at least one wash delivery unit connected to the channel, and an analysis unit connected to the channel.
[0010] The invention is susceptible to modifications and alternative forms. Specific embodiments are shown by way of example. It is to be understood that the invention is not limited to the particular forms disclosed. The invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated into and constitute a part of the specification, illustrate specific embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the specific embodiments, serve to explain the principles of the invention.
[0012] FIG. 1 illustrates one embodiment of an immunoassay device constructed in accordance with the present invention.
[0013] FIG. 2 illustrates another embodiment of an immunoassay device constructed in accordance with the present invention.
[0014] FIG. 3 illustrates yet another embodiment of an immunoassay device constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to the drawings, to the following detailed description, and to incorporated materials, detailed information about the invention is provided including the description of specific embodiments. The detailed description serves to explain the principles of the invention. The invention is susceptible to modifications and alternative forms. The invention is not limited to the particular forms disclosed. The invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims.
[0016] Many biochemical assays are performed using reagents immobilized on beads. Additional liquid reactants and wash fluids are added to the bead based sample and are removed manually, which can be slow and imprecise. Alternatively, fluids are left behind causing dilution, which decreases the sensitivity of an assay. Beads are often removed from a sample according to size using vacuum filtration. However, this step leads to sample loss on the filter membrane or reduction in sensitivity of the assay because of excessive backwash volumes needed to remove beads. The use of a flow through magnetic trap allows beads to be removed from a large quantity of sample and concentrated into a much smaller volume, increasing assay sensitivity. While the beads are trapped, chemical reactions and washing steps can be carried out that generate a signal indicative of the quantity of a specific analyte. The use of the indirect signal mechanism enables assays for multiple components to be performed simultaneously. It also allows detection to occur in preferred reagents rather than in the original sample, which may contain interferents.
[0017] Referring now to FIG. 1 , one embodiment of an immunoassay device constructed in accordance with the present invention is illustrated. The immunoassay device is indicated generally by reference numeral 100 . The immunoassay device 100 is a device that provides biochemical assays. The immunoassay device 100 can, for example, be the type of immunoassay device described and illustrated in U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005. U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005 is incorporated herein by this reference.
[0018] The immunoassay device 100 utilizes a channel 101 through which fluids can be transported. A magnet 102 is positioned adjacent the channel 101 . The channel 101 and magnet 102 provide an immunoassay magnetic trapping device. A photolysis unit 103 is positioned adjacent the channel 101 proximate the magnet 102 .
[0019] A magnetic bead based reagent delivery unit 102 directs a magnetic bead based reagent into the channel 101 . A sample is also directed into the channel 101 by the sample delivery unit 115 . An individual reagent, or a reagent mix, is also directed into the channel 101 . The reagent, or reagent mix, is produced by reagent delivery unit 106 for delivering Reagent 1 and/or reagent delivery unit 113 for delivering other reagents and/or reagent delivery unit 107 for delivering reagent n. The units 106 , 113 , and 107 allow an individual reagent or a reagent mix comprising reagents 1 through reagent n to be delivered into channel 101 .
[0020] Signal molecules 111 are connected to the beads 116 . The signal molecules can, for example, be eTags available from Monogram Biosciences, Inc., 345 Oyster Point Blvd., South San Francisco, Calif. 94080-1913. The signal molecules 111 can be other signal molecules custom made or commercially available. The signal molecules 111 are released from trapped reagents using a cleaving process based on one or more physical or chemical processes.
[0021] A valve 105 downstream of the trapping region directs the flow of reagents to a waste stream 110 , to an analysis unit 104 , or to some other process area 112 . The analysis unit 104 is a device that provides a bio-analysis. Detection of the signal molecules 111 is performed using any type of physical or chemical process, including but not limited to fluorescence, absorption, light scattering, electrochemical processes, conductivity, or mass spectrometry. The analysis unit 104 can, for example, be the type of device described and illustrated in U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005. U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005 is incorporated herein by this reference.
[0022] A wash, or a wash mix, is also directed into the channel 101 . The wash, or wash mix, is produced by wash unit 108 (Wash 1 ) and/or other wash unit 114 and/or wash unit 109 (Wash n). The units 108 , 114 , and 109 allow an individual wash or a wash mix comprising wash 1 through wash n to be delivered into channel 101 .
[0023] The immunoassay device 100 utilizes the channel 101 through which the fluids are transported. The magnet 102 is positioned adjacent the channel 101 . The channel 101 and magnet 102 provide an immunoassay magnetic trapping device. The immunoassay device 100 allows biological assays to be performed using a bead based format. In the past, these were most frequently done in a static, batch configuration and exchange of reagents and washing steps performed manually. Each of the steps can dilute a sample so that the limit of detection for an assay is adversely affected. In the immunoassay device 100 flow through the magnetic trap allows rapid, efficient capture of magnetic bead based reagents, and can be used for pre concentration and sample clean up. Reagents and wash fluids flow past the captured sample and are sent to waste so that no dilution occurs in the assay. After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be removed from the trapping region by withdrawing the permanent magnet or shutting off the electromagnet. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0024] The structural details of the immunoassay magnetic trapping device 100 having been described, the operation of the immunoassay magnetic trapping device 100 will now be considered. Flow through the immunoassay magnetic trapping device 100 allows rapid, efficient capture of magnetic bead based reagents 102 , and can be used for pre concentration and sample clean up. Reagents 106 through 107 and wash fluids 108 through 109 can flow past the captured sample 111 and be sent to waste 102 so that no dilution occurs in the assay. It is to be understood that between 106 and 107 or 108 and 109 any number of additional fluid steps can be included.
[0025] After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be “removed” or “withdrawn” as needed. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0026] The general processes of the immunoassay magnetic trapping device 100 are the following:
1). Reagents immobilized on magnetic beads flow into the magnetic trap region. In the case of an immunoassay, the immobilized reagent is an antibody. With the magnetic field turned on in the trapping region, beads are removed from solution and captured. 2). A sample stream flows past the captured, immobilized reagents. Molecules with an affinity for the immobilized reagents, antigens in the immunoassay case, will be captured. Those that do not have such affinity will flow to waste. A large volume of sample can be processed in this way with the molecules of interest being captured and concentrated in a small volume. 3). Additional reactive streams are introduced into the trapping region. In the case of an eTag based immunoassay, this could be an eTag bound to an antibody. Alternatively, the immobilized reagents can be washed with water or other fluids to improve the stringency of the assay. 4). Any number of reactive streams or wash steps similar to 3) can be carried out. 5). Signal molecules are removed from the trapped reagents by a cleaving step and sent to the analysis region. For example, eTags can be freed by exposing the immobilized reagent complex to 680 nm light and sent to a capillary electrophoresis, laser induced fluorescence detection system. 6). The magnetic field is removed from the trapping region and all reagents are flushed to waste. The magnetic field is removed by translating the permanent magnet away from the flow channel or turning off the current in the electromagnet. Channels can be rinsed with water, bleach, detergent, or other cleaning fluids to minimize sample cross contamination. The system can then perform another analysis.
[0033] Referring now to FIG. 2 , another embodiment of an immunoassay device constructed in accordance with the present invention is illustrated. The immunoassay device is indicated generally by reference numeral 200 . The immunoassay device 200 is a device that provides biochemical assays. The immunoassay device 200 can, for example, be the type of immunoassay device described and illustrated in U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005. U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005 is incorporated herein by this reference.
[0034] The immunoassay device 200 utilizes a channel 201 through which fluids can be transported. A magnet 202 is positioned adjacent the channel 201 . The magnet 202 can be a permanent magnet that can be moved into or withdrawn from the region of the channel. The permanent magnet may be composed of magnetizable iron, NdFeB, SmCo, or other material. The magnet 202 can be positioned near or away from the channel using mechanical actuation. The channel 201 and magnet 202 provide an immunoassay magnetic trapping device. A photolysis unit 203 is positioned adjacent the channel 201 proximate the magnet 202 .
[0035] A magnetic bead based reagent delivery unit 202 directs a magnetic bead based reagent into the channel 201 . A sample is also directed into the channel 201 by the sample delivery unit 215 . An individual reagent, or a reagent mix, is also directed into the channel 201 . The reagent, or reagent mix, is produced by reagent delivery unit 206 for delivering Reagent 1 and/or reagent delivery unit 207 for delivering reagent n. The units 206 and 207 allow an individual reagent or a reagent mix comprising reagents 1 through reagent n to be delivered into channel 201 . It is to be understood that additional reagent delivery units for delivering additional reagents can be added.
[0036] Signal molecules are connected to the beads providing a bead signal molecule combination 211 . The signal molecules can, for example, comprise eTags available from Monogram Biosciences, Inc., 345 Oyster Point Blvd., South San Francisco, Calif. 94080-1913. The signal molecules 211 can be other signal molecules custom made or commercially available. The signal molecules 211 are released from trapped reagents using a cleaving process based on a one or more physical or chemical processes.
[0037] A valve 205 downstream of the trapping region directs the flow of reagents to a waste stream 210 , to an analysis unit 204 , or to some other process area. The analysis unit 204 is a device that provides a bio-analysis. Detection of the signal molecules 211 is performed using any type of physical or chemical process, including but not limited to fluorescence, absorption, light scattering, electrochemical processes, conductivity, or mass spectrometry. The analysis unit 204 can, for example, be the type of device described and illustrated in U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005. U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005 is incorporated herein by this reference.
[0038] A wash, or a wash mix, is also directed into the channel 201 . The wash, or wash mix, is produced by wash unit 208 (Wash 1 ) and/or other wash unit and/or wash unit 209 (Wash n). The units 208 and 209 allow an individual wash or a wash mix comprising wash 1 through wash n to be delivered into channel 201 .
[0039] The immunoassay device 200 utilizes the channel 201 through which the fluids are transported. The magnet 202 is positioned adjacent the channel 201 . The channel 101 and magnet 202 provide an immunoassay magnetic trapping device. The immunoassay device 200 allows biological assays to be performed using a bead based format. In the past, these were most frequently done in a static, batch configuration and exchange of reagents and washing steps performed manually. Each of the steps can dilute a sample so that the limit of detection for an assay is adversely affected. In the immunoassay device 200 flow through the magnetic trap allows rapid, efficient capture of magnetic bead based reagents, and can be used for pre concentration and sample clean up. Reagents and wash fluids flow past the captured sample and are sent to waste so that no dilution occurs in the assay. After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be removed from the trapping region by withdrawing the permanent magnet or shutting off the electromagnet. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0040] The structural details of the immunoassay magnetic trapping device 100 having been described, the operation of the immunoassay magnetic trapping device 200 will now be considered. Flow through the immunoassay magnetic trapping device 200 allows rapid, efficient capture of magnetic bead based reagents 202 , and can be used for pre concentration and sample clean up. Reagents 206 through 207 and wash fluids 208 through 209 can flow past the captured sample, beads/signal molecules 211 and be sent to waste 202 so that no dilution occurs in the assay. It is to be understood that between 206 and 207 or 208 and 209 any number of additional fluid steps can be included.
[0041] After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be “removed” or “withdrawn” as needed. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0042] The general processes of the immunoassay magnetic trapping device 200 are the following:
1). Reagents immobilized on magnetic beads flow into the magnetic trap region. In the case of an immunoassay, the immobilized reagent is an antibody. With the magnetic field turned on in the trapping region, beads are removed from solution and captured. 2). A sample stream flows past the captured, immobilized reagents. Molecules with an affinity for the immobilized reagents, antigens in the immunoassay case, will be captured. Those that do not have such affinity will flow to waste. A large volume of sample can be processed in this way with the molecules of interest being captured and concentrated in a small volume. 3). Additional reactive streams are introduced into the trapping region. In the case of an eTag based immunoassay, this could be an eTag bound to an antibody. Alternatively, the immobilized reagents can be washed with water or other fluids to improve the stringency of the assay. 4). Any number of reactive streams or wash steps similar to 3) can be carried out. 5). Signal molecules are removed from the trapped reagents by a cleaving step and sent to the analysis region. For example, eTags can be freed by exposing the immobilized reagent complex to 680 nm light and sent to a capillary electrophoresis, laser induced fluorescence detection system. 6). The magnetic field is removed from the trapping region and all reagents are flushed to waste. The magnetic field is removed by translating the permanent magnet away from the flow channel or turning off the current in the electromagnet. Channels can be rinsed with water, bleach, detergent, or other cleaning fluids to minimize sample cross contamination. The system can then perform another analysis.
[0049] Referring now to FIG. 3 , another embodiment of an immunoassay device constructed in accordance with the present invention is illustrated. The immunoassay device is indicated generally by reference numeral 300 . The immunoassay device 300 is a device that provides biochemical assays. The immunoassay device 300 can, for example, be the type of immunoassay device described and illustrated in U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005. U.S. Patent Application No. 2005/0239192 by Shanavaz L. Nasarabadi, Richard G. Langlois, Billy W. Colston, Evan W. Skowronski, and Fred P. Milanovich for a hybrid automated continuous nucleic acid and protein analyzer using real-time PCR and liquid bead arrays; published Oct. 27, 2005 is incorporated herein by this reference.
[0050] The immunoassay device 300 utilizes a channel 301 through which fluids can be transported. A magnet 302 is positioned adjacent the channel 301 . The magnet 302 can be an electromagnet. The electromagnet may be composed of any magnetic core material surrounded by a coil that can conduct an electrical current. The magnet 302 can be activated using electro/mechanical actuation. The channel 301 and magnet 302 provide an immunoassay magnetic trapping device. A photolysis unit 303 is positioned adjacent the channel 301 proximate the magnet 302 .
[0051] A magnetic bead based reagent delivery unit 302 directs a magnetic bead based reagent into the channel 301 . A sample is also directed into the channel 301 by the sample delivery unit. An individual reagent, or a reagent mix, is also directed into the channel 301 . The reagent, or reagent mix, is produced by reagent delivery unit 306 for delivering Reagent 1 and/or reagent delivery unit 307 for delivering reagent n. The units 306 and 307 allow an individual reagent or a reagent mix comprising reagents 1 through reagent n to be delivered into channel 301 . It is to be understood that additional reagent delivery units for delivering additional reagents can be added.
[0052] Signal molecules are connected to the beads providing a bead signal molecule combination 311 . The signal molecules can, for example, comprise eTags available from Monogram Biosciences, Inc., 345 Oyster Point Blvd., South San Francisco, Calif. 94080-1913. The signal molecules 311 can be other signal molecules custom made or commercially available. The signal molecules 311 are released from trapped reagents using a cleaving process based on one or more physical or chemical processes.
[0053] A valve 305 downstream of the trapping region directs the flow of reagents to a waste stream 310 , to an analysis unit 304 , or to some other process area. The analysis unit 304 is a device that provides a bio-analysis. Detection of the signal molecules 311 is performed using any type of physical or chemical process, including but not limited to fluorescence, absorption, light scattering, electrochemical processes, conductivity, or mass spectrometry. The analysis unit 304 can, for example, be the type of device described and illustrated in U.S. Pat. No. 6,905,885 by Billy W. Colston, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005. U.S. Pat. No. 6,905,885 by Billy W. Colston, Matthew Everett, Fred P. Milanovich, Steve B. Brown, Kodumudi Venkateswaran, and Jonathan N. Simon for a portable pathogen detection system issued Jun. 14, 2005 is incorporated herein by this reference.
[0054] A wash, or a wash mix, is also directed into the channel 301 . The wash, or wash mix, is produced by wash unit 308 (Wash 1 ) and/or other wash unit and/or wash unit 309 (Wash n). The units 308 and 309 allow an individual wash or a wash mix comprising wash 1 through wash n to be delivered into channel 301 .
[0055] The immunoassay device 300 utilizes the channel 301 through which the fluids are transported. The magnet 302 is positioned adjacent the channel 301 . The channel 101 and magnet 302 provide an immunoassay magnetic trapping device. The immunoassay device 300 allows biological assays to be performed using a bead based format. In the past, these were most frequently done in a static, batch configuration and exchange of reagents and washing steps performed manually. Each of the steps can dilute a sample so that the limit of detection for an assay is adversely affected. In the immunoassay device 300 flow through the magnetic trap allows rapid, efficient capture of magnetic bead based reagents, and can be used for pre concentration and sample clean up. Reagents and wash fluids flow past the captured sample and are sent to waste so that no dilution occurs in the assay. After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be removed from the trapping region by withdrawing the permanent magnet or shutting off the electromagnet. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0056] The structural details of the immunoassay magnetic trapping device 100 having been described, the operation of the immunoassay magnetic trapping device 300 will now be considered. Flow through the immunoassay magnetic trapping device 300 allows rapid, efficient capture of magnetic bead based reagents 302 , and can be used for pre concentration and sample clean up. Reagents 306 through 307 and wash fluids 308 through 309 can flow past the captured sample, beads/signal molecules 311 and be sent to waste 302 so that no dilution occurs in the assay. It is to be understood that between 306 and 307 or 308 and 309 any number of additional fluid steps can be included.
[0057] After performing a number of reaction and washing steps, eTags or other signal molecules that had been immobilized on the trapped beads can be released using a chemical or photolytic cleavage and directed to an analysis region. Signal molecules allow detection of species that themselves may not be easily detectible or are contained in an impure sample. The magnetic field can be “removed” or “withdrawn” as needed. Spent magnetic beads can then be flushed from the trapping region using a pressure driven or electrophoretic flow. Removal of the beads prepares the system for another analysis with little cross contamination between samples.
[0058] The general processes of the immunoassay magnetic trapping device 300 are the following:
1). Reagents immobilized on magnetic beads flow into the magnetic trap region. In the case of an immunoassay, the immobilized reagent is an antibody. With the magnetic field turned on in the trapping region, beads are removed from solution and captured. 2). A sample stream flows past the captured, immobilized reagents. Molecules with an affinity for the immobilized reagents, antigens in the immunoassay case, will be captured. Those that do not have such affinity will flow to waste. A large volume of sample can be processed in this way with the molecules of interest being captured and concentrated in a small volume. 3). Additional reactive streams are introduced into the trapping region. In the case of an eTag based immunoassay, this could be an eTag bound to an antibody. Alternatively, the immobilized reagents can be washed with water or other fluids to improve the stringency of the assay. 4). Any number of reactive streams or wash steps similar to 3) can be carried out. 5). Signal molecules are removed from the trapped reagents by a cleaving step and sent to the analysis region. For example, eTags can be freed by exposing the immobilized reagent complex to 680 nm light and sent to a capillary electrophoresis, laser induced fluorescence detection system. 6). The magnetic field is removed from the trapping region and all reagents are flushed to waste. The magnetic field is removed by translating the permanent magnet away from the flow channel or turning off the current in the electromagnet. Channels can be rinsed with water, bleach, detergent, or other cleaning fluids to minimize sample cross contamination. The system can then perform another analysis.
[0065] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. | A system for immunoassaying a sample comprising providing magnetic beads, connecting signal molecules to the beads, connecting the sample to the magnetic beads with the connected signal molecules, magnetically trapping the magnetic beads with the connected signal molecules and the sample, lysising the sample, and analyzing the sample. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuing application, under 35 U.S.C. § 120, of copending International Application No. PCT/EP2002/012472, filed Nov. 8, 2002, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an exhaust system of a mobile combustion engine or mobile internal combustion engine and to a method for operating the same. The exhaust system is understood in principle as meaning all types of exhaust systems, for example for spark-ignition engines, diesel engines and other types of engines in which a fuel containing carbon is burned.
Hydrocarbon mixtures are produced and consumed in large quantities. Hydrocarbon is the name given to an organic compound, which includes only the elements carbon and water. Short-chain hydrocarbons with up to four carbon atoms are gaseous at room temperature. The hydrocarbons from pentane (C 5 ) are liquid at room temperature. Long-chain hydrocarbons from heptadecane (C 17 ) are solid, wax-like substances. The various hydrocarbons are generally obtained by distillation of mineral oils or fossil fuels. In Germany, the greatest proportion of the total amount is made up of fuels (gasoline and diesel) for automobile traffic. Depending on its origin and how it is processed, gasoline is composed in various forms and is a mixture of aliphatic hydrocarbons (C 5 to C 12 ), often mixed with unsaturated naphthalenes and aromatics.
With regard to the preparation of higher-grade motor fuel for engines in the automotive sector, it is known to provide agents which make it possible to convert the fuel to higher octane numbers. For example, U.S. Pat. No. 3,855,980 and U.S. Pat. No. 5,357,908 disclose catalytically active cracking reactors which crack long-chain hydrocarbons in the fuel mixture, or convert them to short-chain hydrocarbons. The motivation therefor was to accomplish the most effective possible combustion of the fuel with low harmful emissions. However, one problem was that the storage and/or transport of the short-chain and highly flammable types of hydrocarbons was too dangerous to offer them directly as fuel.
In view of the fact that more recent gasoline or diesel fuels are supplied with relatively high octane or cetane numbers, and moreover the harmful emissions are effectively reduced by a wide variety of components in the exhaust system, there is currently no reason to crack the fuel supplied to the combustion engine.
In the operation of exhaust systems which are provided with flow regulators (such as for example throttle valves, valves, etc.) or else have components for treating the exhaust gases (such as for example mixers, flow baffles and the like), occasionally relatively premature failures or restrictions in use are encountered with regard to the aforementioned components. For example, there are instances in which throttle valves do not close completely, valves (in particular rotating poppet valves) no longer move over the entire adjusting range, flow separations are observed on flow guiding surfaces or mixers become clogged. All of those changes have a considerable influence on the sensitive setting of the individual components in the exhaust line. Those problems occur in particular in parts of the exhaust system in which there is a relatively low temperature (in particular lower than 300° C.).
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an exhaust system for a mobile combustion engine and a method for operating the same, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and in which the exhaust system has a simple construction and is inexpensive and the method for operating the exhaust system ensures functional reliability of components in the exhaust system.
With the foregoing and other objects in view there is provided, in accordance with the invention, an exhaust system for a mobile combustion engine. The exhaust system comprises at least one exhaust pipe for exhaust gas. The at least one exhaust pipe has at least one catalytically active reaction chamber for cracking long-chain hydrocarbons, contained in the exhaust gas, in the reaction chamber.
As extensive investigations of various components of the exhaust system have shown, one of the causes of the aforementioned problems can be seen in the tacky, wax-like coking deposits which accumulate in particular in the region of small gaps or interstices. Moving parts such as throttle valves or valves are particularly at risk therefrom. The accumulation of the coking deposits in the region of the lifting or rotating path of the throttle valves and valves has the effect that they are restricted in their freedom of movement. The coking is often caused by long-chain hydrocarbons, which in this region initially form an agglomerate and subsequently lead for example to the sticking of moving parts.
It is now proposed to integrate in the exhaust pipe at least one catalytically active reaction chamber in which long-chain hydrocarbons are cracked. The reaction chamber itself may be part of the exhaust pipe, for example in that the inner surface of the exhaust pipe is provided with a corresponding catalytically active coating. However, it is also possible to integrate the reaction chamber into inner regions of the exhaust pipe as a structural unit. In principle, the position of the at least one reaction chamber is freely selectable, although it should be ensured that the catalyst is also already active in the cold-starting phase of the combustion engine. The cold-starting phase is understood in this connection as meaning the period of time that passes from when the combustion engine is (re)started to when the light-off temperature of the main catalyst in the exhaust system is reached. The light-off temperature of the main catalyst is usually in the range from 260° to 350° C.
In accordance with another feature of the invention, the at least one reaction chamber encloses a catalyst which has such a high acidity that it already cracks long-chain hydrocarbons at temperatures lower than 230° C., in particular lower than 100° C. In a number of trials it has been found that an increased acidity of the catalyst leads to an unexpectedly significant lowering of the reaction temperature with regard to the cracking of long-chain hydrocarbons. In accordance with a further feature of the invention, it is particularly advantageous in this respect that the catalyst includes an activated aluminum silicate. Under some circumstances, it is also advantageous that the catalyst includes boron trifluoride and/or antimony pentafluoride. An X-ray amorphous aluminum silicate (Al 2 O 3 /SiO 2 ) is used, for example, as the catalyst for the cracking and/or oxidation of the long-chain hydrocarbon. In order to increase the acidity or activation of the catalyst, a zeolite ion exchanger, which is for example coated with a rare earth metal and/or a noble metal such as platinum on an acidic carrier such as aluminum trichloride (AlCl 3 ), is also added. Finally, superacidic catalysts such as boron trifluoride (BF 3 ) and/or antimony pentafluoride (SbF 5 ) may also be used for the activation of the aluminum silicate. What is more, when platinum on aluminum trichloride is used for the activation of the aluminum silicate, reaction temperatures of from 80° C. to 200° C. and servicing periods of up to two years are achieved.
In accordance with an added feature of the invention, the at least one reaction chamber encloses at least one honeycomb body, which serves as a carrier for the catalyst. A honeycomb body is understood as meaning a component which has a multiplicity of passages through which the exhaust gas can flow. Honeycomb bodies of this type may be produced from a large number of different, high-temperature-resistant materials. In this respect, reference should be made to known honeycomb bodies for exhaust gas treatment. In principle, honeycomb bodies of this type can be produced from metal or ceramic. As an alternative to the honeycomb body, it goes without saying that a multiplicity of further components with the effect of increasing the surface area can be disposed in the reaction chamber, such as for example screens, knitted or woven fabrics or the like.
In accordance with an additional feature of the invention, it is particularly advantageous if the honeycomb body has a plurality of at least partly structured sheet metal layers, which are stacked and/or coiled in such a way that passages through which the exhaust gas can flow are formed. The use of layers of metal sheet to produce honeycomb bodies has the advantage that they can be produced with particularly thin walls. For example, sheet metal layers with a thickness of from 12 to 50 μm can be used, achieving passage densities over the cross-sectional area of the honeycomb structure, which lie in the range from 200 to 800 cpsi (cells per square inch). The structured sheet metal layers preferably form passages which are disposed substantially parallel to one another. It is possible under some circumstances for microstructures to be provided to create turbulence, openings for gas exchange into adjacent passages and varying thicknesses of the sheet metal layers.
In accordance with yet another feature of the invention, at least one reaction chamber is disposed upstream of a valve in the direction of flow of the exhaust gas. This is advantageous in particular whenever the valve is part of an exhaust-gas recirculation system and regulates the flow of exhaust gas through an exhaust-gas recirculation pipe. This means in other words that the partial stream of exhaust gas which is passed through the exhaust-gas recirculation system is initially freed of long-chain hydrocarbons due to a corresponding catalytic reaction taking place as it flows through the at least one reaction chamber. The exhaust-gas recirculation system is particularly at risk with regard to the agglomeration of tacky coking deposits in the vicinity of the valve, since relatively low temperatures generally prevail in this part of the exhaust system. This is attributable on one hand to the fact that the exhaust-gas recirculation system is usually used especially in the cold-starting phase, in which the exhaust gas itself is not yet at adequately high temperatures, and to the fact that only relatively small mass flows of exhaust gas are passed through, so that heat dissipation to the exhaust-gas recirculation pipe quickly takes place. To this extent, the configuration of such a reaction chamber specifically in or near to the exhaust-gas recirculation system is particularly effective with regard to the functionality of the valve in the exhaust-gas recirculation system.
In accordance with yet a further feature of the invention, in order to ensure that the reaction chamber is catalytically active even after a relatively long time in operation, an exhaust-gas cooler is disposed upstream of the at least one reaction chamber in the direction of flow of the exhaust gas and/or the at least one reaction chamber itself can be cooled. As already described at the outset, the cracking of long-chain hydrocarbons is primarily concerned at low temperatures. Catalysts which are effective in a temperature range below 200° C. but at significantly higher temperatures no longer have adequate catalytic activity, are usually used therefor. For this purpose it is proposed that the catalyst in the reaction chamber be kept at temperatures lower than 200° C., even if the (uncooled) exhaust gas is already at much higher temperatures. With regard to the structure of the exhaust-gas cooler, heat exchangers known to a person skilled in the art may be used. In this respect it is conceivable on one hand that the exhaust-gas cooler is integrated in the exhaust pipe itself, or is a separate component, which is disposed in the interior of the exhaust pipe or around it. The cooling of the reaction chamber itself may be brought about, for example, by cooling coils, which are externally attached around the reaction chamber.
In accordance with yet an added feature of the invention, the at least one reaction chamber has a volume which is less than 0.8 l (liters), in particular less than 0.5 l and preferably even less than 0.2 l. The size of the volume is also determined, inter alia, by the mass throughput of exhaust gas. This means that, in keeping with the configuration in partial streams of exhaust gas or main streams of exhaust gas, a correspondingly large volume is to be provided. It is also significant how high is the proportion of long-chain hydrocarbons in the exhaust gas. Further criteria for selecting the volume may be the type of catalyst, the sensitivity of the downstream components with regard to coking tendency and/or the temperature of the exhaust gas at the location.
In accordance with yet an additional feature of the invention, there are provided components for converting harmful substances contained in the exhaust gas, which are disposed upstream and/or downstream of the at least one reaction chamber. Components of the exhaust system are intended to mean in particular known filters, particle traps, heating elements, heat exchangers, adsorbers, catalytic converters, etc. It is particularly advantageous in this respect that the reaction chamber substantially has only the task of cracking long-chain hydrocarbons, while the actual conversion of harmful substances such as carbon monoxide, nitrogen oxides, etc is attributable to the aforementioned components.
With the objects of the invention in view, there is also provided a method for operating an exhaust system, in particular for a mobile internal combustion engine. The method comprises providing at least one catalytically active reaction chamber in an exhaust pipe carrying exhaust gas. The exhaust gas is guided through the at least one reaction chamber for cracking long-chain hydrocarbons, contained in the exhaust gas, in the at least one reaction chamber.
This ensures that components of the exhaust system, which have a tendency to suffer coking, such as for example throttle valves, valves, etc, function satisfactorily over a long period of time. This leads to particularly easy servicing and great effectiveness of the exhaust system.
In accordance with another mode of the invention, the exhaust gas that is at least partly cracked in the reaction chamber is fed to an exhaust-gas recirculation system, which returns a partial stream of exhaust gas to a combustion engine. This has the advantage that in turn only short-chain hydrocarbons are provided for the combustion engine, and the latter can carry out a combustion that is effective and produces few harmful substances.
In accordance with a further mode of the invention, the exhaust gas entering the reaction chamber and/or the reaction chamber itself is cooled in such a way that temperatures below 230° C. (preferably lower than 150° C. or even lower than 100° C.) are ensured in the reaction chamber during operation.
In accordance with an added mode of the invention, in particular, in the case of such a procedure, it is advantageous that at least 50%, in particular at least 80%, of the long-chain hydrocarbons contained in the exhaust gas are cracked in the at least one reaction chamber, with normal pressure preferably prevailing in the reaction chamber. This has the consequence on one hand that the reaction chamber itself generally does not become gummed up, and consequently only has to be checked at very infrequent servicing intervals, but on the other hand the coking of downstream components is also prevented.
In accordance with a concomitant mode of the invention, after flowing through the at least one reaction chamber, the exhaust gas only contains short-chain hydrocarbon molecules which have fewer than 10 carbon atoms.
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 exhaust system and a method for operating the same, 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, noting that the features of the dependent claims and of the independent claims can be combined with one another in any way desired.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic, plan view of a configuration of an exhaust system according to the invention;
FIG. 2 is a partly broken-away, perspective view of a variant of a reaction chamber; and
FIG. 3 is an enlarged, fragmentary, cross-sectional view of a structure of a coating of the reaction chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a diagrammatic view of a structure of an exhaust system 1 with an exhaust-gas recirculation system 12 and a combustion engine 2 . The exhaust-gas recirculation system 12 is formed with two lines, that is to say it includes a first line 19 and a second line 20 . An exhaust-gas cooler 14 is disposed in the first line 19 , bringing about cooling of a partial stream of exhaust gas flowing through it, in particular at high temperatures of the exhaust gas. Regulation of a direction of flow 10 in the exhaust-gas recirculation system 12 takes place through the use of a valve 11 , which is preferably configured as a rotating double valve. A drive 21 of the valve 11 is connected to a control unit 22 , so that pre-determinable partial streams of exhaust gas can be produced.
In principle, a fuel-air mixture is fed to the combustion engine 2 through an air-intake pipe 24 and throttle valves 26 . In this respect, it is specifically in the cold-starting phase of the combustion engine 2 with an exhaust-gas recirculation system 12 , that coking deposits occur on the feed pipes 24 of the fuel-air mixture with the returned exhaust gas, in particular in the vicinity of the valve 11 . Furthermore, the throttle valves 26 , valves in combustion chambers or spaces 25 or other regions of feed pipes 23 which at least for a time confine only a relatively small free flow cross section, are affected in particular. The combustion of the fuel-air mixture takes place in the combustion chambers 25 of the combustion engine 2 as shown. Exhaust gases containing, for example, hydrocarbons, carbon monoxides, carbon dioxides and nitrogen oxides, are produced and subsequently passed on through an exhaust pipe 3 . Harmful substances contained in the exhaust gas are partly catalytically converted in a downstream emission control system before they are released into the environment. Illustrated components, namely a filter 16 , an adsorber 18 and a catalytic converter 17 , for example, serve that purpose.
The illustrated device has two reaction chambers or spaces 4 for catalytic oxidation and/or cracking of long-chain hydrocarbons, in which a catalyst 5 (shown in FIGS. 2 and 3 ) is applied to an inert support in the reaction chambers 4 . The reaction chamber 4 itself can be cooled, in addition or alternatively to the exhaust gas cooler 14 . The reaction chambers 4 are disposed downstream of the combustion engine 2 , and accordingly the fluid flowing through the reaction chambers 4 is directed toward the combustion chamber 2 in the direction of flow 10 . Since the catalyst 5 has such a high acidity, the long-chain hydrocarbons are already converted at temperatures lower than 100° C. In the illustrated exemplary embodiment, the reaction chambers 4 are disposed in both exhaust-gas recirculation pipes 13 of the two-line exhaust-gas recirculation system 12 , in which the fluid flowing through is a partial stream of exhaust gas to be returned to the combustion engine 2 .
FIG. 2 diagrammatically and perspectively shows an embodiment of the reaction chamber 4 in which a catalyst 5 is applied to a honeycomb body 7 . The honeycomb body 7 is formed as a separate component in the reaction chamber 4 . The metallic honeycomb body 7 with passages 9 through which the fluid can flow is formed by at least partly structured sheet metal layers 8 . The reaction chamber 4 has a volume 15 of about 0.5 liters (meaning the outer overall volume with wall structures and passages 9 ) and is disposed near a connection between the exhaust-gas recirculation system 12 (shown in FIG. 1 ) and the air-intake pipe 24 (shown in FIG. 1 ), so that with any desired setting of the valve 11 (shown in FIG. 1 ) the long-chain hydrocarbons are always cracked or catalytically converted in the entire partial stream of exhaust gas to be returned or fed back.
FIG. 3 diagrammatically shows the structure of a coating of the reaction chamber 4 . The fragmentary view shows a piece of a sheet metal layer 8 of the honeycomb body 7 on which the coating has been applied with high temperature resistance.
The coating has an extremely fissured surface, as is characteristic of zeolites. The coating is doped with a catalyst 5 and includes aluminum silicate 6 . In the present case, the catalyst 5 is activated aluminum silicate 6 , and it additionally includes constituents of boron trifluoride and/or antinomy pentafluoride.
The cracking of the hydrocarbons of the fuel also has the effect of making it better accessible and of its chemical energy content being able to be better utilized. This also results in a reduction in the specific carbon consumption. With the aid of this method, the long-chain hydrocarbons of the gasoline, such as for example decane, can for the first time be transformed in the vehicle into short-chain alkanes and, with additional dehydration, also into alkenes, which leads to an improved octane number of the gasoline. | An exhaust system for a mobile combustion engine includes at least one exhaust pipe. The exhaust pipe has at least one catalytically active reaction chamber, inside which long-chain hydrocarbons contained in the exhaust gas are cracked. A method for operating such an exhaust system is also provided. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to German Patent Application No. 10 2009 032 077.6, filed Jul. 7, 2009 and also claims priority to U.S. Provisional Application No. 61/223,490 filed Jul. 7, 2009, both which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The invention relates to a hydraulic actuator, to the use of a hydraulic actuator and to an aircraft comprising at least one aperture, closable by means of a flap, wherein the flap is driven by a hydraulic actuator
BACKGROUND
For a long time, hydraulic actuators have been used in various systems and devices in which very considerable forces are required in very confined spaces. In modern commercial aircraft, too, hydraulic actuators are used at several positions, for example for moving control surfaces which due to the great dynamic pressure at high flight speeds are subjected to very considerable forces. When an aircraft is on the ground, cargo doors may be operated by hydraulic actuators in order to open or close a cargo space.
In larger commercial aircraft, which comprise a correspondingly large cargo space and thus large cargo doors, it may, at times, be observed that doors that are being opened tend to overshoot when the hydraulic actuator used reaches an end stop. This is due to the fact that the hydraulic actuator moves at full speed against the end stop, which in the state of the art occasionally is elastic, within certain limits, by means of a spring. However, since a larger cargo door is associated with relatively great inertia and since the lever travel of the hydraulic actuator used to open the cargo door is comparatively short, overshooting of the cargo door is induced when the end stop is reached, which overshooting represents a considerable load acting on the structure of the cargo door and of the cargo door frame, as well as on the bearing arrangement of both the cargo door and the hydraulic actuator.
In view of the foregoing, it may therefore be at least one object of the invention to reduce or entirely eliminate the above-mentioned disadvantage. In particular, it may be considered to be at least one object of the invention to propose a hydraulic actuator that is able to move larger objects from an initial position to an end position, and to prevent overshooting or subsequent oscillation when the end position has been reached. In addition, other objects, desirable features, and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
A hydraulic actuator according to an embodiment of the invention comprises a cylinder with a first inflow, a first outflow, and a second inflow and outflow for hydraulic fluid. In this context the term “inflow and outflow” refers to a connection of the hydraulic actuator, which connection may be used both as an inflow and as an outflow. In the following description, for improved differentiation between the first inflow and the first outflow, the above-mentioned inflow and outflow is designated the “second” inflow and outflow, optionally also the “second inflow” and “second outflow,” where this appears sensible on the basis of the direction of flow of the hydraulic fluid.
By means of a closure device the second outflow may be closed off. The hydraulic actuator according to the invention furthermore comprises a resistance device for generating flow resistance; a piston that is movably held in the cylinder; and a piston rod that protrudes from the cylinder, which piston rod is connected to the piston. The resistance device is arranged on the first outflow and is designed to subject the hydraulic fluid flowing through the first outflow to flow resistance. The closure device is connected to the piston and is furthermore equipped, in a region between a switching position and an end position of the piston, to close the second outflow, and between an initial position and a switching position to open the second outflow again.
In accordance with the hydraulic actuator of the invention, it may consist of the outflow of hydraulic fluid being provided by two outflows that are separated from each other and that are arranged in parallel, wherein the second outflow allows unhindered flow of the hydraulic fluid to the outside, while the first outflow as a result of the resistance device subjects the hydraulic fluid to flow resistance. Consequently, flowing-out from the first outflow is made more difficult when compared to flowing-out from the second outflow. As soon as the piston moves to the end position and consequently reaches the switching position, the second outflow is closed so that only the first outflow is available for discharging the hydraulic fluid. As a result of this the movement of the piston and of the objects moved by the hydraulic actuator is slowed or damped.
By means of selecting a corresponding switching position the movement of the hydraulic actuator may be predetermined in such a manner that a particular region of the path to be traveled is to be arranged in the same manner as with a conventional hydraulic actuator, but for the remaining distance damping occurs in order to avoid oscillations or non-cushioned shocks to the object moved by the hydraulic actuator.
It is clear to the average person skilled in the art that this process is reversible so that during each extension process to the end position from the switching position damping occurs, while in a region upstream of this the movement occurs without damping.
According to an advantageous embodiment of the hydraulic actuator according to the invention, the resistance device may be designed as a diaphragm with a predetermined flow resistance. The diaphragm could, for example, be an aperture diaphragm that considerably reduces the cross section through which the hydraulic fluid flows out, thus causing considerable flow resistance. An aperture diaphragm or a diaphragm formed in some other way is very light in weight and is economical to produce.
In a further advantageous embodiment of the hydraulic actuator according to the invention, the resistance device is designed as a throttle with an infinitely adjustable flow resistance. This facilitates, in particular, calibration in order to optimise damping that is adequate for a particular application, because the throttle may be adjusted with simple means.
In an advantageous embodiment of the hydraulic actuator according to the invention, the closure device is implemented by combining a second inflow- and outflow entrance aperture with a cross-sectional profile of the piston rod, wherein the second inflow- and outflow entrance aperture corresponds to the second inflow and outflow, is arranged in the cylinder between the piston and a guide device of the piston rod, and comprises an aperture cross section for taking up outflowing hydraulic fluid or for discharging inflowing hydraulic fluid. The piston rod comprises a first section, which faces away from the piston, with a constant cross section that is smaller than the aperture cross section. The piston rod, furthermore, comprises a second section, which faces the piston, with a cross section that is approximately similar to the aperture cross section and comprises a shape that corresponds to that of the aperture. The second inflow- and outflow entrance aperture and thus the second outflow closes when the second section enters the inflow- and outflow entrance aperture, wherein the position of the switching position is predetermined by the largest cross section of the second section.
This illustrates that in the cylinder an inflow- and outflow entrance aperture is present through which the hydraulic fluid reaches the second outflow when the piston approaches its end position. In the region of the end position a guide device is arranged, through which the piston rod is guided in a linear manner coaxially to the cylinder and extends towards the outside to the object to be moved. In this arrangement the piston rod extends through the aperture cross section of the second inflow- and outflow entrance aperture. The second inflow- and outflow entrance aperture and the first section of the piston rod are dimensioned in such a way that sufficient space remains between the edges of the second inflow- and outflow entrance aperture and the first section of the piston rod for the hydraulic fluid to be discharged to be able to pass through. This essentially permits unhindered movement of the piston in the direction of the end position. However, if the second section of the piston rod approaches the second inflow- and outflow entrance aperture, then the latter is closed. This happens because the largest cross section of the second section of the piston rod is similar to the aperture cross section of the second inflow- and outflow entrance aperture. Consequently, no space exists between the piston rod and the edges of the second inflow- and outflow entrance aperture, through which space hydraulic fluid could discharge. Consequently, all the hydraulic fluid to be discharged may be discharged exclusively through the first outflow, which is, however, coupled to the resistance device, which slows down or dampens the movement of the piston. Accordingly, movement of the piston is automatically damped when the switching position is reached, which is the position of the largest cross section of the second section of the piston rod.
In this context it is immaterial as to the manner in which the changes in the cross section are brought about, so that a multitude of possible changes in the cross section may lead to success. In view of the loads that occur in the movement of relatively heavy objects, a preferred improvement of the hydraulic actuator according to the invention for better insertion of the second section into the second inflow- and outflow entrance aperture comprises a gradual transition between the first section of the piston rod and the largest cross-sectional area of the second section. This could, for example, be a linear rise from a first diameter in the first section to a second diameter in the second section. By means of a gradual approach of the cross sections, the attenuation effect is gradual, which could be advantageous in certain applications.
In an equally advantageous embodiment of the hydraulic actuator according to the invention the piston rod furthermore comprises a third section that is arranged between the second section of the piston rod and the piston. This third section could comprise a constant cross section that is similar to the cross section of the outflow entrance aperture. This third section defines the distance along which a complete damping effect is carried out. By means of a corresponding design of the piston rod, while the hydraulic actuator is otherwise unchanged, for each application the positions and dimensions of the second and of the third section may be adjusted individually to the respective application.
Finally, a further advantageous embodiment of the hydraulic actuator according to the invention comprises a first inflow for feeding hydraulic fluid into the region between the second inflow- and outflow entrance aperture and the piston, a first nonreturn valve for preventing the outflow of hydraulic fluid through the first inflow, and a second nonreturn valve for closing the first outflow when hydraulic fluid is fed in through the first or the second inflow. In this way irregularities in the operation of the hydraulic actuator according to the invention may be precluded so that its reliability increases and the damping effect is not negatively affected.
Furthermore, the at least one object is met by the use of a hydraulic actuator with the characteristics described above for moving an object on a vehicle. Finally, the at least one object of the invention is also met by an aircraft comprising at least one aperture that is closed by a flap or a door, and by a hydraulic actuator with the characteristics as described above, which actuator moves this flap or door.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics, advantages and potential applications of the present invention are disclosed in the following description of the exemplary embodiments and of the figures. All the described and/or illustrated characteristics per se and in any combination form the subject of the invention, even irrespective of their composition in the individual claims or their interrelationships. Furthermore, identical or similar components in the figures have the same reference characters.
FIG. 1 shows the hydraulic actuator according to an embodiment of the invention during an extension movement;
FIG. 2 shows a hydraulic actuator according to an embodiment of the invention during an extension movement at the time damping commences; and
FIG. 3 shows an aircraft comprising at least one aperture that may be closed by a flap, wherein the flap is moved by a hydraulic actuator according to the invention.
DETAILED DESCRIPTION
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. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary the following detailed description.
FIG. 1 shows a hydraulic actuator 2 according to an embodiment of the invention, which hydraulic actuator 2 comprises a cylinder 4 with a first inflow 6 , a second inflow and second outflow 8 , and a first outflow 10 . In the cylinder 4 a piston 12 is movably arranged, which piston 12 may be moved along the longitudinal axis 14 . The piston 12 is arranged on a piston rod 16 that is guided by means of a guide device 18 .
The piston rod 16 comprises a first section 20 , a second section 22 and a third section 24 . The first section 20 comprises the smallest cross section, while the third section 24 comprises the largest cross section. In the second section 22 a gradual increase in the cross section from the first section 20 to the third section 24 is achieved.
The cylinder 4 comprises a second inflow- and outflow entrance aperture 26 that corresponds to the second inflow and second outflow 8 . In this way when the piston 12 is moved to the right in the drawing plane, discharge of hydraulic fluid towards the second inflow- and outflow entrance aperture 26 from the cylinder 4 to a discharge line is made possible. The aperture cross section that is usable for the hydraulic fluid to flow out is defined by the cross section differential between the second inflow- and outflow entrance aperture 26 and the cross section of the first section 20 of the piston rod 16 .
In the case shown, only the first section 20 of the piston rod 16 is in the region of the second inflow- and outflow entrance aperture 26 , so that a relatively large cross-sectional area may be used for the hydraulic fluid to flow out.
The first outflow 10 comprises a resistance device 28 , designed as a throttle, which resistance device 28 subjects outflowing hydraulic fluid to flow resistance. Downstream in the first outflow 10 there is a nonreturn valve 30 that prevents hydraulic fluid from flowing into the cylinder 4 by way of the first outflow 10 .
Since the aperture cross section between the second inflow- and outflow entrance aperture 26 and the first section 20 of the piston rod 16 is the largest, all the hydraulic fluid flows in this way into the second outflow 8 ; the hydraulic fluid does not flow, or only flows to a very small extent, through the first outflow 10 .
When the piston 12 is moved to the right in the drawing plane, the first inflow 6 is closed by means of a nonreturn valve 30 . This prevents the hydraulic fluid from flowing out by way of the first inflow 6 .
It should be pointed out that the end position of the hydraulic actuator 2 or of the piston 12 is in the extreme right region, in the drawing plane, of the cylinder 4 , which region the piston 12 may reach.
FIG. 2 shows the hydraulic actuator 2 in a state moved further towards the end position. In this illustration the second section 22 of the piston rod 16 is almost completely enclosed by the second inflow- and outflow entrance aperture 26 so that the larger cross section 32 touches the edges 34 of the second inflow- and outflow entrance aperture 26 , so that the second inflow- and outflow entrance aperture 26 is closed. Accordingly it is no longer possible to discharge hydraulic fluid by way of the second outflow 8 from the cylinder 4 . Instead, the hydraulic fluid is now forced to move by way of the resistance device 28 through the first outflow 10 , which is made more difficult as a result of the flow resistance determined by the resistance device 28 . As a result of this, greater force is required to move the piston 12 at the same speed, or conversely, with a constant external force the movement of the piston 12 is decelerated and thus damped.
In this way very reliable damping of the end position of the piston 12 is ensured in a manner that is very simple from a design perspective. By dimensioning the individual sections 20 to 24 the switching position that corresponds to the position of the largest cross section 32 of the second section 22 may be selected, and at the same time by dimensioning the length of the third section 24 of the piston rod 16 the route by way of which damping is to take place may be determined
The state of damping is reversible in a very simple manner. As soon as the piston 12 is deflected again towards the left in the drawing plane, the first inflow 6 is activated again, and in this way non-damped movement of the piston 12 up to the switching position is ensured.
An aircraft 36 shown in FIG. 3 comprises several apertures which may be closed by flaps 38 , and the term flaps 38 also covers cargo doors, hatches or the like. These flaps 38 are in each case driven by means of at least one hydraulic actuator 2 , so that during opening of the flaps 38 when their end position is reached any abrupt stopping of the movement and thus subsequent oscillation is prevented. This gentle effect is beneficial to the structure of the aircraft 36 around the flaps 38 as well as on the bearing arrangement of the flaps 38 and of the hydraulic actuators 2 .
In addition, it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that characteristics or steps which have been described with reference to one of the above exemplary embodiments may also be used in combination with other characteristics or steps of other exemplary embodiments described above. Reference characters in the claims are not to be interpreted as limitations. Moreover, while at least one exemplary embodiment has been presented in the foregoing summary and detailed description, 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 in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, 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 set forth in the appended claims and their legal equivalents. | A hydraulic actuator includes, but is not limited to a first outflow and a second inflow and outflow as well as a closure device for closing the second inflow and outflow in the direction of outflow. The first outflow an outflowing hydraulic fluid is subjected to flow resistance. When a switching position is reached, the second inflow and outflow is closed in the direction of outflow so that the hydraulic fluid has to be discharged through the first outflow while overcoming the flow resistance. This damps the movement of the hydraulic actuator in the region of an end position. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from U.S. Patent Application No. 60/427,903, filed Nov. 20, 2002, the entire disclosure of which incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps. More particularly, the present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps from single molecule based approximate ordered maps and locating genes responsible for genetic diseases.
BACKGROUND OF THE INVENTION
[0003] One of the goals of genomics is to locate genes responsible for genetic diseases. The traditional approaches to locating such genes are generally based on finding single polymorphic genetic markers that are co-inherited with the disease with such regularity that it can be assumed that the single disease-causing gene is located very close to the marker. These approaches are traditionally divided into two classes, Linkage Analysis, as described in Neil J. Risch, “Searching for Genetic Determinants in the New Millennium” Nature, 405, June 2000, the disclosure of which is incorporated herein by reference, and (single marker) Association Studies as described in Thomas G. Schulze and Francis J McMahon, “Genetic Association Mapping at the Crossroads: Which Test and Why? Overview and Practical Guidelines” American Journal of Medical Genetics (Neuropsychiatric Genetics) volume 114, pages 1-11 (2002), the disclosure of which is incorporated herein by reference. Both these conventional approaches typically only track a single marker, and therefore do not work for multi-genic diseases, which are now believed to predominate in all undiscovered disease genes. In addition, both approaches generally use complex statistical process to compensate for spurious correlations that can occur due to population stratification and other unknown and non-random genetic variation across the genetic samples studied, which almost always requires samples from related individuals.
[0004] Both of these types of problems could be obviated by using genome wide maps of (polymorphic) genetic markers. If all possible polymorphic genetic markers are available across a large enough set of samples, it is easy to statistically compensate for spurious correlations by randomly sampling large numbers of markers that most likely are not related to the disease of interest. In addition, it is possible to locate all genes involved in multi-genic diseases. The estimate of a statistically sufficient sample size for this problem remains elusive as it depends on the complexity of multi-genic disease with an unknown structure.
[0005] The down side is that the cost of genome wide maps of polymorphic markers is very high even in the current post-genomic era. For example, the most common polymorphic marker, a SNP, is expected to cost about 5¢ cents per marker in the near future. However, there are estimated to be 10 million such markers over the entire human genome, and a realistic association study would require at least 1000 samples to be tested for each of such 10 million SNPs. Fortunately, recent results show the presence of significant linkage disequilibrium, as described in David Altshuler et. al., “The Structure of Haplotype Blocks in the Human Genome”, Science, 296, June 2002, the disclosure of which is incorporated herein by reference, suggesting that the human genome can be broken into haplotype blocks of average size of 30 Kb, with all polymorphic markers within a single haplotype block being nearly 100% correlated with each other. In addition each such haplotype block appears to have an average of only 5 alleles (genetic variations). Thus, on average, 3 carefully selected SNPs should be enough to identify all genetic variation within each haplotype block, and hence testing for about 300,000 carefully selected SNPs should be enough to identify all genetic variation in a single DNA sample. Thus, the cost of genome wide maps of polymorphic markers is significantly reduced. One small inconvenience of linkage disequilibrium is that it is not possible to narrow down the location of the diseases causing gene any more closely than identifying the haplotype block in which it is located.
[0006] One problem with attempting to exploit linkage disequilibrium is that in order to preserve all genetic information the genome wide map must distinguish the two parental DNA strands in the sample (except, of course, for the Y chromosome), so that the allele of each parental DNA strand of each haplotype block can be uniquely identified. Such a genome wide map is referred to as a haplotype map (or haplotype block map), and would likely be two maps per chromosome, except for the Y chromosome. Unfortunately, the most inexpensive SNP genotyping process, whether using assays or array hybridization, do not track the phasing between neighboring SNPs. For a genotyping process to be able to track phasing between neighboring polymorphic markers, it should ultimately be able to test single DNA fragments containing 2 or more polymorphic markers in a single test or needs to simultaneously test groups of related DNA samples (e.g. trios of father-mother-child) to distinguish the parental alleles which would increase the total cost of the association study, as well as reducing the applicability for patients that do not have parental DNA available for analysis.
SUMMARY OF THE INVENTION
[0007] The present invention uses single molecule maps, such as generated by Optical Mapping, and is generally based on statistically combining single molecule restriction maps of long genomic DNAs of average length of about 1 Mb; such a segment in human typically contain more than 2 heterozygous polymorphic markers. Thus, it is possible according to the present invention to combine this raw optical mapping data into genome wide haplotype restriction maps. In addition to being able to generate genome wide haplotype restriction maps, the exemplary embodiment of the system, process and software arrangement according to the present invention has two additional advantages over SNP based approaches. First, restriction maps can reveal not only SNPs that coincide with the restriction sites, but also other polymorphisms such as micro-insertions and deletions, global rearrangements or hemizygous deletions. Second, since single DNA molecule segments can be mapped using fluorescent microscopy, the exemplary approach is capable of very high throughput (limited primarily by the digital camera throughput) using very little DNA, and having a fraction of the comparable cost for the least expensive SNP approaches. The commercial cost estimated by the end of 2003 is the equivalent of 2 cents per (phased) genetic marker, and such cost is expected to drop by at least another order of magnitude as faster/cheaper computers and digital cameras become available over time.
[0008] The raw single molecule map data can consist of approximate restrictions maps of random pieces or segments of genomic DNA with average length of currently about 1-3 Mb. Each approximate map may be derived from a single such segment of uncloned DNA molecule, directly derived from a blood sample. The map is approximate in that it has a number of errors, including sizing errors in the measurement of fragment size or distance between the restriction sites (typically 10% for a 30 Kb fragment for Optical Mapping), missing restriction sites (typically 20% of restriction sites are false negatives), false restriction sites (typically 10% of restriction sites are false positives), and missing small fragments (typically most fragments under 1 Kb are missing). Algorithms to assemble such approximate maps into larger and highly accurate maps using redundant data (50× is typically sufficient) have been used successfully to construct genome wide (non-haplotype) restriction maps of micro-organisms such as E. Coli and P. Falciparum as well as BAC clones of human DNA, as described in Lim A, Dimalanta E T, Potamousis K D, Yen G, Apodoca J, Tao C, Lin J, Qi R., Skiadas J, Ramanathan A, Pema N T, Plunkett G 3rd, Burland V, Mau B, Hacket J, Blattner F R, Anantharaman T S, Mishra B, Schwartz D C. “Shotgun optical maps of the whole Escerichia coli O157:H7 genome”, Genome Research, 11(9): 1584-93, September 2001; Giacalone J, Delobette S, Gibaja V, Ni L, Skiadas Y, Qi R, Edington J, Lai Z, Gebauer D, Zhao H, Anantharaman T, Mishra B, Brown L G, Saxena R, Page D C, Schwartz D C. “Optical mapping of BAC clones from the human Y chromosome DAZ locus,” Genome Research, 10(9): 1421-9, September 2000 and Lai Z, Jing J, Aston C, Clarke V, Apodaca J, Dimalanta E T, Carucci D J, Gardner M J, Mishra B, Anantharaman T S, Paxia S, Hoffman S L, Venter J C, Huff E J; Schwartz D C. “A Shotgun Sequence-Ready Optical Map of the Whole Plasmodium Falciparum Genome,” Nature Genetics, 23 (3): 309-313, November 1999 and bud Mishra and Laxmi Parida, “Partitioning K clones: Inapproximability Results and a Practical Solution to the K-Populations Problem”, RECOMB98 pages 192-201, 1998, the entire disclosures of which are incorporated herein by reference. The algorithms used can be based on Maximum Likelihood scoring using a Bayesian prior, as disclose in Anantharaman T, Mishra B, and Schwartz D C, “Genomics via Optical Mapping II: Ordered Restriction Maps,” Journal of Computational Biology, 4(2):91-118, Summer 1999, the disclosure of which is incorporated herein by reference. Similar to other genomic mapping techniques, these algorithms construct only a single consensus map for each human chromosome pair.
[0009] The system, process and software arrangement according to the present invention can use any ordered maps of small pieces of DNA from the Genome, provided the markers are polymorphic and the error rates are within the bounds listed in the claims, e.g., data generated by Optical Mapping. This invention can then be used to construct genome wide haplotype maps from any single molecule mapping data and then applied to large-scale association studies to locate the genes responsible for specific genetic diseases.
[0010] Optical Mapping, as described in International Application No. PCT/US01/30426, the entire disclosure is incorporated herein by reference, can be used to generate approximate restrictions maps of pieces of single DNA molecules at very low cost and high throughput. Uncloned DNA (e.g., directly extracted from a blood sample) can be randomly sheered into 1-2 mega base pieces and attached to a suitable substrate, where it is first reacted with the restriction enzyme, then stained with a suitable fluorescent dye. The restriction enzyme cleavage sites show up as breakages in the DNA under fluorescent microscope. Tiled images of the surface may be collected automatically using a fluorescent microscope with a computer controlled x-y-z sample translation stage. The images are analyzed automatically by a computer to detect the bright DNA molecules and to locate the breaks in these molecules corresponding to the restriction enzyme cleavage sites. The approximate size of the distance between restriction sites can be estimated based on the integrated fluorescent intensity relative to that of a standard DNA fragment (typically some small cloned piece of DNA, for example some Lambda Phage Clones) that has been added to the sample. The software arrangement by the computer uses the known length and restriction map of the standard to recognize it in the data. Errors can be introduced by the physical process, such as non-uniform staining, failure of restriction enzyme to cleave, random breakage in the DNA molecule that cannot be distinguished from a cleavage site, and errors in the image processing that may introduce additional cleavage sites (due to non-uniform staining) or miss some cleavage sites that produce very small gaps, or accidentally combine two DNA pieces into a single larger piece. These errors include, e.g., sizing errors in the measurement of fragment size or distance between restriction sites (typically 10% for a 30 Kb fragment), missing restriction sites (typically 20% of restriction sites are false negatives), false restriction sites (typically 10% of restriction sites are false positives), and missing small fragments (typically most fragments under 1 Kb are missing). Optical Mapping relies on redundant data to recover from errors. Approximately 50× redundancy is preferred to assemble genome wide maps and recover from most errors (except for a residual sizing error) with high confidence.
[0011] A single restriction map generally detects only a limited number of polymorphic markers, namely those SNPs that coincide with the restriction site and insertions/deletions that are large enough to result in significant changes in the distance between restriction sites. The system, process and software arrangement according to the present invention overcomes this limitation, since even considering SNPs alone, enough coincide with restriction sites, that a small number (2-10) of restriction maps may be sufficient to identify the alleles of most haplotype blocks, and thus contain at least as much information as about 300,000 (phased) SNPs.
[0012] The exemplary embodiment of the present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps. More particularly, the present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps from single molecule based approximate ordered maps and locating genes responsible for genetic diseases.
[0013] Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of preferred embodiments which follows.
DETAILED DESCRIPTION
[0014] The present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps. More particularly, the present invention relates to systems, process and software arrangements for producing genome wide haplotyped maps from single molecule based approximate ordered maps and locating genes responsible for genetic diseases.
[0015] The prevalence of SNPs that coincide with restriction sites can be estimated quite reliably by examining the set of known SNPs and for each possible restriction enzyme determining if there is a restriction site at the SNP location that would not cut for one of the SNP variants. Such a SNPs site can be referred to as a polymorphic restriction site relative to the restriction enzyme considered. The number of such polymorphic restriction sites for each of the 269 distinct restriction enzymes is shown in Table 1 for a selected subset of restriction enzymes (under the column “Poly Site”). Additional columns adjust the raw number to account for the unknown SNPs that have not yet been detected, but would show up in a restriction map. The last column of the tables assumes that the total number of SNPs is 10 million and is linearly extrapolated from the number of polymorphic restriction sites and known SNPs (1.28 million). In addition, some of the polymorphic restriction sites may not be detected by Optical mapping since they are too close to another restriction site to be resolved by Optical mapping. It can be assumed that any polymorphic restriction site within 400 base pairs of another restriction site should not be detected and estimated the fraction of restriction sites that may be lost on average by examining the distribution of restriction fragment sizes from the sequence of chromosome 21 published by NIH (as shown in column “Miss-rate” in Table 1) and extrapolating this rate to the entire human genome. The last column of Table 1 reflects such adjustment. Optical Mapping generally works on human DNA if a methylation insensitive restriction enzyme is used. There are 8 such known restriction enzymes, which are shown in Table 1 marked with an asterix under the “Methyl” column along with a small selection of other restriction enzymes. The ability to use any particular restriction enzyme can be further restricted by the smallest fragment size the Optical mapping can size reliably. This currently may limit Optical Mapping to restriction enzymes that produce average fragment sizes of 15 Kb or more, and limit the use of the last two restriction enzymes in Table 1 (e.g., PacI and SwaI). However, the sizing accuracy would improve sufficiently to allow maps with average fragment size of about 2.0 Kb to be generated. This would allow the use of any of the last six methylation insensitive restriction enzymes shown in Table 1. One shows how much overlap there is between the information provided by different restriction enzymes. Preferably, if there is no overlap, it is possible to simply add the numbers in the last column of Table 1 to estimate the total number of SNPs that can be detected by using multiple restriction enzymes. In this case, the six methylation insensitive restriction enzymes that are usable by Optical Mapping can detect approximately 200,000 SNPs.
[0000]
TABLE 1
restriction sites coinciding with SNPs
Fragsize
Sites/10M
Methyl.
Pattern
Poly Sites
(Kb)
Miss-rate
SNPs
*
AATT
48,912
0.789
0.507
94,552
*
TTAA
41,937
0.827
0.393
92,865
. . .
YACGTR
12,925
3.983
0.007
88,666
ACRYGT
9,216
2.912
0.016
57,572
*
TTTAAA
10,548
2.055
0.040
57,025
*
AATATT
8,932
3.107
0.019
53,989
ACGGA
7,901
2.406
0.021
50,028
GTMKAC
8,345
3.817
0.008
49,096
. . .
*
TTATAA
6,883
4.102
0.009
45,017
...
*
ATTAAT
5,448
4.467
0.008
34,936
. . .
*
ATTTAAAT
980
26.648
0.000
7,520
. . .
*
TTAATTAA
773
33.504
0.000
5,509
[0016] In one exemplary embodiment of the present invention, algorithms can be used to assemble genome wide haplotype maps from Optical mapping data. The map assembly algorithms used to assemble non-haplotype maps from Optical Mapping data may be based on Bayesian/Maximum-Likelihood estimation, as disclosed in Anantharaman T S, Mishra B, and Schwartz D. C., “Genomics via Optical Mapping III: Contiging Genomic DNA and variations.” ISMB 99, 7: 18-27, August 1999, the disclosure of which is incorporated herein by reference. The systems, processes and software arrangements of the present invention for assembling haplotype maps from, e.g., Optical Mapping data, extend these algorithms to handle a mixture hypothesis of pairs of maps for each chromosome, corresponding to the correct restriction map of the two parental chromosomes, and each single-molecule Optical Map can be assumed to have been derived from one of these two hypothesis maps at random. For the sake of simplicity, it can be assumed that all data is derived from a single chromosome so that only one pair of hypothesis maps, e.g., H1 and H2 are used. The general case may be a trivial extension of this special case. It is then possible to use a probabilistic model of the errors in the Optical Maps to derive conditional probability density expression ƒ(D|H 1 ) and ƒ(D|H 2 ) that any particular approximate restriction map D is derived with errors, and some suitable breakage from correct chromosome maps H1 and H2. The goal is to compare different possible H1 and H2 to find the best ones. Hence, it is possible to apply Bayes rule, Equation (0.1) (with M=number of approximate restriction maps in the input data):
[0000] ƒ( H 1 ,H 2 |D 1 . . . D M )∝ƒ( H 1 ,H 2 )ƒ( D 1 . . . D M H 1 ,H 2 ) (0.1)
[0017] The first term on the right side is the prior probability of any hypothesized chromosome maps H1 and H2. Generally, no prior information is available except that the average restriction fragment size is typically approximately known, and it is known that H1 and H2 will be very similar. Polymorphic restriction sites are typically rare around 4% (see last column in Table 1), but can range from 27% (Bpu1831I) to 1.8% (for SdiI) of all restriction sites, depending on the restriction enzyme involved, and can be estimated quite reliably for the restriction enzyme used from the full version of Table 1. For restriction fragment length polymorphisms (RFLPs) there is difficulty estimating how frequently they occur, but it is always possible to estimate a probability (say 4%), and iterate the process if the final maps H1 and H2 that maximize the probability density do not confirm this value. After the first haplotype map with a particular restriction enzyme has been constructed, reliable estimates should carry over to additional maps. Thus, establishing the expression for the prior term is usually possible, and can be further simplified to include only the low prior probability of polymorphic restriction sites or restriction fragment lengths with negligible loss in accuracy.
[0018] For the conditional probability term, it can be assumed that each approximate restriction map (data input) is a statistically independent sample from the genome and that the associated mapping errors are independent, and that molecules were derived from either parental chromosome with equal likelihood. Hence, the following expressions can be obtained:
[0000]
f
(
D
1
…
D
M
H
1
,
H
2
)
=
∏
j
=
1
M
(
f
(
D
j
H
1
)
+
f
(
D
j
H
2
)
)
/
2
(
0.2
)
[0019] Thus, the conditional probability terms are reduced to combinations of the non-haplotype case ƒ(D|H) involving just one hypothesized map at a time. This conditional term can be provided as a summation over all possible (e.g., mutually exclusive) alignments between the particular D and H, and for each alignment the probability density can be based on an enumeration of the map errors implied by the alignment. In order to obtain a reasonably fast evaluation of the probability densities summed over all alignments is the use of a dynamic programming recurrence equation, which is equivalent to factoring out the common sub-expressions of the probability densities across the different alignments. First, a single arbitrary alignment between a particular D and H should be considered. For the sake of convenience, the following discussion drops the subscript j from D and m). The data map D can be described by a vector of locations of restriction sites D[J=0 . . . m+1], where for convenience the first entry D[0] is 0 and the last entry D[m+1] is the total size of the map. For notational convenience, it is possible to also refer to the entries of this array as D J , J=0 . . . m+1 which should not be confused with the distinct data maps D j , j=1 . . . M referred to previously. Similarly, the hypothesis map H can be described by a vector H[I=0 . . . N+1] also denoted as H I ,I=0 . . . N+1. An arbitrary alignment can be provided as a list of pairs of restriction sites from H and D that describe which restriction site from H is aligned with which restriction site from D. According to the example shown in FIG. 1 , the alignment consists of 4 aligned pairs (4,2) (5,2) (I,J) and (P,Q). All restriction sites in H or D need be aligned. For example, between aligned pairs (I, J) and (P, Q), there is one misaligned site on H and D each, corresponding to a missing site (false-negative) and extra-site (false-positive) in D. In this alignment, a true small fragment between sites 4 and 5 in H are missing from D, which is shown by aligning both sites 4 and 5 in H with the same site 2 in D. If two or more consecutive fragments in H are missing in D, this can be described by aligning all sites for the missing fragments in H with the same site in D (rather than showing only the outermost of this set of consecutive sites in H aligned with D, for example). This convention provides that for each missing fragment two consecutive sites in H (those flanking the missing fragment) can be aligned with the site in D in which the fragment is presumed missing.
[0020] The expression for the conditional probability density of any alignment such as this can be provided as the product of a term corresponding to the region of alignment between each pair of aligned sites, plus one term for the unaligned region at each end of the alignment. For an aligned region that is not a missing fragment (e.g. (I, J) and (P, Q), such that P>I and Q>J), this probability density can be denoted by a function of the form FA I,J,P,Q , which may depend on the specific errors in the corresponding region of the alignment between D and H. Similarly for an aligned region that corresponds to a consecutive number of missing fragments, the probability density may be denoted by a function FM I,P (e.g. (I,J) and (I+1,J) can correspond to FM I,I+1 ). For the probability density of the unaligned portion on the left and right end of each alignment, UR I,J can be used on the right end if (I, J) is the rightmost aligned pair, and UL I,J on the left end if (I, J) is the leftmost aligned pair.
[0021] Their exact form does not affect the complexity of the system, process and software arrangement according to the present invention, as long as they can be evaluated in constant time. The form of these functions for a good Optical Mapping data model is shown in example 1 in equations (0.7)(0.8) and (0.9).
[0022] The probability density of a particular alignment is the product of each of the terms FA I,J,P,Q , PM I , UL I,J , UR I,J that apply to that alignment. The probability density of any alignment can be separated into the product of those terms on either side of any particular alignment pair (I, J). This forms the basis of a two-dimensional recurrence using an array AR I,J , where I=1 . . . N, J=0 . . . m+1. AR I,J represents the sum of the probability densities of all those alignments between the part of H to the right of site I, and the part of D to the right of site J, for which (I, J) is the leftmost aligned pair. Thus, it is possible to derive the recurrence for AR I,J in Equation (0.3).
[0000]
A
R
I
,
J
=
U
R
I
,
J
+
(
I
≥
N
?
0
:
1
)
F
M
I
,
I
+
1
A
R
I
+
1
,
J
+
∑
P
=
I
+
1
N
∑
Q
=
J
+
1
m
+
1
A
R
P
,
Q
F
A
I
,
J
,
P
,
Q
(
0.3
)
[0023] This array can then be used to compute the total probability density by summing over every possible leftmost alignment pair (I, J) as shown in Equation (0.4).
[0000]
f
(
D
H
)
=
∑
I
=
1
N
∑
J
=
0
m
+
1
A
R
I
,
J
U
L
I
,
J
(
0.4
)
[0024] Equations (0.3)(0.4) are able to sum up all of the alignments in time proportional to m j 2 N 2 , where m j is the number of restriction sites in D j and N is the number of restriction sites in H. If an acceptable a good approximate location of the best alignment between D and H is known, which is possible if the conditional density has been previously evaluated for a similar H or with the help of geometric hashing algorithms, a constant width band of the recurrence array AR I,J should be evaluated which can be performed in time proportional to 2m j Δ 3 , where Δ is the number of restriction sites representing the width of the band. A fixed value of Δ=8 works well for error rates typical in Optical Mapping data.
[0025] The computationally expensive part is the search over possible correct maps H1 and H2. First, assuming that both H1 and H2 is very similar, and a single hypothesis H that best matches all data can be reached for. This first stage is similar to the case of non-haplotype map assembly. Then the maps can be heuristically and quickly assembled into larger contigs using a similar and approximate dynamic programming scheme to obtain the best alignment between any two approximate maps D. If this alignment is good enough, the maps can be combined into a larger map (contig map) by averaging the two maps in their overlap region. This heuristic stage relies on geometric hashing to quickly identify the maps that overlap, and the complexity of this stage can be determined by the geometric hashing and is estimated to be approximately O (M D 4/3 ) where
[0000]
M
D
≡
∑
j
=
1
M
m
j
[0000] is the total number of fragments in the Optical Mapping data. Geometric hashing can have sub-quadratic complexity in the worst case and the complexity may be as good as linear. The actual time for this state of computation is usually small compared to the time for the remaining search over possible H1 and H2, unless the genome being used is much larger than the human genome. The resulting contig maps can be used as a basis for an initial hypothesis H, which should then be refined by trying to add or delete restriction sites and by adjusting the distance between restriction sites by doing a gradient optimization of the probability density of all maps for each fragment size. The first two derivatives of ƒ(D|H) with respect to any single fragment size can be computed by a recurrence similar to AR I,J , by taking the derivatives of the recurrence equations applying the normal chain rule. Outlined below is an algorithm that can compute the derivative for all fragment sizes in a single step only 2-3 times as expensive as doing so for a single fragment size.
[0026] This initial search stage, which constructs a genotype map H, is then followed by an additional search in which H1 and H2, initially the same as the best H, are gradually modified by attempting to introduce a restriction site polymorphism at each site in H1 or H2 (and also at locations between them) as well as restriction fragment length polymorphisms (RFLPs) for each fragment in H1 or H2 and evaluating the complete probability density using Equation (0.1). Attempting each new restriction site polymorphism involves modifying H1 or H2 by adding or deleting a restriction site from H1 (or H2) only, while attempting an RFLP involves modifying the same interval in H1 and H2 by adding some delta to H1 and subtracting the same delta from H2. In each case, 2 possible orientations of each polymorphism are possibly, reversing the use of H1 and H2 above. Both orientations should be tested and the better scoring orientations selected, except when adding the first polymorphism to H1 and H2. In this manner the correct phasing of neighboring polymorphisms can be detected in a natural manner whenever possible. If the data cannot allow the phasing to be determined because there may be insufficient or no data molecules spanning both polymorphisms, both phases (orientations) can have the same score . This fact is also recorded since it marks a break in the phasing of polymorphisms, and the interval between such breaks can be referred to as a “phase contig.” RFLP polymorphisms are more expensive to score, since in addition to the orientation (whether H1 or H2 has the bigger fragment) estimates are generally made regarding the value of delta (the amount of the fragment size difference for H1 and H2), which can involve some form of trial and error procedure.
[0027] By testing a preliminary implementation of the above algorithm on simulated data, a purely greedy addition of polymorphisms to H1 and H2 can get lodged in local maxima when two or more actual polymorphisms are in a close vicinity. For example, if the true H1 has a 10 Kb fragment followed by a 1 Kb fragment while the true H2 has an 11 Kb fragment in the same location, the correct solution is to add a restriction site polymorphisms to the initial contig map at the right end of the 10-11 Kb fragment. However, given the possibility of sizing errors and missing small fragments of 1 Kb, it is also possible to score this as a RFLP (the 10 Kb vs. 11 Kb) and the 1 Kb fragment being missing in half the data. By attempting both cases before committing to a change in H1 and H2, the restriction site polymorphism can score slightly higher than the RFLP. This can be implemented by using a heuristic look ahead distance of a certain number of restriction sites, and scoring all alternate possible polymorphisms within this distance of the best scoring one, before committing the best scoring polymorphism in H1 and H2. In general, it is possible to score all possible pairs (or triples) of polymorphisms in a local region, which would increase the search cost.
[0028] Simple heuristics can be used to significantly accelerate the evaluation of Equation (0.1). First H1 and H2 are typically modified in a single location at a time. Data maps are typically only 1-2 Mega bases, while a complete chromosome map represented by H1 or H2 can be much larger. If a data map D j did not previously overlap H1 or H2 anywhere near the location being modified, the conditional probability density terms ƒ(D j |H i ), can be reused for that data map from the last time it was evaluated. This effectively makes the cost of re-evaluating Equation (0.1) for a local change proportional to the coverage depth times m j the number of restriction sites per map, rather than M D the total number of restriction sites in all data maps. Since all restriction sites should be considered 2-3 times until it is assured that no further improvements to H1 and H2 are possible, this makes the total cost of the search for the best H1 and H2 proportional to (M D |C)mC=M D m, where m is the average number of sites per data map D, and C is the coverage depth. Since this usually dominates the O (M D 4/3 ) cost for the initial map H, the total cost remains roughly proportional to the total number of restriction sites in the data.
[0029] Second, for the case of restriction site polymorphism, it is possible to accelerate the program by another factor of 2 by avoiding evaluating both possible orientations separately. Referring to Equation (0.2), i.e., that each hypothesis H1 or H2 can occur in just two version for any particular restriction site; either the restriction site is present or it is absent. For example, if previously both H1 and H2 have a restriction site present Equation (0.2) is reevaluated first with the restriction site deleted from just H1, next with the restriction site deleted from just H2. Since it is possible to remember the previous values of these terms (with the restriction site present in H1 and H2), these terms can be recomputed and recoded with the restriction site absent in both H1 and H2 and then perform the inexpensive averaging operations twice by combining the appropriate probability density terms already computed. It is also possible to evaluate the case where neither H1 nor H2 have a restriction site at almost no extra cost, which can be the best option as a result of other changes in H1 and H2 nearby.
[0030] Both of these simple heuristics provide significant acceleration, while the resulting program can currently take about 2 hours per Mega base to search over the possible space of H1 and H2. In the next section describes improvements to these algorithms in order to provide the acceleration of 20-140× or more, in addition to ways to parallelize the algorithms for a 16 or 96 processor Linux cluster.
[0031] In a further embodiment of the present invention, a system, process and software arrangement to accelerate a single processor performance of the haplotype map assembly can be provided. An algorithm used by the system process and software arrangement for assembling the map and locating and phasing all polymorphisms in time proportional to O(M D 4/3 +M D m) where M D is the total number of fragments in all input maps and m is the average number of fragments per input map has been described above. The second term dominates the time complexity for a human genome, and is due to the evaluation of the probability density repeatedly for different assumed parental chromosome maps H1 and H2. An algorithm is described that will drop the complexity of the second term to O(M D ). However, this algorithm has a constant overhead that we estimate at about 4-6×. Hence, the potential speed up is likely to be about m/4 to m/6, which with an average fragment size of 15 kB and an average molecule size of 2 MB is about 20-30×. For an average fragment size of 2 kB, the acceleration is even greater at over 150×, and the time now remains proportional to the total number of input fragments and hence the total time increases by a factor of 7.5×.
[0000] This exemplary embodiment provides fast way to re-evaluate ƒ(D|H) when H has been changed locally in just one place in any of the following ways:
1. Delete one of the existing restriction sites in H. 2. Add a new restriction site at a specified location in H. 3. Increase or decrease one of the fragments (restriction site intervals) in H by a specified amount. 4. The first and second derivative of ƒ(D|H) relative to any fragment size in H.
[0036] In all of the above cases, e.g., the cost of all such evaluations of ƒ(D|H) (or its derivatives) for all restriction sites spanning the molecule D can be done in just 2-3 times the time it previously took to do just one such evaluation at one restriction site. This will allow the evaluation of Equations (0.1) (0.2) for all possible changes over a window of 2m restriction sites in time that is just 4-6 times greater than the cost for testing a single change at a single restriction site previously. The extra factor of 2 is due to the fact that the number of molecules D for which ƒ(D|H) is recomputed roughly double.
[0037] The first step is to compute a new recurrence array AL I,J which represents the sum of the probability densities of all those alignments between the part of H to the left of site I and the part of D to the left of site J, for which (I, J) is the rightmost aligned pair. As previously discussed the corresponding recurrence equation can be derived as follows:
[0000]
A
L
I
,
J
=
U
L
I
,
J
+
(
I
≤
0
?
0
:
1
)
F
M
I
-
1
,
I
A
L
I
-
1
,
J
+
∑
P
=
1
I
-
1
∑
Q
=
0
J
-
1
A
L
P
,
Q
F
A
P
,
Q
,
I
,
J
(
0.5
)
[0038] This array is preferably the mirror image of AR I,J , this recurrence array can be used to compute ƒ(D|H) using an Equation similar to Equation (0.4). However, one exemplary reason to compute both AR I,J and AL I,J is that if H is changed locally near some restriction site H K , this will not change AR I,J for I<K or AL I,J for I>K. It is possible to use mainly the parts of AR I,J and AL I,J that didn't change to compute ƒ(D|H). Then, the additional cost can be limited to re-computing the parts of AR I,J and AL I,J near I=K. In addition, some of this cost of re-computing can be amortized over different values of K, if the effect of local changes at consecutive restriction sites H K is simultaneously checked. To express ƒ(D|H) in terms of both AR I,J and AL I,J so that those recurrence terms that do not change if we change H near H K are used, the following formulations are used:
[0000]
f
K
(
D
H
)
=
P
r
(
Alignments
with
righmost
aligned
I
≤
K
)
+
P
r
(
Alignments
with
leftmost
aligned
I
>
K
)
+
P
r
(
Alignments
with
a
fragment
spanning
[
H
K
,
H
K
+
1
]
)
=
∑
I
=
1
K
∑
J
=
0
m
+
1
A
L
I
,
J
U
R
I
,
J
+
∑
I
=
K
+
1
N
∑
J
=
0
m
+
1
A
R
I
,
J
U
L
I
,
J
+
∑
J
=
0
m
+
1
{
(
K
<
N
?
1
:
0
)
A
L
K
,
J
F
M
K
,
K
+
1
A
R
K
+
1
+
∑
I
=
1
K
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
M
+
1
A
L
I
,
J
F
A
I
,
J
,
P
,
Q
A
R
P
,
Q
}
(
0.6
)
[0039] All instances AR I,J and AL I,J used in Equation (0.6) remain unchanged if the interval H K . . . H K+1 in H is changed. Only the non-recurrence terms FA I,J,P,Q , FM K,K+1 , UR I,J UL I,J change, and the modified forms of these terms can be computed in approximately constant time.
[0040] The exemplary algorithms for each of the 4 cases are described below. To summarize, the computation cost in each of these 4 cases turns out to be:
1. To delete a restriction site from H: Total cost 6mΔ 3 for m restriction sites. 2. To change the size of a restriction fragment in H: Total cost 6mΔ 3 for changing each of m+1 restriction fragments by the same increment Δ H . 3. To add a restriction site at any point in H: Total cost 6mΔ 3 +4TΔ 4 to add one restriction site at T arbitrary locations. Note that to add one restriction site within each fragment (T=m), the total cost is about Δ times more expensive than for the previous 2 cases, since it is not possible to amortize the cost associated with the unique location of each new restriction site. 4. To compute the first two derivatives of ƒ(D|H) relative to each of m+1 fragment sizes: Total cost 8mΔ 3 (slightly higher than for first two cases since we have to compute 2 derivatives).
[0045] The 2 nd case (i.e., changing the size of a restriction fragment), the result is limited to the case when each fragment is changed by the same amount Δ H , otherwise the computation cost is 4mΔ 3 +4TmΔ 2 +2TΔ 4 . A possible strategy for finding RFLPs is to first check each fragment using a standard small value of Δ H and −Δ H to check if an RFLP exists. Most fragments do not exhibit any RFLP. For the small number that do, a search can be performed for the optimal Δ H value, using T different Δ H , values over all fragments exhibiting an RFLP may have a computation cost of 4mΔ 3 +4TmΔ 2 +2TΔ 4 if it is started from scratch or a cost of just 4TmΔ 3 +2TΔ 4 if the arrays AL I,J and AR I,J are saved for each data molecule from the first phase. For example, if 2 fragments are polymorphic it is possible to iterate 2-3 times with T=20 (10 Δ H values per fragment), thereby reducing the uncertainty in the optimal value of Δ H by a factor of 10 in each such iteration.
[0046] In the 4 th case computing the two derivatives for each fragment may not be enough. In particular, all fragment sizes should be updated using some approximation to Newton's process, and iterate this a few times (4-10 typically) to insure convergence. Since the diagonal of the Jacobian (2 nd Gradient) is computed, the result may be unstable and suitable step size scaling may be preferable to insure convergence. It is also possible to compute a few off diagonal terms of the Jacobian (e.g., the first off diagonal terms resulting in a tri-diagonal Jacobian matrix), if this will accelerate convergence.
[0047] The 3 rd case prefers to use a systematic way to decide where a new restriction site should be added. Possible strategies may be to attempt 3-5 uniformly spaced locations inside each existing fragment OR every location for which a data molecule currently has a misaligned restriction site. It may be difficult to pick optimal locations in this manner, and therefore may miss the true location, unless an improvement is observed in the value of the total probability density and subsequently optimize the location by optimizing fragment sizes (4 th case). In still a further embodiment, a 5 th type of local modification to H is provided that is combination of the 3 rd and 4 th cases. For each proposed new restriction site the new probability density can be computed as well as its first two derivatives relative to the location of the new restriction site, and then use a quadratic extrapolation of the probability density to score the new restriction site.
[0048] In still a further embodiment of the present invention, the above described algorithms can apply to each molecule D independently, and they may be executed on a parallel Linux cluster by having each processor work on a separate molecule. It is preferable that each processor's workload is as balanced as possible. Since not all molecules would be of equal size, it may not be possible to obtain exact results. However, since it is possible to obtain a good estimate of the computation time as a function of the molecule size (m in the previous section), known bin-packing heuristics can be used to divide the set of molecules into 16 (or 96) groups that have similar total computation cost. For large data sets (300,000 molecules will be typical for a human genome at 50× coverage), the load balancing can be better than 95%. The bandwidth used between processors can be quite low since the final probabilities for each molecule D and possible local changes to map H are communicated to the master processor responsible for deciding how to modify H.
[0049] FIG. 3 shows an exemplary flow chart of an exemplary embodiment of the process according to the present invention for producing at least one haplotyped genome wide map. This process can be performed by a processing device, such as for example a computer that includes a microprocessor. The processing device receives data 310 , which can be, for example, Optical Mapping data. Then, in step 320 , the processing device prepares chromosome maps associated with at least one chromosome. In step 330 , a conditional probability density expression can be determined using the Optical Mapping data. Then, in step 340 , a portion of at least one haplotyped genome wide map may be produced. In step 350 , the processing device determines whether all portions of the at least one haplotyped genome wide map have been produced. If not, in step 360 , a next portion of at least one haplotyped genome wide map can be produced. If all portions have been produced, in step 370 , the process stops.
[0050] To facilitate a further understanding of the present invention, the following example of some of the preferred embodiments are provided. In no way do such example be read to limit the scope of the invention.
EXAMPLE 1
[0051] According to a process according to one exemplary embodiment of the present invention will now be described, an alignment probability expressions is provided that correspond to a good error model for Optical Mapping data:
[0000]
F
A
I
,
J
,
P
,
Q
≡
λ
Q
-
J
-
1
(
1
-
P
d
)
P
-
I
-
1
P
d
G
(
D
Q
-
D
J
,
H
P
-
H
I
)
(
1
-
P
v
H
P
-
H
I
)
(
0.7
)
F
M
I
,
P
≡
P
v
H
P
-
H
I
(
0.8
)
U
R
I
,
J
≡
{
∑
P
=
I
+
1
N
+
1
F
R
I
,
J
,
P
,
P
-
1
,
If
J
≤
m
P
v
H
N
+
1
-
H
N
+
R
e
(
P
v
H
N
+
1
-
H
N
-
1
)
/
log
P
v
,
If
I
=
N
and
J
=
m
+
1
0
,
otherwise
(
0.9
)
U
L
I
,
J
≡
{
∑
P
=
0
I
-
1
F
L
I
,
J
,
P
,
P
+
1
,
If
J
>
0
P
v
H
1
+
R
e
(
P
v
H
1
-
1
)
/
log
P
v
,
If
I
=
1
and
J
=
0
0
,
otherwise
Where
,
F
R
I
,
J
,
P
,
Q
≡
λ
m
-
J
(
1
-
P
d
)
P
-
I
-
1
(
1
-
P
v
H
p
-
H
I
)
(
R
e
G
E
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
H
Q
)
+
(
P
>
N
?
1
:
0
)
G
(
D
m
+
1
-
D
J
,
H
N
+
1
-
H
I
)
)
F
L
I
,
J
,
P
,
Q
≡
λ
J
-
1
(
1
-
P
d
)
I
-
P
-
1
(
1
-
P
v
H
I
-
H
P
)
(
R
e
G
E
(
D
J
,
H
I
-
H
P
,
H
Q
-
H
P
)
+
(
P
=
0
?
1
:
0
)
G
(
D
J
,
H
I
)
)
G
(
d
,
h
)
≡
-
(
d
-
h
)
2
/
2
σ
2
h
2
π
σ
2
h
G
E
(
d
,
h
,
b
)
≅
1
2
{
erf
(
d
-
h
+
b
σ
2
max
(
h
-
b
,
min
(
d
,
h
)
)
)
+
erf
(
h
-
d
σ
2
max
(
h
-
b
,
min
(
d
,
h
)
)
)
}
[0052] Where P d is the digest rate, and hence (1−P d ) is the missing restriction site rate, λ is the false-positive site rate (sites per Mega base for example), σ 2 h is the Gaussian sizing error variance for a fragment of size h, and P v is the probability that a fragment of unit size will be missing in the data, and R e is the breakage rate of the original DNA (the inverse of the average size of the DNA maps D). A C-style notation (condition?1:0) is used before a term that should be present if condition is true.
[0053] Although it does not appear that UR I,J or UL I,J can be computed in constant time, and likely 3-7 of the terms FR I,J,P,Q or FL I,J,P,Q (which can each be computed in constant time) are significant, these significant terms are stable and can be determined during an initial pass, and updated periodically as H1/H2 change. Equation (0.9) is provided under the assumption that each end of H is the end of a chromosome: the equations are likely simpler if H is an incomplete chromosome.
[0054] Next a detailed description of processes for handling each of the four types of local modifications to the true map hypothesis H are described. In particular,
1. Delete an existing restriction site from H. 2. Add a new restriction site at a specified location in H. 3. Increase or decrease one of the fragments (restriction site intervals) in H by a specified amount. 4. The first and second derivative of ƒ(D|H) relative to any fragment in H.
[0059] First, described below is a way to re-compute ƒ(D|H), while deleting one restriction site H K from H at a time for all possible K (1≦K≦N).
[0060] The first step is to derive an equation for ƒ(D|H) that uses only those parts of AR I,J and AL I,J that will not change when H K is deleted, while excluding the probability for alignments that align with H K :
[0000]
f
κ
(
D
H
)
=
P
r
(
Alignments
with
righmost
aligned
I
<
K
)
+
P
r
(
Alignments
with
leftmost
aligned
I
>
K
)
+
P
r
(
Alignments
with
a
fragment
spanning
[
H
K
-
1
,
H
K
+
1
]
)
=
∑
I
=
1
K
-
1
∑
J
=
0
m
+
1
A
L
I
,
J
U
R
I
,
J
+
∑
I
=
K
+
1
N
∑
J
=
0
m
+
1
A
R
I
,
J
U
L
I
,
J
+
∑
J
=
0
m
+
1
{
(
K
<
N
?
1
:
0
)
A
L
K
-
1
,
J
F
M
K
-
1
,
K
+
1
A
R
K
+
1
+
∑
I
=
1
K
-
1
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
M
+
1
A
L
I
,
J
F
A
I
,
J
,
P
,
Q
A
R
P
,
Q
}
(
0.10
)
[0061] In Equation (0.10), none of the terms AR I,J or AL I,J change if the restriction site H K is removed from H. However, the terms FA I,J,P,Q and UR I,J and UL I,J change if H K is deleted. Referring to Equations (0.7)(0.8)(0.9), the change to FA I,J,P,Q is simple, and involves a dropped term of (1−P d ). To see the effect on UR I,J and UL I,J these are expanded in terms of FR I,J,P,Q and FL I,J,P,Q according to Equation (0.9) and simplified to obtain:
[0000]
f
K
(
D
H
)
=
∑
I
=
1
K
-
1
∑
J
=
0
m
A
L
I
,
J
∑
P
=
I
+
1
N
+
1
F
R
I
,
J
,
P
,
P
-
1
+
∑
I
=
K
+
1
N
∑
J
=
1
m
+
1
A
R
I
,
J
∑
P
=
0
I
-
1
F
L
I
,
J
,
P
,
P
+
1
+
∑
J
=
0
m
+
1
{
(
K
<
N
?
1
:
0
)
A
L
K
-
1
,
J
F
M
K
-
1
,
K
+
1
A
R
K
+
1
,
J
+
∑
I
=
1
K
-
1
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
m
+
1
A
L
I
,
J
F
A
I
,
J
,
P
,
Q
A
R
I
,
J
}
(
0.11
)
[0062] Equation (0.11) can then be modified to reflect the deletion of H K from H and corresponding changes in FA I,J,P,Q , FR I,J,P,Q and FL I,J,P,Q to obtain the following:
[0000]
f
(
D
H
-
H
K
)
=
∑
I
=
1
K
-
1
∑
J
=
0
m
A
L
I
,
J
∑
P
=
I
+
1
N
+
1
F
R
D
K
,
I
,
J
,
P
+
∑
I
=
K
+
1
N
∑
J
=
1
m
+
1
A
R
I
,
J
∑
P
=
0
I
-
1
F
L
D
K
,
I
,
J
,
P
=
∑
J
=
0
m
+
1
{
(
K
<
N
?
1
:
0
)
A
L
K
-
1
,
J
F
M
K
-
1
,
K
+
1
A
R
K
+
1
,
J
+
∑
I
=
1
K
-
1
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
m
+
1
A
L
I
,
J
F
A
I
,
J
,
P
,
Q
A
R
P
,
Q
/
(
1
-
P
d
)
}
(
0.12
)
where
,
F
R
D
K
,
I
,
J
,
P
≡
{
F
R
I
,
J
,
P
,
P
-
1
/
(
1
-
P
d
)
if
K
<
P
-
1
F
R
I
,
J
,
P
,
P
-
2
if
K
=
P
-
1
0
if
K
=
P
F
R
I
,
J
,
P
,
P
-
1
if
K
>
P
F
L
D
K
,
I
,
J
,
P
≡
{
F
L
I
,
J
,
P
,
P
+
1
if
K
<
P
0
if
K
=
P
F
L
I
,
J
,
P
,
P
+
2
if
K
=
P
+
1
F
L
I
,
J
,
P
,
P
+
1
/
(
1
-
P
d
)
if
K
>
P
+
1
[0063] As previously described, a small number (Δ≦8) of significant FRD or FLD terms in the inner summation. Also, only a banded region of width Δ≦8 of the arrays indexed by I and J is needed to be evaluated. Hence, the computation time of the first two summations in Equation (0.12) is approximately 2mΔ 2 , while the time for the third summation in Equation (0.12) is approximately 2Δ 4 . This is an improvement over the original computation time of 2mΔ 3 , however the improvement can be greater if the equation is evaluated for all possible K(1≦K≦N), since in that case the innermost terms FA I,J,P,Q , FR I,J,P,Q and FL I,J,P,Q for different K are similar and may be evaluated only once. For example, any term in the third summation is likely the same for all K s.t. I<K<P and absent for all other K. Thus all possible terms in the third summation can be computed in a single pass, and each term added to the probability sum of a number of results ƒ(D|H−H K ) for I<K<P. For each term, this can be done in constant time regardless of the range of possible K, an array of the differences of ƒ(D|H−H K ) is computed for consecutive K, and each term is add at the start of the K-range and subtract at the end of the K-range in the array of differences. From the array of differences, the individual ƒ(D|H−H K ) can be recovered at a later point. Similar argument applies to the terms in the first two summations of Equation (0.12), but each of the four variants involved should be computed and added to the corresponding four K ranges, which may only takes a constant amount of time. Thus, the overall time to evaluate ƒ(D|H−H K ) for all K is approximately 2mΔ 3 plus the cost to pre-compute AL I,J and AR I,J , which are each also 2mΔ 3 . Thus, the total cost to compute all ƒ(D|H−H K ) is likely at most 3 times the cost to compute just AR I,J , hence it is possible to compute ƒ(D|H−H K ) for all K for just 3 times, and the cost to compute it for a single K. If enough memory is available in the computer executing this process or other memory is available, the cost of computing the complex terms FA I,J,P,Q , FR I,J,P,Q and FL I,J,P,Q can be shared between Equations (0.12)(0.5) and (0.3), which can reduce the total cost to perhaps just 2 times the cost to compute ƒ(D|H−H K ) for a single K.
[0064] The equivalent of the final Equation (0.12) for each of the remaining three local modifications to H is described below.
[0065] Equation (0.13) shows the result for adding a restriction site at H T to H.
[0000]
f
(
D
H
+
H
T
,
H
K
-
1
<
H
T
<
H
K
)
=
∑
I
=
1
K
-
1
∑
J
=
0
m
∑
P
=
I
+
1
N
+
1
A
L
I
,
J
F
R
A
K
,
I
,
J
,
P
+
∑
I
=
K
N
∑
J
=
1
m
+
1
∑
P
=
0
I
-
1
A
R
I
,
J
F
L
A
K
,
I
,
J
,
P
+
∑
J
=
0
m
+
1
{
A
L
K
-
1
,
J
F
M
K
-
1
,
K
A
R
K
,
J
+
∑
I
=
1
K
-
1
∑
P
=
K
N
∑
Q
=
J
+
1
m
+
1
A
L
I
,
J
F
A
I
,
J
,
P
,
Q
A
R
P
,
Q
(
1
-
P
d
)
}
+
∑
J
=
0
m
+
1
A
L
T
J
A
R
T
J
(
0.13
)
where
,
A
L
T
J
≡
A
L
K
,
J
(
H
K
->
H
T
)
see
recurrance
for
A
L
I
,
J
A
R
T
J
≡
A
R
K
-
1
,
J
(
H
K
-
1
->
H
T
)
see
recurrance
for
A
R
I
,
J
F
R
A
K
,
I
,
J
,
P
≡
{
(
1
-
P
d
)
F
R
I
,
J
,
P
,
P
-
1
if
K
≤
P
-
1
F
R
I
,
J
,
K
,
K
-
1
(
H
K
->
H
T
)
+
F
R
I
,
J
,
K
,
K
-
1
(
H
K
-
1
->
H
T
)
if
K
=
P
F
R
I
,
J
,
P
,
P
-
1
if
K
>
P
F
L
A
K
,
I
,
J
,
P
≡
{
F
L
I
,
J
,
P
,
P
+
1
if
K
≤
P
F
K
I
,
J
,
K
-
1
,
K
(
H
K
-
1
->
H
T
)
+
F
L
I
,
J
,
K
-
1
,
K
(
H
K
->
H
T
)
if
K
=
P
+
1
(
1
-
P
d
)
F
L
I
,
J
,
P
,
P
+
1
if
K
>
P
+
1
[0066] The notation AL K,J (H K →H T ) means to evaluate AL K,J (using its defining equation provided previously) while replacing any occurrence of H K with H T . Equation (0.13) preferably depends on the exact value of H T , e.g., only in the last summation term. All other summations can be done simultaneously for all K (1≦K≦N+1) as described hereinabove for Equation (0.12). Only the last summation is preferably performed separately for each specific value of H T . Hence, the total computation time is preferably proportional to 6mΔ 3 +4TΔ 4 , where T is the number of different values of H T for which ƒ(D|H+H T ) is computed.
[0067] Equation (0.14) shows the result for increasing one fragment size between H K and H K+1 by a specified amount Δ H .
[0000]
f
(
D
H
:
H
T
->
H
T
+
Δ
H
∀
T
>
K
)
=
∑
I
=
1
K
∑
J
=
0
m
∑
P
=
I
+
1
N
+
1
A
L
I
,
J
F
R
D
K
,
I
,
J
,
P
+
∑
I
=
K
+
1
N
∑
J
=
1
M
+
1
∑
P
=
0
I
-
1
A
R
I
,
J
F
L
D
K
,
I
,
J
,
P
+
∑
J
=
0
m
+
1
{
(
K
≤
N
?
1
:
0
)
A
L
K
,
J
P
v
Δ
H
F
M
K
,
K
+
1
A
R
K
+
1
,
J
+
∑
I
=
1
K
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
m
+
1
A
L
I
,
J
F
A
D
I
,
J
,
P
,
Q
A
R
P
,
Q
}
(
0.14
)
where
,
F
A
D
I
,
J
,
P
,
Q
≡
F
A
I
,
J
,
P
,
Q
(
H
P
->
H
P
+
Δ
H
)
F
R
D
K
,
I
,
J
,
P
≡
{
F
R
I
,
J
,
P
,
P
-
1
(
H
P
-
1
->
H
P
-
1
+
Δ
H
,
H
P
->
H
P
+
Δ
H
)
if
K
<
P
-
1
F
R
I
,
J
,
P
,
P
-
1
(
H
P
->
H
P
+
Δ
H
)
if
K
=
P
-
1
F
R
I
,
J
,
P
,
P
-
1
if
K
≥
P
F
L
D
K
,
I
,
J
,
P
≡
{
F
L
I
,
J
,
P
,
P
+
1
if
K
<
P
F
L
I
,
J
,
P
,
P
+
1
(
H
P
->
H
P
-
Δ
H
)
if
K
=
P
F
L
I
,
J
,
P
,
P
+
1
(
H
P
->
H
P
-
Δ
H
,
H
P
+
1
->
H
P
+
1
-
Δ
H
)
if
K
>
P
[0068] If the same value of Δ H is used for all fragments, it is possible to evaluate Equation (0.14) for all possible K (1≦K≦N+1) in time proportional to 6mΔ 3 , in the same manner as described above for Equation (0.12). On the other hand, if each Δ H value is different, Equation (0.14) may be evaluated separately for each one at a cost proportional to 4mΔ 2 +2Δ 4 . To this result the costs of pre-computing AR I,J and AL I,J of 2mΔ 3 should be added. Hence, the total cost for T unrelated Δ H values can be proportional to 4mΔ 3 +T(4mΔ 2 +2Δ 4 ). It may be possible to reduce this result to be to close to 4mΔ 3 +2TΔ 4 , since most of the terms in the first two summations in Equation (0.14) are likely to be negligible, except for a few terms when K is close to either end of H. This is the case for Equations (0.12) and (0.13) as well, while the cost of evaluating the terms of the first two summations are likely significant only in the current case, and even then likely only if m≧Δ 2 .
[0069] In order to compute the first two (d=1,2) derivatives of ƒ(D|H) relative to all fragment sizes F K ≡H K+1 −H K ,0≦K≦N, Equation is (0.15) can be used.
[0000]
∂
d
f
(
D
H
)
∂
F
K
d
=
∑
I
=
1
K
∑
J
=
0
m
∑
P
=
I
+
1
N
+
1
A
L
I
,
J
∂
d
F
R
I
,
J
,
P
,
P
-
1
∂
F
K
d
+
∑
I
=
K
+
1
N
∑
J
=
1
m
+
1
∑
P
=
0
I
-
1
A
R
I
,
J
∂
d
F
L
I
,
J
,
P
,
P
+
1
∂
F
K
d
+
(
K
=
N
?
1
:
0
)
A
L
N
,
M
+
I
∂
d
F
M
R
∂
F
N
d
+
(
K
=
0
?
1
:
0
)
A
R
1
,
0
∂
d
F
M
L
∂
F
0
d
+
∑
J
=
0
m
+
1
{
(
K
<
N
?
1
:
0
)
A
L
K
,
J
A
R
K
+
1
,
J
∂
d
F
M
K
,
K
+
1
∂
F
K
d
+
∑
I
=
1
K
∑
P
=
K
+
1
N
∑
Q
=
J
+
1
m
+
1
A
L
I
,
J
A
R
P
,
Q
∂
d
F
A
I
,
J
,
P
,
Q
∂
F
I
d
}
(
0.15
)
[0070] The differential expressions in Equation (0.15) can be computed as shown in Equations (0.16)(0.17)(0.18)(0.19)(0.20)(0.21)(0.22) and (0.23).
[0000]
∂
d
F
M
K
,
K
+
1
∂
F
K
d
=
F
M
K
,
K
+
1
(
log
P
v
)
d
(
0.16
)
∂
d
F
M
R
∂
F
N
d
=
F
M
N
,
N
+
1
(
R
e
+
log
P
v
)
(
log
P
v
)
d
-
1
∂
d
F
M
L
∂
F
0
d
=
F
M
0
,
1
(
R
e
+
log
P
v
)
(
log
P
v
)
d
-
1
∂
F
R
I
,
J
,
P
,
P
-
1
∂
F
K
=
{
F
R
A
I
,
J
,
P
′
-
F
R
B
I
,
J
,
P
′
if
K
<
P
-
1
F
R
A
I
,
J
,
P
′
if
K
=
P
-
1
0
if
K
≥
P
∂
F
L
I
,
J
,
P
,
P
-
1
∂
F
K
=
{
0
if
K
<
P
F
L
A
I
,
J
,
P
′
if
K
=
P
F
L
A
I
,
J
,
P
′
-
F
L
B
I
,
J
,
P
′
if
K
>
P
∂
2
F
R
I
,
J
,
P
,
P
-
1
∂
F
K
2
=
{
F
R
A
I
,
J
,
P
″
-
F
R
B
I
,
J
,
P
″
if
K
<
P
-
1
F
R
A
I
,
J
,
P
″
if
K
=
P
-
1
0
if
K
≥
P
∂
F
L
I
,
J
,
P
,
P
-
1
∂
F
K
2
=
{
0
if
K
<
P
F
L
A
I
,
J
,
P
″
if
K
=
P
F
L
A
I
,
J
,
P
″
-
F
L
B
I
,
J
,
P
″
if
K
>
P
∂
F
A
I
,
J
,
P
,
Q
∂
F
I
=
F
A
I
,
J
,
P
,
Q
{
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
G
(
D
Q
-
D
J
,
H
P
-
H
I
)
-
F
M
I
,
P
log
P
v
(
1
-
F
M
I
,
P
)
}
(
0.17
)
∂
2
F
A
I
,
J
,
P
,
Q
∂
F
I
2
=
F
A
I
,
J
,
P
,
Q
[
{
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
G
(
D
Q
-
D
J
,
H
P
-
H
I
)
-
F
M
I
,
P
log
P
v
(
1
-
F
M
I
,
P
)
}
2
+
G
″
(
D
Q
-
D
J
,
H
P
-
H
I
)
G
(
D
Q
-
D
J
,
H
P
-
H
I
)
-
(
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
G
(
D
Q
-
D
J
,
H
P
-
H
I
)
)
2
-
F
M
I
,
P
(
log
P
v
)
2
(
1
-
F
M
I
,
P
)
2
]
F
R
A
I
,
J
,
P
′
≡
λ
m
-
j
(
1
-
P
d
)
P
-
I
-
1
{
(
1
-
F
M
I
,
P
)
[
R
e
G
A
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
1
-
H
1
)
+
(
P
>
N
?
1
:
0
)
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
]
-
F
M
I
,
P
(
log
P
v
)
[
R
e
G
E
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
1
-
H
1
)
+
(
P
>
N
?
1
:
0
)
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
]
}
(
0.18
)
F
R
B
I
,
J
,
P
′
≡
λ
m
-
J
(
1
-
P
d
)
P
-
I
-
1
(
1
-
F
M
I
,
P
)
R
e
G
B
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
1
-
H
I
)
F
L
A
I
,
J
,
P
′
≡
λ
J
-
1
(
1
-
P
d
)
I
-
P
-
1
{
(
1
-
F
M
P
,
I
)
[
R
0
G
A
(
D
J
,
H
I
-
H
P
,
H
I
-
H
P
+
1
)
+
(
P
=
0
?
1
:
0
)
G
′
(
D
J
,
H
I
-
H
P
)
]
-
F
M
P
,
I
(
log
P
v
)
[
R
e
G
E
(
D
J
,
H
I
-
H
P
,
H
I
-
H
P
+
1
)
+
(
P
=
0
?
1
:
0
)
G
(
D
J
,
H
I
-
H
P
)
]
}
(
0.19
)
F
L
B
I
,
J
,
P
′
≡
λ
J
-
1
(
1
-
P
d
)
I
-
P
-
1
(
1
-
F
M
P
,
I
)
R
e
G
B
(
D
J
,
H
I
-
H
P
,
H
I
-
H
P
+
1
)
F
R
A
I
,
J
,
P
″
≈
λ
m
-
J
(
1
-
P
d
)
P
-
I
-
1
{
R
e
G
A
′
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
1
-
H
I
)
+
(
P
>
N
?
1
:
0
)
G
′
(
D
Q
-
D
J
,
H
P
-
H
I
)
}
(
0.20
)
F
R
B
I
,
J
,
P
″
≈
λ
m
-
J
(
1
-
P
d
)
P
-
I
-
1
R
e
G
B
′
(
D
m
+
1
-
D
J
,
H
P
-
H
I
,
H
P
-
1
-
H
I
)
F
L
A
I
,
J
,
P
″
≡
λ
J
-
1
(
1
-
P
d
)
I
-
P
-
1
{
R
e
G
A
′
(
D
J
,
H
I
-
H
P
,
H
I
-
H
P
+
1
)
+
(
P
=
0
?
1
:
0
)
G
″
(
D
J
,
H
I
-
H
P
)
}
(
0.21
)
F
L
B
I
,
J
,
P
″
≡
λ
J
-
1
(
1
-
P
d
)
I
-
P
-
1
R
e
G
B
′
(
D
J
,
H
I
-
H
P
,
H
I
-
H
P
+
1
)
G
A
(
d
,
h
1
,
h
2
)
≡
-
(
d
-
h
1
)
2
/
2
σ
2
A
2
π
σ
2
A
,
A
≈
max
(
min
(
d
,
h
1
)
,
h
2
)
(
0.22
)
G
B
(
d
,
h
1
,
h
2
)
≡
-
(
d
-
h
2
)
2
/
2
σ
2
A
2
π
σ
2
A
G
A
′
(
d
,
h
1
,
h
2
)
≡
d
-
h
1
σ
2
A
G
A
(
d
,
h
1
,
h
2
)
G
B
′
(
d
,
h
1
,
h
2
)
≡
d
-
h
2
σ
2
A
G
B
(
d
,
h
1
,
h
2
)
G
(
d
,
h
)
≡
-
(
d
-
h
)
2
/
2
σ
2
h
2
π
σ
2
h
G
″
(
d
,
h
)
≡
[
(
d
2
-
h
2
-
σ
2
h
2
σ
2
h
2
)
2
d
2
σ
2
h
3
+
1
2
h
2
]
G
(
d
,
h
)
G
″
(
d
,
h
)
≡
[
(
d
2
-
h
2
-
σ
2
h
2
σ
2
h
2
)
2
d
2
σ
2
h
3
+
1
2
h
2
]
G
(
d
,
h
)
(
0.23
)
EXAMPLE 2
[0071] An application of one exemplary embodiment of the present invention to a simulated data set is described below. For this exemplary embodiment, the basic map assembly algorithms is preferably extended by adding a post processing phase to carefully examine the component input maps that go into each consensus map, assign each input map to one of two populations and reassemble them into two separate consensus maps. This implementation uses simulated data to allow the performance for data error rates greater than present in actual data to be determined.
[0072] To generate simulated data the first 5 megabases of human chromosome 21 published by NIH can be used, and an in-silico restriction map may be generated for the restriction enzyme PacI, and then random errors are repeatedly introduced into this restriction map using the error rates described above and selected a random piece of between 1.5 and 2.5 Megabases. This set of simulated data can represents one parental copy of chromosome 21. In order to generate the set for the other chromosome, the 5 Mb sequence can be randomly modified by inserting a random base modification to simulate SNPs and random insertions and deletions of about 3 Kb (the current sizing error averages 3 Kb per 30 Kb average restriction fragment, hence smaller insertions/deletions would likely be difficult to detect), so that the number of SNPs that coincide with restriction sites is approximately the same as the number of insertions and deletions. Such modified sequence can then be used to generate the second set of simulated maps, which correspond to the second parental copy of chromosome 21. The two sets of data may be combined in a 1:1 ratio and mixed together randomly.
[0073] The system, process and software arrangement according to the present invention can generate, e.g., 2 consensus maps and assign input maps to either of these consensus maps or can leave them unassigned. The accuracy of the results can be scored by comparing them with the true in-silico maps (generated along with the simulated data). This procedure can be repeated for different amounts of simulated data corresponding to data redundancy of 6×, 12×, 16×, 24× and 0×. Such redundancy can be measured per haplotype, and thus, the results for 6× redundancy generally corresponds to 6×2×5 Mb of simulated data or 30 molecules of average size 2 Mb. The exemplary results are summarized in Table 2. To further understand these results row 4 (16× Redundancy) can be reviewed. The last column shows that 80 molecules have been in the simulation. Of these molecules 71 molecules have been stated to be classified as belonging to one of the two phases (or haplotype variants). 2 errors were made and only 69 molecules have been correctly classified. By comparing the two consensus maps generated by the software, a list of restriction sites classified as polymorphic (i.e. a SNP was claimed by the software to exists at a restriction site), has been generated and this list was then compared to the correct list of SNPs generated from the true in-silico maps. The column with the header “fp SNPs” shows the number of generated false-positive SNPs (i.e. extra incorrect SNPs) and, in this case the number is 2. The column with the header “fn SNPs” shows the corresponding number of false-negative SNPs (i.e. SNPs missed by the software), and in this case the number is 1. Similarly for RFLPs (i.e. fragment size polymorphisms due to the simulated insertions/deletions), the numbers of false-positives is 0 and false-negatives is 12. The total numbers of correct SNPs and RFLPs are 16 and 24, respectively.
[0000]
TABLE 2
Haplotyping algorithm performance for 16 SNPs and 24 RFLPs
Redun-
Phase
dancy
fp SNPs
fn SNPs
fp RFLPs
fn RFLPs
err
Molecules
6x
5
5
1
18
7/26
30
12x
4
2
4
16
2/55
60
16x
2
1
0
12
2/71
80
24x
2
1
1
11
3/111
120
50x
0
1
1
5
4/228
250
100x
0
0
2
1
2/441
500
[0074] Exemplary statistics of errors in Haplotype maps is shown in FIG. 4 . These exemplary results show the system process and software arrangement according to the present invention can advantageously classify molecules to the right phase (haplotype) whenever redundancy was 12× or higher. However, to detect all the SNPs and RFLPs in the data additional redundancy may be used. For example, at least 16-24× redundancy should be used to achieve 80% or more accuracy finding SNPs, and 50× redundancy to achieve similar accuracy finding RFLPs. These results indicate that with 50× data redundancy, it is possible to reliably detect most SNPs and over 80% of RFLPs for insertions/deletions equal to 1 standard deviation of the sizing error (currently 3 Kb). The accuracy for larger insertions/deletions would likely be higher.
[0075] Therefore, the exemplary embodiment of the system process and software arrangement according to the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted, described, and is defined by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalence in all respects. | System, process and software arrangement produces high resolution, high accuracy, ordered, genome wide haplotyped maps from single molecule based approximate ordered maps and the location of genes responsible for genetic diseases are determined by performing an association study using a population of genome wide haplotyped maps. This can also be used with Optical Mapping data to assemble a genome wide haplotyped restriction map based on multiple distinguishable restriction enzymes. This invention can also be used with any other single molecule process that can produce approximate ordered physical map from randomly broken DNA pieces of a particular genome. | 6 |
TECHNICAL FIELD
[0001] This disclosure relates generally to internal combustion engines and, more particularly, to an apparatus for varying valve timing.
BACKGROUND
[0002] The operation of an internal combustion engine requires, among other things, the timed opening and closing of a plurality of valves. For example, with a typical four-stroke engine, one of ordinary skill in the art will readily recognize such an engine operates through four distinct strokes of a piston reciprocating through a cylinder, with intake and exhaust valves operating in conjunction with the piston. In an intake stroke, the piston moves from top dead center (TDC) where the piston is near a head portion to bottom dead center (BDC) where the piston is at a predetermined distance from the head. An intake valve is opened allowing air or a fuel and air mixture into the cylinder as the piston travels from TDC to BDC. In a subsequent compression stroke, the piston moves from BDC to TDC while both an exhaust valve and intake valve inhibit gas flow from the cylinder, thereby compressing the air and any residual gasses within the cylinder. A combustion or power stroke follows the compression stroke wherein fuel is injected into the compressed air and thereby ignited. Alternatively, an ignition device such as a spark plug may ignite the mixture of fuel and air. The force resulting from the combustion pushes the piston toward BDC while both the intake and exhaust valves are closed. Finally, the piston reverses direction and moves back toward TDC with the exhaust valve open, thereby pushing the combustion gases out of the cylinder.
[0003] Historically, valves on internal combustion engines have been operated in a regular cyclical fashion through the operation of a cam mechanically connected to the valves. Mechanical operation provides an efficient transfer of energy. However, advanced engine cycles may require at least temporary changes in the regular cyclical operation.
[0004] As an example, a Miller cycle in an internal combustion engine may be desired to reduce the compression work while maintaining a desired expansion ratio. One method of operating an engine in a Miller cycle closes an intake valve later than provided for by regular cyclical operation of a cam. The exhaust valve may also close later than provided for by the cam to provide internal exhaust gas recirculation (EGR). As known by those skilled in the art, EGR reduces the oxygen available for combustion and reduces formation of an uncertain form of oxides of nitrogen (NOx).
[0005] In U.S. Pat. No. 6,237,551 issued to Macor et al. on 29 May 2001, a system is described to vary a duration the valve is in an open position. The cam is connected to a rocker arm to cyclically operate a valve. A hydraulic linkage is placed between the rocker arm and the valves. When activated, the hydraulic linkage allows the rocker arm to move the valve according to a profile of the cam. This system, may also be called a “lost motion” system, allows the valve duration to be shortened by decoupling the cam movement from the valve actuation. The decoupling of the valve from cam allows the valve to return to a valve seat or closed position earlier than produce by the cam movement. However, accidental decoupling or loss of hydraulic pressure will let all valves return to their closed position. The engine in turn will not be able to operate.
[0006] As an alternative an actuating mechanism may instead alter the valve movement by acting against the valve to hold the valve as shown in U.S. Pat. No. 6,321,706 issued to Wing on 27 Nov. 2001. In normal operation, the cam cyclically operates on the valve. However, the regular cyclical operation may be altered to extend duration of valve in its open position through the use of various valve holding devices. In one embodiment, a valve member has a shaft extending through a magneto-rheological fluid placed in a sealed chamber. The shaft includes an enlarged portion positioned within the sealed chamber. The valve closing may be delayed by energizing a magnetic field near the chamber to increase the resistance against the enlarged portion moving through the magneto-rheological fluid and delaying closing of the valve. The valve holding device of Wing requires a specifically designed valve shaft and spring arrangement.
[0007] The present disclosure is directed to overcoming one or more of the problems or disadvantages associated with the prior art.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention an engine valve actuator for varying valve timing includes an actuator cylinder. An electromagnetic coil connects with the actuator cylinder. An actuator piston is reciprocatingly disposed in the actuator cylinder. A biasing means is connected with the actuator piston. An electrorheological fluid is disposed in at least a portion of the actuator cylinder.
[0009] In another aspect of the present invention an internal combustion engine includes a cam connecting with an intake valve and exhaust valve to cyclically move the valves. An engine valve actuator connects with intake valve. The engine valve actuator includes an actuator cylinder. An actuator piston is reciprocatingly positioned in the actuator cylinder along with an elecrtorheological fluid. An electromagnetic coil is positioned in close proximity with the electrorheological fluid. A biasing means is connected with the actuator piston.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is cross-sectional view of an engine having an engine valve actuator with an embodiment of the present invention;
[0011] FIG. 2 is a schematic representation an engine valve actuator having an embodiment of the present invention;
[0012] FIG. 3 is a schematic representation of an engine valve actuator having another embodiment of the present invention;
[0013] FIG. 4 is a graph plotting valve lift vs. engine crank angle during normal operation;
[0014] FIG. 5 is a graph plotting valve lift vs. engine crank angle during internal exhaust gas recirculation operation; and
[0015] FIG. 6 is a graph plotting valve lift vs. engine crank angle during Miller cycle operation.
DETAILED DESCRIPTION
[0016] Referring now to the drawings, and with specific reference to FIG. 1 , an embodiment of an internal combustion engine is generally referred to by reference numeral 20 . While the engine 20 is depicted and will be described in further detail herein with reference to a four stroke, internal combustion diesel engine, it is to be understood that the teachings of the disclosure can be employed in conjunction with any other type of reciprocating engine such as spark ignited engines, two-stroke engines, or rotary engines.
[0017] The engine 20 may include a plurality of engine cylinders 22 in each of which is reciprocatingly mounted an engine piston 24 . As known in the art, the engine 20 may include any number of cylinders and may be arranged in various manners such as, for example, in-line or “V”. A connecting rod 26 connects with each engine piston 24 , and in turn connects to a crank shaft 27 so as to capitalize on the motion of the engine piston 24 to produce useful work in a machine (not shown) with which the engine 20 is associated. Each engine has an engine block 28 defining the cylinder 24 and a cylinder head 30 .
[0018] A pair of exhaust ports 38 and intake ports (not shown) may be provided in the cylinder head 30 to allow for fluid communication into and out of the engine cylinder 22 . In normal engine operation, air may be allowed to enter the engine cylinder 22 through the intake ports, while combustion or exhaust gases may be allowed to exit the engine cylinder 22 through the exhaust ports 38 . An exhaust valve 42 may be provided within each gas port. As shown the exhaust ports 38 and exhaust valves 42 will be described in relation to an exhaust system. However, it should be understood that the intake ports and intake valve element act in similar manner as known in the art.
[0019] Each of the exhaust valves 42 may include a valve head 44 from which a valve stem 46 extends. The valve head 44 includes a sealing surface 48 adapted to seal against a valve seat 50 about a perimeter 52 of the valve ports 38 . A bridge 54 is adapted to contact the valve stems 46 of the valve 42 . A valve spring 56 imparts force between the top of each valve stem 46 and the cylinder head 30 , thereby biasing the stem 46 away from the cylinder head 30 and thus biasing the valve head 44 into seating engagement with the corresponding valve seats 50 or move the exhaust valve 42 into a closed position blocking the exhaust port 38 .
[0020] Movement of the exhaust valve 42 is controlled not only by the springs 56 , but by a cam assembly 58 as well. As one of ordinary skill in the art will readily recognize, rotation of the cam 60 cyclically causes a push rod 62 to rise, thereby causing a rocker arm 64 , connected thereto, to pivot about a pivot 66 . In so doing, an end 68 of the rocker arm 64 is caused to move downwardly and thereby move the exhaust valve element 42 to an open position unblocking the exhaust port 38 . Under normal engine operation, the cam 60 imparts sufficient force to the valve stem 46 to overcome the biasing force of the spring 56 and thereby push the valve head 44 away from the valve seat 50 , to move the exhaust valve 42 to an open position. Further rotation of the cam 60 allows the spring 56 to push the end 68 of the rocker arm 64 upward and the push rod 62 downward until the cam 60 completes another revolution. Alternatively, the cam 60 may act directly on either the rocker arm 64 or valve element 42 in a conventional manner.
[0021] In certain modes of engine operation, such as with the compression release braking, Miller cycle operation, and EGR referenced above, it is desirable for the exhaust valves 42 to be held in the open position for longer periods, or at a timing sequence other than that dictated by the cam 60 . In such situations, an engine valve actuator 70 may be used to so hold the exhaust valve 34 in the open position.
[0022] As shown in FIG. 2 , the engine valve actuator 70 includes an actuator piston 72 reciprocatingly positioned in an actuator cylinder 74 . The actuator piston has an actuating surface 76 opposite a control surface 78 . An actuating rod 80 may extend from the actuating surface 76 through an opening 82 in the actuating cylinder 74 to engage the actuator arm 68 . In this embodiment, a spring 84 attaches to the control surface 78 as a biasing means to urge the actuating piston to engage with the exhaust valves 42 . Any conventional biasing means may be used such as a pressurized hydraulic or pneumatic cylinder that may be passively or actively controlled. An electromagnetic coil 86 is connected with the actuator cylinder 74 . The electromagnetic coil 86 may be any conventional device capable of generating a magnetic flux or electric current operatively associated with an electrorhelological fluid 88 . As shown, the electromagnetic coil 86 may be integral with actuator cylinder 74 . The electrorehological fluid 88 is contained within the actuator cylinder 74 . The electrorheological fluid 88 includes magnetorheological fluids and other any fluid where viscosity may be controllable in response to controlling an applied magnetic flux or electrical current. The electrorheological fluid 88 may pass from the actuating surface 76 to the control surface 78 via flow control device 90 represented by a plurality of orifices in the present embodiment. An electronic controller 92 is connected with the electromagnetic coils 86 .
[0023] An alternative engine valve actuator 70 ′ shown in FIG. 3 includes the actuator piston 72 ′, a control piston 94 , the actuator cylinder 74 ′, and a control cylinder 96 (where the “′” represents a component corresponding to an element of the embodiment shown in FIG. 2 ). The control piston 94 is reciprocatingly positioned in the control cylinder 96 . The spring 84 ′ or similar biasing means positions the control piston 94 so as to reduce a control volume 98 in the control cylinder 96 for the electrorheological fluid 88 . In this embodiment, the electrorheological fluid 88 is in fluid contact with the control surface 78 of the actuator piston 72 ′. The actuator cylinder 74 ′ and control cylinder 96 may be formed from a single cylinder 100 separated by a partition 102 . The flow control device 90 ′, represented by an orifice in this embodiment, is positioned in the partition 102 . The flow control device 90 ′ allows the electrorhelogoical fluid 88 to fluidly communicate between the control cylinder 96 and the actuator cylinder 74 ′. While this embodiment shows an orifice, any conventional flow control device 90 ′ may be used. The electromagnetic coils 86 ′ in this embodiment are shown as being attached to the single cylinder 100 .
Industrial Applicability
[0024] FIG. 4 shows a typical trace of an exhaust valve 42 when operated using the cam assembly 58 . Each valve opens and closes in a regular, cyclical fashion (i.e. at a predetermined crank angle for each engine cycle.) Alternative engine cycles such as internal EGR and Miller cycle operation require alteration of the regular, cyclical cam operation. In the present invention, the engine valve actuator 70 may be used with existing engine designs without modifying existing components.
[0025] Taking internal EGR shown in FIG. 6 , moving the exhaust valve 42 to the closed position may be delayed by sending a signal to the electromagnetic coil 86 . During an exhaust stroke, as the piston 24 moves toward TDC, the cam will cause the exhaust valve 34 to move away from the seat 50 . To prevent the exhaust valve from following the cam motion, a signal is sent by the controller 92 to establish a magnetic flux (not shown) in the electrorhelogical fluid 88 causing the viscosity to increase. Motion of the actuator piston 72 is slowed or stopped by the increased resistance due to the change in viscosity. At such time the exhaust valve 34 is desired to return to its seat 50 , the controller 92 terminates the signal to reduce or eliminate the magnetic flux. The exhaust valve 42 returns to its seat 50 . The flow control device 90 provides dampening to the actuator piston 72 .
[0026] Continuing with the example of EGR, when the exhaust valve 34 is held in the open position as the engine piston 24 ascends to a TDC position, and remains in the open position after the engine piston 24 reverses and descends. A portion of the exhaust gases vented from neighboring engine cylinders 22 through the exhaust ports 36 are thereby reintroduced to the engine cylinder 22 by the resulting pressure differential. After a predetermined stroke length (e.g., ninety degrees of a seven hundred and twenty degree four stroke cycle), the exhaust valve 42 is in the closed position, while the intake valve remains in the open position to complete the intake stroke as explained above.
[0027] The teachings of the present disclosure can also be used to provide Miller cycle benefits. As illustrated in FIG. 6 , the intake valves may be held open during the initial stages of the compression stroke to thereby reduce the compression work of the engine 20 and provide the engine efficiencies of the Miller cycle as well known by those of ordinary skill in the art. The intake valve could be so held by employing the engine actuator 70 after the cam assembly 58 moves the intake valve to the open position during the intake stroke. More specifically, as the intake valve is about to be moved to the closed position by the spring 56 at the conclusion of a normal intake stroke, the electromagnetic coil 86 could be actuated so as to slow movement of the actuator piston and thereby the intake valve toward the seat 50 .
[0028] Other aspects and features of the present disclosure can be obtained from a study of the drawings, the disclosure, and the appended claims. | An engine with a valve actuator to extend duration of a valve event and method of controlling an engine with such an actuator are disclosed. The actuator may include an actuator cylinder with an actuator piston. The actuator contains an electrorheological fluid. A magnetic flux may be applied the electrorheological fluid to prevent or slow movement of the actuator piston and change valve movement with respect to its regular, cyclical operation provide for with a cam. A biasing means is connected with the actuator piston to allow positioning of the valve actuator in an existing engine design. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/387,348, filed on Dec. 23, 2015, U.S. Provisional Application No. 62/328,876, filed Apr. 28, 2016, U.S. Provisional Application No. 62/279,315, filed Jan. 15, 2016; U.S. Provisional Application No. 62/328,885, filed Apr. 28, 2016; and U.S. Provisional Application No. 62/422,279, filed Nov. 15, 2016, each of which is incorporated in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of male fertility and more specifically provides methods of identifying a reproductive approach to use in order to achieve fertilization and/or modifying the time period at which insemination is performed in order to achieve fertilization.
BACKGROUND
[0003] The diagnosis of male infertility is based predominantly on the results of standard semen analysis for concentration, total motility, progressive motility, volume, pH, viscosity and/or morphology. However, measurements of sperm morphology, motility and concentration do not assess fertilizing potential, including the complex changes that sperm undergo during residence within the female reproductive tract. In addition to the challenges associated with assessing fertilizing potential, cryopreservation is often used to preserve sperm cells and preserve male fertility for extended periods of time. Unfortunately, freezing and thawing can negatively affect sperm viability and function. Cryopreservation is reported to alter capacitation and shift/limit the fertilization window.
[0004] Newly developed fertility tests should determine the ability of sperm to fertilize, as well as initiate and maintain pregnancy (Oehninger et al., “Sperm functional tests,” Fertil Steril. 102: 1528-33 (2014); Wang et al., “Limitations of semen analysis as a test of male fertility and anticipated needs from newer tests,” Fertil Steril. 102: 1502-07 (2014)). While freshly ejaculated spermatozoa appear morphologically mature and motile, they are fertilization incompetent. They must first undergo a maturational process known as “capacitation,” which renders them capable of fertilization (Austin, “The capacitation of the mammalian sperm,” Nature, 170: 326 (1952); Chang, “Fertilizing capacity of spermatozoa deposited into the fallopian tubes,” Nature, 168: 697-8 (1951)). In most species, capacitation is dependent upon the removal of sterols from the sperm plasma membrane (sterol efflux) and the influx of bicarbonate and calcium ions (Baldi et al., “Intracellular calcium accumulation and responsiveness to progesterone in capacitating human spermatozoa,” J Androl. 12: 323-30 (1991); Bedu-Addo et al., “Bicarbonate and bovine serum albumin reversibly ‘switch’ capacitation-induced events in human spermatozoa,” Mol Hum Reprod., 11: 683-91 (2005); Cohen et al., “Lipid modulation of calcium flux through Ca V 2.3 regulates acrosome exocytosis and fertilization,” Dev Cell. 28: 310-21 (2014); Gadella et al., “Bicarbonate and its role in mammalian sperm function,” Anim. Reprod. Sci. 82: 307-19 (2004)). The efflux of sterols that occurs during sperm capacitation changes membrane fluidity patterns and allows for the redistribution of specific membrane components (Cohen et al. 2014; Cross, “Role of cholesterol in sperm capacitation,” Biol Reprod. 59: 7-11 (1998); Selvaraj et al., “Mechanisms underlying the micron-scale segregation of sterols and G M1 in live mammalian sperm,” J Cell Physiol. 218: 522-36 (2007); Selvaraj et al, “G M1 dynamics as a marker for membrane changes associated with the process of capacitation in murine and bovine spermatozoa,” J Androl. 28: 588-99 (2009))
[0005] Currently, there are few if any sensitive and simple capacitation biomarkers suitable for clinical application. For example, the phosphorylation of tyrosine residues has been well detailed in association with capacitation (Battistone et al., “Functional human sperm capacitation requires both bicarbonate-dependent PKA activation and down-regulation of Ser/Thr phosphatases by Src family kinases,” Mol, Human Reprod. 19: 570-80 (2013); Osheroff et al., “Regulation of human sperm capacitation by a cholesterol efflux-stimulated signal transduction pathway leading to protein kinase A-mediated up-regulation of protein tyrosine phosphorylation,” Mol, Human Reprod. 5: 1017-26 (1999); Visconti et al. “Capacitation of mouse spermatozoa. I. Correlation between the capacitation state and protein tyrosine phosphorylation,” Development, 121: 1129-37 (1995)). However, evaluating these events can take multiple days and provide only a semi-quantitative assessment, making it inappropriate for the clinical evaluation of male fertility.
[0006] It has been known for some time that sperm must undergo sterol efflux to become fertilization competent (Osheroff et al. 1999; Travis et al., “The role of cholesterol efflux in regulating the fertilization potential of mammalian spermatozoa,” The Journal of Clinical Investigation, 110: 731-36 (2002)). In addition, cholesterol and other lipids, such as the ganglioside G M1 , are organized into microdomains within the sperm's plasma membrane (Asano et al., “Biochemical characterization of membrane fractions in murine sperm: Identification of three distinct sub-types of membrane rafts,” J Cell Physiol., 218: 537-48 (2009); Asano et al., “Characterization of the proteomes associating with three distinct membrane raft sub-types in murine sperm,” Proteomics, 10: 3494-505 (2010); Travis et al., “Expression and localization of caveolin-1, and the presence of membrane rafts, in mouse and Guinea pig spermatozoa,” Dev Biol., 240: 599-610 (2001); Selvaraj et al. 2009). These membrane rafts consolidate signaling pathways, making them sensible candidates for mediating sperm function. Interestingly, predictable changes in G M1 localization patterns have been measured both in mouse and bull sperm that have been stimulated for capacitation (Selvaraj et al. 2007). What's more, G M1 regulates the activity of an R-type calcium channel, triggering a transient calcium flux that is essential for acrosome exocytosis and thus successful fertilization (Cohen et al. 2014). These findings substantiate the use of G M1 localization patterns to assess sperm function and accordingly male fertility.
[0007] Various G M1 localization patterns have been identified and associated with capacitation or non-capacitation. In particular, apical acrosome (AA) G M1 localization patterns and acrosomal plasma membrane (APM) G M1 localization patterns have been associated with capacitation in bovine and human sperm. Sperm capacitation can be quantitatively expressed as a Cap-Score™ value, generated via the Cap-Score™ Sperm Function Test (“Cap-Score™ Test” or “Cap-Score”), is defined as ([number of apical acrosome (AA) G M1 localization patterns+number of acrosomal plasma membrane (APM) G M1 localization patterns]/total number of G M1 labeled localization patterns) where the number of each localization pattern is measured and then ultimately converted to a percentage score. In addition to APM G M1 localization patterns and AA G M1 localization patterns, the other labeled localization patterns included Lined-Cell G M1 localization patterns, intermediate (INTER) G M1 localization patterns, post acrosomal plasma membrane (PAPM) G M1 localization patterns, apical acrosome/post acrosome (AA/PA) G M1 localization patterns, equatorial segment (ES) G M1 localization patterns, and diffuse (DIFF) G M1 localization patterns. (Travis et al., “Impacts of common semen handling methods on sperm function,” The Journal of Urology, 195 (4), e909 (2016)).
SUMMARY OF INVENTION
[0008] In an embodiment, the disclosure provides for a method to identify an approach for achieving mammalian fertilization. A first sample, of in vitro capacitated sperm cells, is treated with a fluorescence label. One or more t 0 -fluorescence images are obtained where the images display one or more G M1 localization patterns associated with t 0 -fluorescence labeled in vitro capacitated sperm cells. The t 0 -fluorescence images are obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ). A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 0 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 0 -fluorescence images to determine a percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. A fertility status associated with a percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] is determined wherein a reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than 35% indicates a high fertility status; one standard deviation below 35% indicates a medium fertility status; and two or more standard deviations below 35% indicates a low fertility status. The percentage of measured t 0 -[AA G M1 localization patterns and APM G M1 localization patterns] is compared to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]. A reproductive approach is identified based on fertility status in order to achieve fertilization.
[0009] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration: (i) the reproductive approach for high fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0010] In another instance of the foregoing embodiment, where the male has a less than normal sperm concentration: (i) the reproductive approach for high fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0011] In an instance of each of the foregoing embodiments, a second sample of in vitro capacitated sperm cells is treated with a fluorescence label, wherein the second sample of in vitro capacitated sperm cells and first sample of in vitro capacitated sperm cells are associated with the same male. One or more t 1 -fluorescence images displaying one or more G M1 localization patterns associated with t 1 -fluorescence labeled in vitro capacitated sperm cells are obtained, wherein t 1 -fluorescence images are obtained at post capacitation time t 1 , wherein t 1 is selected from greater than t 0 or greater than 18 hours. A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns for the t 1 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 1 -fluorescence images are measured to determine a percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns]. The percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] is compared to determine an in vivo capacitation time selected from a late in vivo capacitation time greater than 12 hours or a standard in vivo capacitation time of less than 12 hours. A difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% indicates a late in vivo capacitation time greater than 12 hours; or less than one standard deviation from the standard of 35% indicates a standard in vivo capacitation time less than 12 hours. Further when a difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]; or less than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] or the percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. Based on the male's t 1 -fertility status and in vivo capacitation time, a time period for insemination and a reproductive approach to use are identified in order to achieve fertilization.
[0012] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time; pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0013] In an instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for t 1 -high fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for t 1 -medium fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for t 1 -low fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; intracytoplasmic sperm injection (ICSI), modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time, pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0014] In another instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0015] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0016] In an embodiment, the disclosure provides for a method to identify an approach for achieving mammalian fertilization. A sample of t 0 -in vitro capacitated sperm cells is treated with a fluorescence label and a sample of t 1 -in vitro capacitated sperm cells is treated with a fluorescence label. One or more t 0 -fluorescence images is obtained, the t 0 -fluorescence images displaying one or more G M1 localization patterns associated with t 0 -fluorescence labeled in vitro capacitated sperm cells. And one or more t 1 -fluorescence images is obtained, the t 1 -fluorescence displaying one or more G M1 localization patterns associated with t 1 -fluorescence labeled in vitro capacitated sperm cells. The t 0 -fluorescence images are obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ); and the t 1 -fluorescence images being obtained at post capacitation time t 1 wherein t 1 is greater than t 0 . A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 0 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 0 -fluorescence images to determine a percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. And a number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 1 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 1 -fluorescence images to determine a percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns]. The percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] is compared to the percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] to determine an in vivo capacitation time selected from a late in vivo capacitation time greater than 12 hours or a standard in vivo capacitation time of 12 hours or less. A difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% indicates a late in vivo capacitation time greater than 12 hours; or less than one standard deviation from a standard of 35% indicates a standard in vivo capacitation time less than 12 hours. A reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than 35% indicates a high fertility status; one standard deviation below 35% indicates a medium fertility status; and two or more standard deviations below 35% indicates a low fertility status. Further when a difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35%, then a t 1 -fertility status is determined based on a comparison of the percentage of measured t r [AA G M1 localization patterns plus APM G M1 localization patterns] to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]; or less than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] or the percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. Based on the male's t 1 -fertility status and in vivo capacitation time, a time period for insemination and a reproductive approach are identified to use in order to achieve fertilization.
[0017] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time; pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0018] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for t 1 -high fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination (ICI), or pre-capacitating sperm prior to intrauterine insemination (IUI); (ii) the reproductive approach for t 1 -medium fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for t 1 -low fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; intracytoplasmic sperm injection (ICSI), modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time, pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0019] In another instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0020] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0021] In one embodiment, the present disclosure provides for a method identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. Data are generated that illustrate one or more G M1 localization patterns of the fluorescence label treated in vitro capacitated sperm cells said data obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ); and times greater than t 0 (t 1 ). A male's fertility status data are then characterized using the data of one or more G M1 localization patterns at those times. Based on the male's fertility status data, a time period for insemination and a reproductive approach is identified to use in order to achieve fertilization. In one embodiment, the sperm cells were cryopreserved and stored prior to being treated in vitro with capacitation conditions. In another embodiment, the sperm cells were treated in vitro with capacitation conditions, the fertility status assessed using the data of one or more G M1 localization patterns at those times, and then the sperm were cryopreserved and stored.
[0022] In yet another embodiment, the present disclosure provides method of identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. One or more fluorescence images of fluorescence labeled in vitro capacitated sperm cells are obtained. A Cap-Score value is measured for fluorescence labeled in vitro capacitated sperm sample after the sperm cells are treated in vitro with capacitation conditions for varying periods of time. The Cap-Score value is compared to reference Cap-Score values associated with males of known fertility status at those times. Based on the Cap-Score value, a time period for insemination and a reproductive approach are identified for use in order to achieve fertilization. In one embodiment, the sperm cells were cryopreserved and stored prior to being treated in vitro with capacitation conditions. In another embodiment, the sperm cells were treated in vitro with capacitation conditions, the fertility status assessed using the data of one or more G M1 localization patterns at those times, and then the sperm were cryopreserved and stored.
[0023] In yet another embodiment, the present disclosure provides method of identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. One or more fluorescence images of fluorescence labeled in vitro capacitated sperm cells are obtained. A Cap-Score value is measured for fluorescence labeled in vitro capacitated sperm sample after the sperm cells were treated with cryopreservation procedures and treated in vitro with capacitation conditions for varying lengths of time. The Cap-Score values are compared to reference Cap-Score values associated with males of known fertility status at those times. Based on the Cap-Score values at those times, a time period for insemination and a reproductive approach is identified for use in order to achieve fertilization.
[0024] In still yet another embodiment, the present disclosure provides for a method identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. Data are generated that illustrate one or more G M1 localization patterns of in vitro capacitated sperm cells after the sperm cells were treated with cryopreservation procedures and treated in vitro with capacitation conditions for varying lengths of time. A male's fertility status data are then characterized using the data of one or more G M1 localization patterns at those times. Based on the male's fertility status data, a time period for insemination and a reproductive approach is identified to use in order to achieve fertilization.
[0025] In another embodiment, the present disclosure provides for a method of identifying an appropriate method for achieving successful mammalian pregnancy. In vitro capacitated sperm cells are treated with a fluorescence label. One or more fluorescence images of fluorescence labeled in vitro capacitated sperm cells are obtained. A Cap-Score value is measured for fluorescence labeled in vitro capacitated sperm sample. The Cap-Score value is compared to a reference Cap-Score value associated with fertile males. An appropriate mechanism to achieve a successful pregnancy is determined based on the Cap-Score value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings.
[0027] FIG. 1A illustrates a plot of the average Cap-Score is shown on the x-axis and the corresponding Standard Deviation is shown on the y-axis. The average SD for all images was found to be three (3) and is shown by the solid horizontal line. The dotted lines show the linear dependence of the SD (y=0.06x+0.02; r=0.69; p=0.00).
[0028] FIG. 1B illustrates a plot of the average Cap-Score shown on the x-axis and Coefficient of Variation is shown on the y-axes. The CoV for all images was found to be thirteen ( 13 ) and is shown by the solid horizontal line. The dotted lines show the linear dependence of the CoV (y=−0.32x+0.22; r=−0.84; p=0.00) to the Cap-Score average.
[0029] FIG. 2A illustrates the reproducibility of mean Cap-Scores between operators. Ten stitched images, containing up to 5,000 sperm each, were obtained for “less than normal” (more than one (1) SD below the mean Cap-Score result for a population of normal men. Two different readers determined Cap-Scores by randomly resampling each image 20 times and counting 150 cells each time (reader 1 open bars, reader 2 grey bars).
[0030] FIG. 2B illustrates the reproducibility of mean Cap-Scores between operators. Ten stitched images, containing up to 5,000 sperm each, were obtained for “presumed normal” classified as above one (1) SD below the mean Cap-Score result for a population of normal men. Two different readers determined Cap-Scores by randomly resampling each image 20 times and counting 150 cells each time (reader 1 open bars, reader 2 grey bars).
[0031] FIG. 3A illustrates the repeatability of Cap-Score variances between operators. Ten stitched images, containing up to 5,000 sperm each, were obtained for “less than normal” (more than one (1) SD below the mean Cap-Score result for a population of normal men. Two different readers determined Cap-Scores by randomly resampling each image 20 times and counting 150 cells each time (reader 1 open bars, reader 2 grey bars).
[0032] FIG. 3B illustrates the repeatability of Cap-Score variances between operators. Ten stitched images, containing up to 5,000 sperm each, were obtained for “presumed normal” classified as above one (1) SD below the mean Cap-Score result for a population of normal men. Two different readers determined Cap-Scores by randomly resampling each image 20 times and counting 150 cells each time (reader 1 open bars, reader 2 grey bars).
[0033] FIG. 4 illustrates various localization patterns of G M1 in normal human sperm and sperm from infertile males which form under in vitro capacitating conditions.
DETAILED DESCRIPTION
[0034] As described herein, the time period for sperm capacitation among and within different males varies. It has been discovered that determining the time period for a male's sperm capacitation can be used to identify a time period for insemination and a reproductive approach to use during the insemination time period in order to achieve fertilization.
[0035] G M1 refers to monosialotetrahexosylganglioside and is a member of the ganglio series of gangliosides.
[0036] For human sperm, eight different G M1 localization patterns have been reported when the sperm was under in vitro capacitating conditions as illustrated in FIG. 4 . To visualize the location patterns, the capacitated sperm were treated with labeling molecule for G M1 , such as cholera toxin b, which has a florescence detectable label on it.
[0037] INTER is characterized by a sperm cell where the vast majority of the fluorescence signal is in a band around the equatorial segment, with some signal in the plasma membrane overlying the acrosome. There is usually a gradient of the fluorescence signal, with the most at the equatorial segment and then progressively less toward the tip. There is often an increase in fluorescence signal intensity on the edges of the sperm head in the band across the equatorial segment.
[0038] Apical Acrosome “AA” is characterized by a sperm cell where the fluorescence signal is concentrated toward the apical tip, increased in brightness and reduced in area with signal.
[0039] Acrosomal Plasma Membrane “APM” is characterized by a sperm cell exhibiting a distributed fluorescence signal in the plasma membrane overlying the acrosome. APM signal is seen either from the bright equatorial INTER band moving apically toward the tip, or it can start further up toward the tip and be found in a smaller region, as it is a continuum with the AA.
[0040] Post-Acrosomal Plasma Membrane “PAPM” is characterized by a sperm cell where the fluorescence signal is exclusively in the post-acrosomal plasma membrane.
[0041] Apical Acrosome Post-Acrosome “AA/PA” is characterized by a sperm cell where the fluorescence signal is located both in the plasma membrane overlying the acrosome and post-acrosomal plasma membrane. The equatorial segment does not exhibit a fluorescence signal.
[0042] Equatorial Segment “ES” is characterized by a sperm cell having a bright fluorescence signal located solely in the equatorial segment. It may be accompanied by thickening of the sperm head across the equatorial region.
[0043] Diffuse “DIFF” is characterized by a sperm cell having a diffuse fluorescence signal located over the whole sperm head.
[0044] Lined-Cell is characterized by a sperm cell having a diffuse fluorescence signal ontop of the post-acrosomal region and at the plasma membrane overlying the acrosome as well as the bottom of the equatorial segment (i.e., the post acrosome/equatorial band). A fluorescence signal is missing around the equatorial segment.
[0045] The various G M1 localization patterns are identified by treating sperm cells with labeling molecule for G M1 , such as cholera toxin b, which has a florescence detectable label on it. The labeled sperm cells are then visualized using a fluorescence microscope as known to those of skill in the art.
[0046] Cap-Score is defined as the ratio of [the number of apical acrosome (AA) G M1 localization patterns+the number of acrosomal plasma membrane (APM) G M1 localization patterns] divided by [the total number of G M1 labeled localization patterns.] (Travis et al., “Impacts of common semen handling methods on sperm function,” The Journal of Urology, 195 (4), e909 (2016)). To arrive at the number of different G M1 localization patterns, the number of, localization patterns, are counted for at least 100 sperm cells.
[0047] For the purposes of this application “t 0 ” corresponds to the number of hours after treating sperm cells with in vitro capacitation conditions and is selected from 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours.
[0048] For the purposes of this application “t 1 ” corresponds to the number of hours after treating sperm cells with in vitro capacitation conditions and is greater than 18 hours or greater than t 0 .
[0049] For the purposes of this application images is understood to mean (i) digital images; (ii) G M1 patterns directly viewed by an operator through an eye piece; or (iii) G M1 patterns discerned by flow cytometry.
[0050] For the purposes of this application “insemination” is understood to have a meaning dependent upon the reproductive approach. For example, for “intercourse,” insemination is understood to mean introduction of sperm into a female's reproductive tract. For example, for “intracervical insemination (ICI),” insemination is understood to mean introduction of sperm into a female's cervix. For “intrauterine insemination (IUI),” insemination is understood to mean when sperm is introduced into a female's uterus. For “in vitro fertilization (IVF),” insemination is understood to mean when sperm are introduced into a droplet of medium containing egg cells (oocytes) to allow co-incubation of sperm and egg cell(s). For “pre-capacitating sperm prior to in vitro fertilization,” insemination is understood to mean when sperm are introduced into a droplet of medium containing egg cells (oocytes) to allow co-incubation of sperm and egg cell(s). For “intracytoplasmic sperm injection (ICSI),” insemination is understood to mean injection of sperm or pre-capacitated sperm into an egg cell. For “gamete intra-fallopian transfer (GIFT),” insemination is understood to mean injection of sperm or pre-capacitated sperm and egg cell(s) into the female's Fallopian tubes. For “subzonal insemination (SUZI),” insemination is understood to mean injection of a single sperm cell or a single pre-capacitated sperm cell just beneath the zona pellucida. For purposes of this application, the term “cryopreservation” refers to the entire process of freezing, storing, and thawing the cells for use
[0051] As used herein below, the male is a mammal. In an embodiment, the male is a human. In another embodiment, the male is a non-human mammal. In one such embodiment, the male is a companion animal. In another embodiment, the male is an agricultural animal. In one such embodiment, the male is a canine, feline, equine, bovine, sheep, goat, pig, camellid, or buffalo.
[0052] In an embodiment, the disclosure provides for a method to identify an approach for achieving mammalian fertilization. A first sample, of in vitro capacitated sperm cells, is treated with a fluorescence label. One or more t 0 -fluorescence images are obtained where the images display one or more G M1 localization patterns associated with t 0 -fluorescence labeled in vitro capacitated sperm cells. The t 0 -fluorescence images are obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ). A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 0 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 0 -fluorescence images to determine a percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. A fertility status associated with a percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] is determined wherein a reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than 35% indicates a high fertility status; one standard deviation below 35% indicates a medium fertility status; and two or more standard deviations below 35% indicates a low fertility status. The percentage of measured t 0 -[AA G M1 localization patterns and APM G M1 localization patterns] is compared to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]. A reproductive approach is identified based on fertility status in order to achieve fertilization.
[0053] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration: (i) the reproductive approach for high fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0054] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration: (i) the reproductive approach for high fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0055] For the foregoing embodiments, where the sperm is pre-capacitated and the reproductive approach corresponds to pre-capacitating sperm prior to in vitro fertilization, the time period for pre-capacitation corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0056] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to intracytoplasmic sperm injection (ICSI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0057] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to gamete intra-fallopian transfer (GIFT), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0058] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to subzonal insemination (SUZI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0059] In an instance of each of the foregoing embodiments, a second sample of in vitro capacitated sperm cells is treated with a fluorescence label, wherein the second sample of in vitro capacitated sperm cells and first sample of in vitro capacitated sperm cells are associated with the same male. One or more t 1 -fluorescence images displaying one or more G M1 localization patterns associated with t 1 -fluorescence labeled in vitro capacitated sperm cells are obtained, wherein t 1 -fluorescence images are obtained at post capacitation time t 1 , wherein t 1 is selected from greater than t 0 or greater than 18 hours. A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns for the t 1 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 1 -fluorescence images are measured to determine a percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns]. The percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] is compared to determine an in vivo capacitation time selected from a late in vivo capacitation time greater than 12 hours or a standard in vivo capacitation time of less than 12 hours. A difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% indicates a late in vivo capacitation time greater than 12 hours; or less than one standard deviation from the standard of 35% indicates a standard in vivo capacitation time less than 12 hours. Further when a difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]; or less than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] or the percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. Based on the male's t 1 -fertility status and in vivo capacitation time, a time period for insemination and a reproductive approach to use are identified in order to achieve fertilization.
[0060] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time; pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0061] In an instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for t 1 -high fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for t 1 -medium fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for t 1 -low fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; intracytoplasmic sperm injection (ICSI), modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time, pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0062] In another instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0063] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0064] For the foregoing embodiments, where the sperm is pre-capacitated and the reproductive approach corresponds to pre-capacitating sperm prior to in vitro fertilization, the time period for pre-capacitation corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0065] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to intracytoplasmic sperm injection (ICSI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0066] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to gamete intra-fallopian transfer (GIFT), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0067] For embodiments where the sperm is pre-capacitated and the reproductive approach corresponds to subzonal insemination (SUZI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0068] In an instance of each of the foregoing embodiments, the identifying step is also based on one or more of the following: patient demographics, reproductive status of female partner, sperm concentration, total motility, progressive motility, semen volume, semen pH, semen viscosity and/or sperm morphology and combinations thereof.
[0069] In an instance of each of the foregoing embodiments, the more than one G M1 localization patterns include AA G M1 localization pattern, APM G M1 localization pattern, Lined-Cell G M1 localization pattern, INTER G M1 localization pattern, PAPM G M1 localization pattern, AA/PA G M1 localization pattern, ES G M1 localization pattern, and DIFF G M1 localization pattern.
[0070] In an instance of each of the foregoing embodiments, sperm cells are treated in vitro with capacitation conditions for a capacitation time period of: at least one hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; for a capacitation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 24 hours; 12 hours to 24 hours; or 18 hours to 24 hours.
[0071] In an instance of each of the foregoing embodiments, the in vitro capacitated sperm cells are treated with a fixative for a fixative time period of: at least 0.5 hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; at least 30 hours; at least 36 hours; or at least 48 hours, for a fixation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 18 hours; 6-18 hours; 6-24 hours; 12 hours to 24 hours; 18 hours to 24 hours; 18-30 hours; 18-36 hours; 24-30 hours; 24-26 hours; 18-48 hours; 24-48 hours; or 36-48 hours.
[0072] In an instance of each of the foregoing embodiments, the sperm cells were treated to cryopreservation procedures and stored prior to being treated in vitro with capacitation conditions.
[0073] In an embodiment, the disclosure provides for a method to identify an approach for achieving mammalian fertilization. A sample of t 0 -in vitro capacitated sperm cells is treated with a fluorescence label and a sample of t 1 -in vitro capacitated sperm cells is treated with a fluorescence label. One or more t 0 -fluorescence images is obtained, the t 0 -fluorescence images displaying one or more G M1 localization patterns associated with t 0 -fluorescence labeled in vitro capacitated sperm cells. And one or more t 1 -fluorescence images is obtained, the t 1 -fluorescence displaying one or more G M1 localization patterns associated with t 1 -fluorescence labeled in vitro capacitated sperm cells. The t 0 -fluorescence images are obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ); and the t 1 -fluorescence images being obtained at post capacitation time t 1 wherein t 1 is greater than t 0 . A number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 0 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 0 -fluorescence images to determine a percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. And a number of apical acrosome (AA) G M1 localization patterns, a number of acrosomal plasma membrane (APM) G M1 localization patterns and a total number of G M1 localization patterns are measured for the t 1 -fluorescence labeled in vitro capacitated sperm cells displayed in the t 1 -fluorescence images to determine a percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns]. The percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] is compared to the percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] to determine an in vivo capacitation time selected from a late in vivo capacitation time greater than 12 hours or a standard in vivo capacitation time of 12 hours or less. A difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35% indicates a late in vivo capacitation time greater than 12 hours; or less than one standard deviation from a standard of 35% indicates a standard in vivo capacitation time less than 12 hours. A reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than 35% indicates a high fertility status; one standard deviation below 35% indicates a medium fertility status; and two or more standard deviations below 35% indicates a low fertility status. Further when a difference in percentage of t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns] and the percentage of t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] corresponding to: greater than one standard deviation from a standard of 35%, then a t 1 -fertility status is determined based on a comparison of the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] to the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns]; or less than one standard deviation from a standard of 35% then a t 1 -fertility status is determined based on a comparison of the reference percentage of [AA G M1 localization patterns plus APM G M1 localization patterns] to the percentage of measured t 1 -[AA G M1 localization patterns plus APM G M1 localization patterns] or the percentage of measured t 0 -[AA G M1 localization patterns plus APM G M1 localization patterns]. Based on the male's t 1 -fertility status and in vivo capacitation time, a time period for insemination and a reproductive approach are identified to use in order to achieve fertilization.
[0074] In an instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time; pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0075] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and late in vivo capacitation time: (i) the reproductive approach for t 1 -high fertility status is selected from the group consisting of: modifying the timing of intercourse to late in vivo capacitation time; modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination (ICI), or pre-capacitating sperm prior to intrauterine insemination (IUI); (ii) the reproductive approach for t 1 -medium fertility status is selected from group consisting of: modifying the timing of intracervical insemination (ICI) to late in vivo capacitation time; modifying the timing of intrauterine insemination (IUI) to late in vivo capacitation time; modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; pre-capacitating sperm prior to intracervical insemination, pre-capacitating sperm prior to intrauterine insemination; or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for t 1 -low fertility status is selected from group consisting of: modifying the timing of in vitro fertilization (IVF) to late in vivo capacitation time; intracytoplasmic sperm injection (ICSI), modifying the timing of intracytoplasmic sperm injection (ICSI) to late in vivo capacitation time; modifying the timing of gamete intra-fallopian transfer (GIFT) to late in vivo capacitation time; modifying the timing of subzonal insemination (SUZI) to late in vivo capacitation time, pre-capacitating sperm prior to in vitro fertilization, pre-capacitating sperm prior to intracytoplasmic sperm injection, pre-capacitating sperm prior to gamete intra-fallopian transfer, or pre-capacitating sperm prior to subzonal insemination.
[0076] In another instance of the foregoing embodiment, wherein the male has at least normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from the group consisting of: intercourse, intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI), or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from the group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination; intrauterine insemination (IUI); pre-capacitating sperm prior to intrauterine insemination; or in vitro fertilization (IVF) or pre-capacitating sperm prior to in vitro fertilization; or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI), or pre-capacitating sperm prior to subzonal insemination.
[0077] In another instance of the foregoing embodiment, wherein the male has a less than normal sperm concentration and standard in vivo capacitation time: (i) the reproductive approach for high t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; (ii) the reproductive approach for medium t 1 -fertility status is selected from group consisting of: intracervical insemination (ICI), pre-capacitating sperm prior to intracervical insemination, intrauterine insemination (IUI) or pre-capacitating sperm prior to intrauterine insemination; in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, or (iii) the reproductive approach for low t 1 -fertility status is selected from group consisting of: in vitro fertilization (IVF), pre-capacitating sperm prior to in vitro fertilization, intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to intracytoplasmic sperm injection, gamete intra-fallopian transfer (GIFT), pre-capacitating sperm prior to gamete intra-fallopian transfer, subzonal insemination (SUZI) or pre-capacitating sperm prior to subzonal insemination.
[0078] In an instance of each of the foregoing embodiments, the identifying step is also based on one or more of the following: patient demographics, reproductive status of female partner, sperm concentration, total motility, progressive motility, semen volume, semen pH, semen viscosity and/or sperm morphology and combinations thereof.
[0079] In an instance of each of the foregoing embodiments, the more than one G M1 localization patterns include AA G M1 localization pattern, APM G M1 localization pattern, Lined-Cell G M1 localization pattern, INTER G M1 localization pattern, PAPM G M1 localization pattern, AA/PA G M1 localization pattern, ES G M1 localization pattern, and DIFF G M1 localization pattern.
[0080] In an instance of each of the foregoing embodiments, the sperm cells are treated in vitro with capacitation conditions for a capacitation time period of: at least one hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; for a capacitation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 24 hours; 12 hours to 24 hours; or 18 hours to 24 hours.
[0081] In an instance of each of the foregoing embodiments, the in vitro capacitated sperm cells are treated with a fixative for a fixative time period of: at least 0.5 hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; at least 30 hours; at least 36 hours; or at least 48 hours, for a fixation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 18 hours; 6-18 hours; 6-24 hours; 12 hours to 24 hours; 18 hours to 24 hours; 18-30 hours; 18-36 hours; 24-30 hours; 24-26 hours; 18-48 hours; 24-48 hours; or 36-48 hours.
[0082] In an instance of each of the foregoing embodiments, the sperm cells were treated to cryopreservation procedures and stored prior to being treated in vitro with capacitation conditions.
[0083] In one embodiment, the present disclosure provides for a method identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. Data are generated that illustrate one or more G M1 localization patterns of the fluorescence label treated in vitro capacitated sperm cells said data obtained at post in vitro capacitation times selected from: 0.1 hour to 5 hours; 0.1 hour to 8 hours; 0.1 to 12 hours; or 0.1 hour 18 hours (t 0 ); and times greater than t 0 (t 1 ). A male's fertility status data are then characterized using the data of one or more G M1 localization patterns at those times. Based on the male's fertility status data, a time period for insemination and a reproductive approach are identified to use in order to achieve fertilization. In one embodiment, the sperm cells were cryopreserved and stored prior to being treated in vitro with capacitation conditions.
[0084] In one such embodiment, the sperm cells are treated in vitro with capacitation conditions for a capacitation time period of: at least one hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; for a capacitation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 24 hours; 12 hours to 24 hours; or 18 hours to 24 hours. In one embodiment, capacitation conditions include in vitro exposure to 2-hydroxypropyl-β-cyclodextrin. In another embodiment, non-capacitation conditions include lack of in vitro exposure to any of bicarbonate ions, calcium ions and a mediator of sterol efflux such as 2-hydroxypropyl-β-cyclodextrin for varying periods of time.
[0085] In one such other embodiment, the in vitro capacitated sperm cells are treated with a fixative for a fixation time period of: at least 0.5 hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; for a capacitation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 24 hours; 12 hours to 24 hours; or 18 hours to 24 hours. In one embodiment, the fixative includes paraformaldehyde or glutaraldehyde.
[0086] In an instance of the foregoing embodiments, the male's fertility status data are characterized by comparing data illustrating the G M1 localization patterns of in vitro capacitated sperm cells to reference data illustrating G M1 localization patterns of in vitro capacitated sperm cells for males having a known fertility status. In one such embodiment, the number of each G M1 labeled localization patterns is determined for a predetermined number of the in vitro capacitated sperm cells. A ratio is then calculated for a sum of the number of apical acrosome (AA) G M1 localization patterns and the number of acrosomal plasma membrane (APM) G M1 localization patterns over a sum of the total number of G M1 labeled localization patterns. The ratio of G M1 localization patterns is then compared to reference ratios of G M1 localization patterns for males having a known fertility status. In such embodiments, the more than one G M1 localization patterns correspond to apical acrosome (AA) G M1 localization pattern, acrosomal plasma membrane (APM) G M1 localization pattern, Lined-Cell G M1 localization pattern, intermediate (INTER) G M1 localization pattern, post acrosomal plasma membrane (PAPM) G M1 localization pattern, apical acrosome/post acrosome (AA/PA) G M1 localization pattern, equatorial segment (ES) G M1 localization pattern, and diffuse (DIFF) G M1 localization pattern.
[0087] In another instance of the foregoing embodiments, the male's fertility status data are compared to data of known male fertility status which is associated with a known time period for insemination and associated with a known reproductive approach. In such embodiments, the known fertility status includes: fertile with sperm capacitation within 3 hours; fertile with sperm capacitation within 12 hours, fertile with capacitation between 12 and 24 hours; and non-fertile.
[0088] In the foregoing embodiments, the reproductive approach may correspond to natural insemination approaches and artificial insemination approaches as known in the art. In one embodiment, the reproductive approach includes: intercourse; intracervical insemination (ICI), intrauterine insemination (IUI), in vitro fertilization (IVF), intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to in vitro fertilization, gamete intra-fallopian transfer (GIFT), and subzonal insemination (SUZI).
[0089] For embodiments where the reproductive approach corresponds to intercourse, the time period for intercourse is determined relative to the female's timing of ovulation, as visualized with ultrasonography, and/or predicted based on timing of the menstrual cycle, use of ovulation timing kits, changes in body temperature, or timing relative to one or more injections with one or more hormones designed to induce follicular growth and ovulation. For example, the insemination time period may correspond to: 96 hours before the time of ovulation; 72 hours before the time of ovulation; 48 hours before the time of ovulation; 24 hours before the time of ovulation; 12 hours before the time of ovulation; 6 hours before the time of ovulation; or at the time of ovulation.
[0090] For embodiments where the reproductive approach corresponds to ICI or IUI, the time period for insemination is determined relative to the female's timing of ovulation, as visualized with ultrasonography, and/or predicted based on timing of the menstrual cycle, use of ovulation timing kits, changes in body temperature, or timing relative to one or more injections with one or more hormones designed to induce follicular growth and ovulation. For example, the insemination time period may correspond to: 96 hours before the time of ovulation; 72 hours before the time of ovulation; 48 hours before the time of ovulation; 24 hours before the time of ovulation; 12 hours before the time of ovulation; 6 hours before the time of ovulation; or at the time of ovulation.
[0091] For embodiments where the reproductive approach corresponds to IVF, the time period for insemination corresponds to 3 hours before determination of pronuclear formation; 4 hours before determination of pronuclear formation; 6 hours before determination of pronuclear formation; 12 hours before determination of pronuclear formation; 18 hours before determination of pronuclear formation; 24 hours before determination of pronuclear formation; or 30 hours before determination of pronuclear formation.
[0092] For embodiments where the reproductive approach corresponds to pre-capacitating sperm prior to in vitro fertilization, the time period for pre-capacitation corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0093] For embodiments where the reproductive approach corresponds to intracytoplasmic sperm injection (ICSI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0094] For embodiments where the reproductive approach corresponds to gamete intra-fallopian transfer (GIFT), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0095] For embodiments where the reproductive approach corresponds to subzonal insemination (SUZI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0096] In some instances of the foregoing embodiments, other parameters may be used to identify a time period for insemination and a reproductive approach. The other parameters may include one or more of the following: patient demographics, reproductive status of female partner, sperm concentration, total motility, progressive motility, semen volume, semen pH, semen viscosity and/or sperm morphology and combinations thereof.
[0097] In another embodiment, the present disclosure provides method of identifying an approach for achieving mammalian fertilization. In vitro capacitated sperm cells are treated with a fluorescence label. One or more fluorescence images of fluorescence labeled in vitro capacitated sperm cells are obtained. A Cap-Score value is measured for fluorescence labeled in vitro capacitated sperm sample after the sperm cells are treated in vitro with capacitation conditions for varying periods of time. The Cap-Score value is compared to reference Cap-Score values associated with males of known fertility status at those times. Based on the Cap-Score value, a time period for insemination and a reproductive approach are identified for use in order to achieve fertilization.
[0098] In one such embodiment, the sperm cells are treated in vitro with capacitation conditions for a capacitation time period of: at least one hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; for a capacitation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 24 hours; 12 hours to 24 hours; or 18 hours to 24 hours. In another embodiment, non-capacitation conditions include lack of in vitro exposure to any of bicarbonate ions, calcium ions and a mediator of sterol efflux such as 2-hydroxypropyl-β-cyclodextrin for varying periods of time.
[0099] In one other such embodiment, the in vitro capacitated sperm cells are treated with a fixative for a time period of: at least 0.5 hour; at least 3 hours; at least 12 hours; at least 18 hours; at least 24 hours; at least 30 hours; at least 36 hours; or at least 48 hours, for a fixation time period ranging between 0.5 hours to 3 hours; 3 hours to 12 hours; 6 hours to 12 hours; 3 hours to 18 hours; 6-18 hours; 6-24 hours; 12 hours to 24 hours; 18 hours to 24 hours; 18-30 hours; 18-36 hours; 24-30 hours; 24-26 hours; 18-48 hours; 24-48 hours; or 36-48 hours. In one embodiment, the fixative includes paraformaldehyde or glutaraldehyde.
[0100] In an instance of the foregoing embodiments, the Cap-Score value is compared to reference Cap-Score values for known male fertility status which is associated with known time period for insemination and associated with known reproductive approach. In such embodiments, the known fertility status includes: fertile with sperm capacitation within 3 hours; fertile with sperm capacitation within 12 hours, fertile with capacitation between 12 and 24 hours; and non-fertile.
[0101] In instances of the forgoing embodiments, Cap-Score corresponds to a ratio for a sum of a number of AA G M1 localization patterns and a number of APM G M1 localization patterns over a sum of a total number of G M1 labeled localization patterns, each determined for the in vitro capacitated sperm sample. In such embodiments, the one or more G M1 labeled localization patterns comprises AA G M1 localization pattern, APM G M1 localization pattern, Lined-Cell G M1 localization pattern, INTER G M1 localization pattern, PAPM G M1 localization pattern, AA/PA G M1 localization pattern, ES G M1 localization pattern, and DIFF G M1 localization pattern.
[0102] In the foregoing embodiments, the reproductive approach may correspond to natural insemination approaches and artificial insemination approaches as known in the art. In one embodiment, the reproductive approach includes: intercourse; intracervical insemination (ICI), intrauterine insemination (IUT), in vitro fertilization (IVF), intracytoplasmic sperm injection (ICSI), pre-capacitating sperm prior to in vitro fertilization, gamete intra-fallopian transfer (GIFT), and subzonal insemination (SUZI).
[0103] For embodiments where the reproductive approach corresponds to intercourse, the time period for intercourse is determined relative to the female's timing of ovulation, as visualized with ultrasonography, and/or predicted based on timing of the menstrual cycle, use of ovulation timing kits, changes in body temperature, or timing relative to one or more injections with one or more hormones designed to induce follicular growth and ovulation. For example, the insemination time period may correspond to: 96 hours before the time of ovulation; 72 hours before the time of ovulation; 48 hours before the time of ovulation; 24 hours before the time of ovulation; 12 hours before the time of ovulation; 6 hours before the time of ovulation; or at the time of ovulation.
[0104] For embodiments where the reproductive approach corresponds to ICI or IUI, the time period for insemination is determined relative to the female's timing of ovulation, as visualized with ultrasonography, and/or predicted based on timing of the menstrual cycle, use of ovulation timing kits, changes in body temperature, or timing relative to one or more injections with one or more hormones designed to induce follicular growth and ovulation. For example, the insemination time period may correspond to: 96 hours before the time of ovulation; 72 hours before the time of ovulation; 48 hours before the time of ovulation; 24 hours before the time of ovulation; 12 hours before the time of ovulation; 6 hours before the time of ovulation; or at the time of ovulation.
[0105] For embodiments where the reproductive approach corresponds to IVF, the time period for insemination corresponds to 3 hours before determination of pronuclear formation; 4 hours before determination of pronuclear formation; 6 hours before determination of pronuclear formation; 12 hours before determination of pronuclear formation; 18 hours before determination of pronuclear formation; 24 hours before determination of pronuclear formation; or 30 hours before determination of pronuclear formation.
[0106] For embodiments where the reproductive approach corresponds to pre-capacitating sperm prior to in vitro fertilization, the time period for pre-capacitation corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0107] For embodiments where the reproductive approach corresponds to intracytoplasmic sperm injection (ICSI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0108] For embodiments where the reproductive approach corresponds to gamete intra-fallopian transfer (“GIFT”), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0109] For embodiments where the reproductive approach corresponds to subzonal insemination (SUZI), the time period for pre-capacitation prior to insemination corresponds to incubating sperm in media containing one or more stimuli for capacitation, for periods of 24 hours before insemination; 18 hours before insemination; 12 hours before insemination; 6 hours before insemination; 4 hours before insemination; 3 hours before insemination; or 1 hour before insemination.
[0110] In yet another embodiment, the present disclosure provides for a method of identifying an appropriate mechanism for achieving successful mammalian pregnancy. In vitro capacitated sperm cells are treated with a fluorescence label. One or more fluorescence images of fluorescence labeled in vitro capacitated sperm cells are obtained. A Cap-Score value is measured for fluorescence labeled in vitro capacitated sperm sample after the sperm cells are treated in vitro with capacitation conditions for varying periods of time. The Cap-Score value is compared to a reference Cap-Score value associated with fertile males. An appropriate mechanism to achieve a successful pregnancy is determined based on the Cap-Score value. In one embodiment, the determination is also based on one or more of the following: patient demographics, reproductive status of female partner sperm concentration, total motility, progressive motility, semen volume, semen pH, semen viscosity and/or sperm morphology.
[0111] In an instance of any of the foregoing embodiments, a semen sample is processed using a wide orifice pipette having an orifice of sufficient size in diameter to prevent shearing of a sperm membrane and the semen sample is processed without use of a reagent that can damage sperm membranes. In one such embodiment, the processed semen sample is exposed to capacitating media, fixative, and reagents for determining G M1 localization patterns.
[0112] In an embodiment, a reagent that can damage sperm membranes is selected from the group consisting of: (i) a protease; (ii) a nuclease (iii) a mucolytic agent; (iv) a lipase; (v) an esterase and (vi) Glycoside hydrolases. Examples of compounds which may similarly interfere with the ability of sperm to respond to capacitation stimuli include: (i) a protease, including but not limited to, chymotrypsin, trypsin, collagenase, bromelain; (ii) a nucleases, including but not limited to, Dornase, HindIII, EcoRI; (iii) a mucolytic agent, including but not limited to, Erdostein, Acetylcysteine, Guiafenesin; (iv) a lipase, including but not limited to, Phospholipase A1, Phospholipase C, Lipoprotein lipase; (v) an esterase, including but not limited to, Cholinesterase, Thioesterase, Alkaline phosphatase; and (vi) Glycoside hydrolases, including but not limited to, Alpha-amylase, beta-galactosidase, hyaluronidase, neuorminodases, and lysozyme.
[0113] In instances of any of the foregoing embodiments, the population size for one or more G M1 labeled localization patterns is determined, such that the percent change about Cap-Score is minimized within an individual. In some such embodiments, the one or more G M1 labeled localization patterns comprises AA G M1 localization pattern, APM G M1 localization pattern, Lined-Cell G M1 localization pattern, intermediate (INTER) G M1 localization pattern, post acrosomal plasma membrane (PAPM) G M1 localization pattern, apical acrosome/post acrosome (AA/PA) G M1 localization pattern, equatorial segment (ES) G M1 localization pattern, and diffuse (DIFF) G M1 localization pattern.
EXAMPLES
[0114] The following examples further describe and demonstrate illustrative embodiments within the scope of the present invention. The examples are given solely for illustration and are not to be construed as limitations of this invention as many variations are possible without departing from the spirit and scope thereof.
Example 1
Sperm Handling Methods
[0115] Three common methods to reduce viscosity were evaluated. Ejaculates were: 1) Incubated for 0.25, 1.25 or 2 hours, 2) diluted 1:1 with Modified Human Tubal Fluid (Irvine Scientific; Santa Anna, Calif.) and then passed through a wide orifice transfer pipette (“WOTP”) or a Pasteur pipette (“PP”), 3) Enzymatically digested with chymotrypsin (“chymo”). Pilot studies revealed that passage through a hypodermic needle negatively affected motility and membrane integrity and was not studied further. After liquefaction, samples were washed and incubated under capacitating (CAP) and non-capacitating (NC) conditions. Cap-Score values were obtained via fluorescence microscopy according to the calculation described above.
Reliability and Reproducibility of Cap-Score™
[0116] Following liquefaction of semen samples from consenting men, sperm were washed, incubated, fixed and then evaluated via fluorescence microscopy for G M1 localization patterns. Precision of scoring within one sample, and variation between readers scoring the same samples were both assessed. Student's t-Test employing unequal variance was done using Microsoft Excel (2013).
[0000] Cap-Score Correlation with Traditional Semen Analysis Parameters
[0117] Semen samples from consenting patients were liquefied, washed and incubated under both non-capacitating and capacitating conditions. Semen analysis was performed according to WHO guidelines. Cap-Score values were obtained via fluorescence microscopy. Statistical analyses were done using Microsoft Excel (2013) and XLSTAT (2015).
[0000] Assessment of Capacitation using Cap-Score™ For Males of Demonstrated Fertility Compared to Males Being Assessed for Fertility
[0118] The Cap-Score values were determined on consenting men from two cohorts: 1) known fertility (pregnant partner or fathering a child less than 3 years old), and 2) patients seeking their first semen analysis. Following liquefaction, sperm were washed and 3 million incubated for 3 hour under non-capacitating (NC) and capacitating (CAP) conditions. Sperm were fixed overnight and G M1 localization patterns assessed via fluorescence microscopy.
Results
[0119] Liquefaction time, dilution and pipetting did not alter Cap-Score values. Control (incubation only), WOTP and PP treated samples had Cap-Score values of 41±4, 40±5, and 41±6 (n=5; CAP). A decrease in response to capacitating stimuli was observed when samples were liquefied using chymo (P=0.03). Control samples had Cap-Score values of 40±6 (n=5; CAP) whereas samples enzymatically liquefied had Cap-Score values of 31±4 (n=5; CAP). Because chymo is a protease that can cut membrane proteins, it was examined to determine if the reduced Cap-Score value resulted from an alteration in labeling. Samples not exposed to capacitation stimuli were compared and no difference was observed. Control and enzymatically liquefied samples had Cap-Score values of 22±4 and 21±5 (n=5; NC). These data support the view that treating semen with chymo, although widely used in clinical practice, can inhibit the ability of sperm to respond to capacitation stimuli.
[0120] Classes of compounds which may similarly interfere with the ability of sperm to respond to capacitation stimuli include: (i) a protease, including but not limited to, chymotrypsin, trypsin, collagenase, bromelain; (ii) a nucleases, including but not limited to, Dornase, HindIII, EcoRI; (iii) a mucolytic agent, including but not limited to, Erdostein, Acetylcysteine, Guiafenesin; (iv) a lipase, including but not limited to, Phospholipase A1, Phospholipase C, Lipoprotein lipase; (v) an esterase, including but not limited to, Cholinesterase, Thioesterase, Alkaline phosphatase; and (vi) Glycoside hydrolases, including but not limited to, Alpha-amylase, beta-galactosidase, hyaluronidase, neuorminodases, and lysozyme.
[0121] Liquefaction times of up to 2 hours and mechanical liquefaction using WOTP and/or PP did not influence capacitation. In contrast, the use of enzymes such as chymo reduced the ability of sperm to capacitate, as measured by Cap-Score™ Test. These results demonstrate the importance of knowing how semen processing methods impact sperm function.
[0122] Precision was evaluated by comparing the percent change about Cap-Score values (% Δ=(y 2 −y 1 )/y 2 ) when 50, 100, 150 and 200 sperm were evaluated. Changes in values of 11, 6 and 5% were observed for each addition of 50 sperm (n≦23). To be conservative, Cap-Score value was determined by counting the G M1 localization patterns of at least 150 cells. To assess variation within and between readers, 8 large image files containing up to 5,000 sperm were generated by combining images taken from multiple visual fields. Two different readers were trained and they determined Cap-Score values by randomly resampling each image 20 times, counting 150 cells each time. When scoring the same sample, individual readers reported an average SD of three (3) Cap-Score units. The difference between readers when scoring the same sample ranged from 0.00 to 1.52, with an average difference of one (1) between the readers for any given sample. Applying the Bonferroni correction for multiple comparisons, no difference between readers was observed for any image file (p-values ranged from 0.02 to 0.99).
[0123] Cap-Score was not affected by liquefaction time or mechanical liquefaction with WOTP or PP (n=5), though after washing and incubation, samples that had undergone two (2) hours liquefaction or passage through a PP showed a greater decline in motility (p=0.02, 3E-3). Use of a needle damaged sperm and was not investigated further. Liquefaction with chymo reduced Cap-Scores in CAP (p=0.03), but not NC samples (p=0.74). Samples incubated with chymo (n=5; 3 mg/ml) could not be scored due to membrane damage, yet showed an increase in motility under NC conditions (p=9E-4).
Example 2
[0124] This example was conducted using a cohort comparison between fertile (cohort 1, pregnant or recent father) and potential subfertile/infertile men (cohort 2, men questioning fertility). Relationships between Cap-Score and traditional semen measures were also explored.
[0125] All studies approved by WIRB (20152233). Semen samples were liquefied, washed, and incubated under non-capacitating and capacitating conditions. Sperm were fixed overnight and Cap-Score determined via fluorescence microscopy. Semen quality measures were evaluated according to WHO. T-Test, ANOVA and correlation analyses were done using Microsoft Excel (2013) and XLSTAT.
[0126] The mean Cap-Score for cohort 1 was 35.3 (SD=7.7%; n=76 donors; 187 collections). Cap-Scores were lower for cohort 2 (p=1.0E-03), with 33.6% (41/122) having Cap-Scores below one (1) SD below the mean for cohort 1, versus an expected 16%. For cohort 2, no relationship was observed between Cap-Score and morphology (p=0.28), motility (p=0.14) or concentration (p=0.67). 93.4% (114/122) of men in cohort 2 exhibited normal motility, yet 30.7% (35/114) of them had Cap-Scores below one (1) SD below the mean. Similarly, 101 of 122 men (82.7%) exhibited normal concentration with 32.6% (33/101) having Cap-Scores below one (1) SD below the mean. These results show that capacitation defects are common in men having difficulty conceiving and the Cap-Score provides functional data that complement semen analysis.
[0127] The ability of sperm to capacitate differs between fertile men and those having trouble conceiving. Because capacitation is required for fertilization, the Cap-Score can provide an important functional complement to standard semen analysis and may help in choosing the most appropriate fertility treatment.
[0128] Common measures of semen quality are subjective and can vary within and among readers, making the assessment of male fertility challenging. The Cap-Score™ Test evaluates the ability of sperm to capacitate, a necessity for male fertility. The data presented here show that the Cap-Score™ Test is highly reproducible and reliable within and between readers, which are key considerations when attempting to diagnose male infertility.
[0129] The Cap-Score mean (μ=39) and SD (σ=7) from 41 fertile men were used to estimate the number of known fertile men needed for establishing a robust fertile capacitation profile. For a power analysis, an acceptable range about the mean was set at 3% and a two-tailed t-test at the p<0.01 level, with a probability of detecting a difference this large of 90% were applied. Results suggested that a valid standard can be established with ≧85 individuals. A preliminary normal fertile standard was created using 125 observations from 41 unique donors. The Cap-Score values were averaged by donor and then converted to z-scores ((X−μ)/σ; X=observation, μ=39; σ=7). This transformed the μ to 0 and the σ to 1, with converted values representing the distance from the μ (mean) in units of σ (S.D.). The normal fertile standard was tested against Cap-Score values from 93 men seeking fertility exams. This cohort scored significantly below the fertile population (p=1.6E-5), with 27 and 38% having z-scores≦−2 and between −1 and −2. Only 35% scored near or above the mean. These data suggest that, in comparison to fertile men, many men seeking fertility exams have defects in capacitation.
Example 3
[0130] The procedures used in Examples 1 and 2 were used in Example 3.
[0131] Classic semen analyses provide little information on the ability of samples to fertilize and egg. Capacitation is required for fertilization and can be assessed using G M1 localization. A comparison of the Cap-Score values from two cohorts of men revealed significant differences in their ability to capacitate. A robust capacitation profile can be defined and employed for identifying abnormalities. Remarkably, 33% of men questioning their fertility had z-scores≦−1, versus an expected result of 16%. Combining the Cap-Score™ Test with traditional analyses should prove valuable in diagnosing male infertility.
[0132] Samples from 122 men referred to an infertility specialist were analyzed and had Cap-Scores ranging from 13 to 52%. An analysis of variance was done to compare Cap-Score values and sperm morphology. Samples were classified as having 0, 1, 2, 3, or ≧4% normal forms (scores≧4% are considered normal, WHO) and mean Cap-Scores were compared among the groups. No relationship between Cap-Score value and morphology was observed (P=0.67). Next, sperm concentration (range 3×10 6 to 210×10 6 /mL) was compared to Cap-Score value using the Pearson product-moment correlation coefficient and no connection was found (r=0.01, P=0.90). Lastly, Cap-Score value was compared to total % motility (range 15 to 80%) and the two measures were determined to be independent (r=0.14 P=0.21). Multiple donors who were classified as normal by WHO criteria had Cap-Score values more than two (2) SD below the normal mean, supporting the view that even normal appearing sperm can have functional abnormalities.
[0133] Traditional semen analysis identifies only 50% of male infertility cases. This study shows that there is little relationship between Cap-Score value and standard semen analysis parameters. Since capacitation is necessary for fertilization, the addition of the Cap-Score test to traditional semen evaluations could both identify cases of idiopathic infertility and help clinicians counsel couples towards the most appropriate treatment
[0134] The data presented herein demonstrate that a male's Cap-Score value may provide guidance on an appropriate mechanism for achieving successful mammalian pregnancies, including recommended assisted reproductive technology such as in vitro fertilization (IVF), or intracytoplasmic sperm injection (ICSI). The male may be a human or a non-human mammal. The Cap-Score value in combination with other components of a semen analysis, including concentration, total motility, progressive motility, volume, pH, viscosity and/or morphology may be considered. For example, the recommended assisted reproductive technology for two males with the same Cap-Score may differ if their sperm counts or sperm motility differ. In addition, the fertility status or reproductive health of the female partner would also be considered by the clinician.
Example 4
[0135] Semen samples from consenting men were liquefied, washed and aliquots incubated under non-capacitating (NC) or capacitating (CAP) conditions. The consenting men included men who were classified as fertile based on a pregnant partner or the male being a recent biological father. The consenting men also included men seeking fertility exams. Capacitation conditions include in vitro exposure to 2-hydroxypropyl-β-cyclodextrin. Non-capacitation conditions include lack of in vitro exposure to any of bicarbonate ions, calcium ions and a mediator of sterol efflux such as 2-hydroxypropyl-β-cyclodextrin for varying periods of time. The in vitro capacitated sperm and the in vitro non-capacitated sperm were then fixed in a fixative such as paraformaldehyde or glutaraldehyde. The fixed in vitro capacitated sperm and the in vitro non-capacitated sperm were then labeled with a fluorescent labeled cholera toxin b subunit.
[0136] For one dataset, the sperm samples were incubated in capacitation or non-capacitation conditions for three (3) hours, fixed, labeled and then analyzed (“day0”). For a second dataset, the sperm samples were incubated in capacitation or non-capacitation conditions for three (3) hours, fixed overnight, labeled and then analyzed (“day1”). For a third dataset, the sperm samples were incubated in capacitation or non-capacitation conditions for three (3) hours, fixed, labeled and then analyzed. For a third dataset, the sperm samples were incubated in capacitation or non-capacitation conditions for 24 hours, fixed, labeled and then analyzed (“24 hrCap”). Sperm capacitation was assessed using localization of G M1 (Cap-Score™).
[0137] 102 sperm samples from 36 fertile men were evaluated at day0 and day1. Between day0 and day1, an increase in Cap-Score was observed in 81% (83/102) of sperm samples, with 44% of the sperm samples (45/102) having an increase in in Cap-Score of more than one (1) standard deviation (7%).
[0138] Sperm samples from 17 men seeking fertility treatment were evaluated at day0 and day 1. Between day0 and day1, an increase in Cap-Score was observed in 29% (5/17) where the Cap-Scores increased more than one (1) standard deviation (7%).
[0139] To determine whether this change in Cap-Score was physiological or an artifact of being in fixative overnight, semen samples from nine (9) fertile men were analyzed at day0, day1 and after 24 hours of in vitro incubation in capacitation or non-capacitation medium and then fixed. All in vitro non-capacitated samples were equivalent (Cap-Scores of 19±2, 23±2 and 20±1%) and were different from the in vitro capacitated samples (Cap-Scores of 28±1, 34±2 and 31±2%, respectively). The Cap-Scores on day1 were significantly greater than the Cap-Scores for day0 (p=0.03). However, the Cap-Scores for in vitro capacitated samples incubated overnight in the fixative (day1) or in capacitating medium (24 hrCap) were the same (p=0.33).
[0140] Consistent with prior literature, these data show that sperm membrane changes involved in capacitation still occur over time in certain fixatives. These data suggest that sperm achieve capacitation at different times in different ejaculates. To see if this was reproducible for an individual, 91 samples from 25 fertile men were classified as either early or late capacitators (day1-day0>7). The average concordance of change within donors was 76%, showing that capacitation timing was highly consistent within men.
Example 5
[0141] Semen samples from 8 fertile men (pregnant partner or recent father) were used to examine the effect of cryopreservation on capacitation timing. Liquefied ejaculates were split; half processed immediately (fresh) and the other cryopreserved in test yolk buffer with glycerol (Irvine Scientific). Cryopreserved samples were subsequently thawed and processed (CryoT). Fresh and CryoT aliquots were washed and then incubated under non-capacitating (NC) and capacitating (CAP) conditions for 3 hours. Capacitation timing differs among men and can be evaluated by comparing Cap-Score differences from day 1 (after overnight incubation under conditions that promote/allow capacitation) to day 0 (analyzed after 3 hours incubation).
[0142] Cap-Score increased in NC CryoT treatments for both day 0 and day 1 when compared to fresh. For day 0 there was a 155% increase ((fresh−CryoT)/fresh; 11±1.6% vs 28±2.4%; n=7; p=0.00) and a 79% increase for day 1 (19±2.6% vs 34±2.7%; n=8; p=0.00). Conversely, Cap-Score for CAP treatments remained the same for both day 0 (26±3.1% vs 30±2.5%; n=7; p=0.31,) and day 1 (34±2.9% vs 34±1.7%; n=8; p=0.86,). Average post-thaw and post wash motilities of 27±3.5% and 31±8.6% for CryoT samples suggest reasonable post-thaw viability. When samples for day 0 and day 1 were compared, no difference in capacitation timing (day 1-day 0; n=7) was observed between fresh and CryoT samples for NC (10±2.2% vs 8±2.7%) or CAP treatments (8±3.8% vs 5±2.3%).
Example 6
[0143] All procedures, for specimen collection, were approved by WIRE (Protocol #20152233). Semen samples were collected from consenting men by manual masturbation after a minimum of 2 and a maximum of 5 days of sexual abstinence. Those samples having fewer than 10×10 6 motile sperm cells were discarded from this study.
[0144] Ejaculates were liquefied at 37° C. for at least 15 minutes and for no more than two (2) hours. Subsequent to liquefaction, the sperm were removed from the seminal plasma by centrifugation through Enhance S-Plus Cell Isolation Media (Vitrolife, reference: 15232 ESP-100-90%) at 300×g for 10 minutes. The cells were collected, resuspended in ˜4 ml of Modified Human Tubal Fluid medium (mHTF; Irvine Scientific; reference 90126) and pelleted at 600×g for 10 minutes. The sperm were resuspended in mHTF with and without capacitation stimuli and incubated for three (3) hours. Following incubation, the samples were fixed as described (Selvaraj V, et al., “Segregation of micron-scale membrane sub-domains in live murine sperm,” J Cell Physiol. 206: 636-46 (2006)) with paraformaldehyde (Electron Microscopy Sciences; Hatfield, Pa.) for at least 30 minutes prior to labeling.
[0145] Samples were labeled with 2 μg/mL of Cholera Toxin B, conjugated with Alexa Fluor 488 (CTB; Thermo Fisher: C34775). After ten minutes, 5 μl of the labeled sperm were placed on a microscope slide, overlaid with a cover slip and moved to an imaging station.
[0146] Imaging stations consisted of Nikon Eclipse NI-E microscopes equipped with: CFI60 Plan Apochromat Lambda 40× Objectives, C-FL AT GFP/FITC Long Pass Filter Sets, Hamamatsu ORCA-Flash 4.0 cameras, H101F—ProScan III Open Frame Upright Motorized H101F Flat Top Microscope Stages, and 64 bit imaging workstations running NIS Elements software (Nikon; Melville, N.Y.). These systems were programmed to automatically capture sets of 15×15 stitched images containing up to 5,000 sperm.
[0147] The Cap-Score SFT detects and analyzes localization patterns of the ganglioside G M1 . Two independent readers were trained to identify G M1 localization patterns that have been associated with capacitation of human sperm. The proportion of sperm within a sample having undergone capacitation was determined and reported as the Cap-Score.
[0148] Power Analysis was done using G*power (Faul et al., “G*Power 3: A flexible statistical power analysis program for the social, behavioral, and biomedical sciences,” Behav Res Methods. 39: 175-91 (2007)). Student's t-Test was done using Microsoft Excel (2013). Linear Regression and Bartlett's test of homoscedasticity were carried out in XLSTAT Version 2015.5.01.22912.
Results
[0149] The first step in determining Cap-Score precision was to define the number of cells to count per sample. In general, as the number of cells counted increases, there is an increase in precision. However, at some point counting additional cells becomes redundant, as the Cap-Score will not change with additional observations. To identify the point when counting additional cells is unnecessary, the percent change about Cap-Score when 50, 100, 150 and 200 sperm was evaluated (Table 1).
[0000] TABLE 1 Percent change in Cap-Score with increasing number of counted sperm. No. of No. counted Mean of 95% CI sperm % Δ STDEV Obs. SEM LL UL from 50 to 100 11% 9% 23 2% 7% 14% from 100 to 150 6% 5% 26 1% 4% 8% from 150 to 200 5% 3% 26 1% 4% 6%
The percent change in Cap-Score when counting 50 or 100 sperm was large when compared to the percent change when counting 100 or 150 and 150 or 200 sperm. These observations supported the view that Cap-Score precision was only modestly improved by counting more than 100 sperm. However, the 95% confidence intervals for the percent change when counting 50 or 100 and 150 or 200 did not overlap, suggesting a significant reduction in percent change when at least 150 cells were counted. To be conservative, Cap-Score was determined by counting the G M1 localization patterns of at least 150 cells.
[0150] To further explore Cap-Score reliability and assess its potential as an objective measure of semen quality, its measurement was investigated to determine its accuracy within individual readers. Accuracy is defined as the proximity of measurements to the true value. The true value of an unknown population can be estimated by its central tendency, or the mean. One can judge whether a data set has a strong or a weak central tendency based on its dispersion, or the inverse of precision (JCGM/WG2 2008). That is to say that as dispersion increases, there is a decrease in precision. The standard deviation (SD) and Coefficient of Variation (CoV) measure the amount of dispersion within a sample. A standard deviation close to zero (0) indicates that the data points tend to be clustered tightly about the mean, while a high standard deviation indicates that the data points are spread out. Similarly, the CoV represents the amount of dispersion relative to the mean (CoV=SD/mean) and is useful for comparing the degree of variation from one data series to another, even if the means are drastically different from each other.
[0151] Prior to evaluating Cap-Score accuracy within readers, the number of images for each reader to sample was estimated. To this end, two semen donor groups were defined based on a cut-off of one (1) SD below the mean Cap-Score for a population of men with presumed fertility (pregnant wife or child less than 3 years old). The mean Cap-Score for the group with “lower Cap-Scores” was 27 and the “presumed fertile” group was 40. The standard deviations for each group were 5.2 and 4.9 respectively. A power analysis using a two-tailed test was done at the p<0.05 and p<0.01 level, with a probability of detecting a difference this large, if it exists, of 90% (1−beta=0.90). The results of these analyses indicated that sample 10 and 14 images respectively (5 and 7 per group) should be sampled. To be conservative, 10 images, each in the “lower Cap-Score” and “presumed fertile” groups, were generated. Sampling this number of images per group ensured that each was sufficiently interrogated to identify any differences in reproducibility that might occur because of either low- or high-value Cap-Scores.
[0152] To evaluate the accuracy of the Cap-Score SFT, two different readers determined Cap-Score by randomly resampling 10 images, that contained up to 5,000 sperm each, from the “lower Cap-Score” and “presumed fertile” groups and resampled 20 times by each reader. The SD and CoV were calculated on a per image basis for each reader. The average SD across images and readers was 3 ( FIG. 1A ) and the average CoV was 13% ( FIG. 1B ). Both the SD and CoV showed a linear relationship to Cap-Score. Thus, while there was greater dispersion associated with reading higher Cap-Scores, this appeared to result from a greater Cap-Score magnitude. These data were consistent with a high degree of accuracy, because when the same population of sperm was randomly resampled by the same or different reader, Cap-Score values were clustered tightly about the true value. Since these measure of variance and (or) dispersion are small and stable, they reveal a high degree of Cap-Score reproducibility within readers.
[0153] In general, a distribution can be described using its mean and variance. The mean indicates the location of the distribution, while the variance describes how dispersed the data are. One can envisage two distributions where the means are the same, yet the variances are different. For example, one distribution might resemble a normal bell shape, while the other is flatter having more extreme values. To demonstrate similar Cap-Score distributions between readers, 10 stitched images were obtained each for the “lower Cap-Score” and “presumed fertile” groups. Two different readers determined Cap-Scores by randomly resampling each image 20 times. Since each image file contained several magnitudes more sperm than were being sampled, each random resampling represented a distinct subsample of cells from within an individual ejaculate.
[0154] An average difference of one (1) in mean Cap-Score was observed between the readers for the 20 different images ( FIG. 3 ). When the Bonferroni correction was applied, no discernable differences were observed. Similarly, Cap-Score variances were not different between readers ( FIG. 3 ). These data support the view that Cap-Score was reproducible between readers, as independent readers obtained similar Cap-Score distributions when resampling the same population of sperm. Collectively, these data provide strong evidence that the Cap-Score SFT is highly reproducible and reliable within and between readers, which are key considerations when attempting to evaluate male reproductive fitness.
[0155] The data presented in the current study demonstrate that the Cap-Score SFT is highly reproducible and reliable within and between readers. The data and image files acquired should serve as a foundation for the continued quality control (QC) and quality assurance (QA) within and among laboratories in the evaluation of Cap-Score. For example, two of the 20 image files, one each from the “lower Cap-Scores” and “presumed fertile” groups could be selected at random and scored each day to demonstrate a reader's daily ability to read Cap-Scores. If values are obtained that are outside of acceptable ranges from the established mean (Westgard et al., “A multi-rule Shewhart chart for quality control in clinical chemistry,” Clin Chem. 27: 493-50 (1981), the laboratory director can be consulted for remediation. These data can also be used to track individual readers over time and to identify potential changes in Cap-Score determination. Similarly, as new personal and (or) laboratories are trained and incorporated into the reading rotation, their reading ability can be evaluated by scoring multiple image files and comparing their Cap-Scores to established values. Such an approach would ensure comparable data both within and among laboratories. Only through continued internal and external QA and QC can high standards of sperm function evaluations be maintained.
[0156] Male fertility diagnosis has historically been plagued by the inability to assess sperm function; namely, the ability to fertilize (Oehninger et al., “Sperm functional tests,” Fertil Steril. 102: 1528-33 (2014); Wang et al., “Limitations of semen analysis as a test of male fertility and anticipated needs from newer tests,” Fertil Steril. 102: 1502-07 (2014)). Such a diagnostic capability would provide a functional complement to the descriptive assessments of traditional semen evaluations. Identifying sperm with deficiencies in fertilizing ability may allow for a more specific diagnosis of what is now categorized as idiopathic infertility. Of much greater practical importance, this information could enable a clinician to help counsel a couple toward the most appropriate form of ART to achieve pregnancy. To achieve the previously specified goal, many assays of sperm function have been suggested (e.g., hamster zona penetration assays (Barros et al., “Human Sperm Penetration into Zona-Free Hamster Oocytes as a Test to Evaluate the Sperm Fertilizing Ability,” Andrologia. 11: 197-210 (1979); Rogers et al., “Analysis of human spermatozoal fertilizing ability using zona-free ova,” Fertil Steril. 32: 664-70)1979), sperm-ZP binding tests (Liu et al., “Clinical application of sperm-oocyte interaction tests in in vitro fertilization-embryo transfer and intracytoplasmic sperm injection programs,” Fertil Steril. 82: 1251-63 (2004), and cervical mucus penetration assays (Alexander, “Evaluation of male infertility with an in vitro cervical mucus penetration test,” Fertil Steril. 36: 201-8 (1981); Menge et al., “Interrelationships among semen characteristics, antisperm antibodies, and cervical mucus penetration assays in infertile human couples.” Fertil Steril. 51: 486-92 (1989); Eggert-Kruse et al., “Prognostic value of in vitro sperm penetration into hormonally standardized human cervical mucus,” Fertil Steril. 51: 317-23 (1989). However, their use has been limited by the great difficulty in obtaining needed materials in a logistically practical fashion. To fill the current void, a diagnostic tool has been developed to evaluate the ability of sperm to undergo the physiological changes required to fertilize an oocyte.
[0157] The present disclosure may be embodied in other specific forms without departing from the spirit or essential attributes of the invention. Accordingly, reference should be made to the appended claims, rather than the foregoing specification, as indicating the scope of the disclosure. Although the foregoing description is directed to the preferred embodiments of the disclosure, it is noted that other variations and modification will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the disclosure. | The diagnosis of male infertility is based predominantly on the results of standard semen analysis for concentration, total motility, progressive motility, volume, pH, viscosity and/or morphology. When sperm enter the female reproductive tract, they must undergo a series of physiological changes, known as capacitation, in order to fertilize an egg. This process involves plasma membrane changes that occur in response to stimuli within the female tract. These changes include removal of sterols and redistribution of the ganglioside G M1 . Semen analysis identifies only half the cases of male infertility due to standard semen analysis providing little information on sperm functional competence. Previous data demonstrated that localization of the ganglioside, G M1 , identifies sub-populations of sperm capable of undergoing the functional maturation process known as capacitation and tracks strongly with fertility. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 12/656,445, filed Jan. 29, 2010 (pending), which is a continuation of U.S. application Ser. No. 10/850,077, filed May 19, 2004 (now U.S. Pat. No. 8,030,549), which applications are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of plant breeding and variety development, and more specifically, relates to the development of a new and distinct broccoli type for easier harvest.
[0004] 2. Description of Related Art
[0005] Broccoli is a native of the Mediterranean region, and has been grown in Italy from at least the time of the Roman Empire. It was a favorite vegetable in Rome where a variety called Calabrese was developed. Before the Calabrese variety was cultivated, Romans ate a purple sprouting broccoli that turned green when cooked.
[0006] During the 16th century, the popularity of broccoli spread throughout Europe and it was cultivated in the United States by the late 18th century. However, broccoli did not become a commercially important crop in the United States until after World War II. In the late 20th century broccoli became popular in the United States, and has recently been touted for its health benefits. Presently, the United States is the world's largest producer of broccoli, with most of the broccoli grown in the U.S. marketed as fresh produce. The leading broccoli-producing states are California (with approximately 90 percent of the crop), Arizona, Texas, and Oregon. Broccoli also is grown on a large scale in Spain, northern Europe, Central America and Australia.
[0007] Broccoli is a member of the Cruciferae family, as are cabbage, cauliflower, brussels sprouts, kohlrabi, turnips, mustards, and Chinese cabbage. The word broccoli comes from the Italian word “brocco”, which means arm branch, more particularly, from the word broccolo, which is the diminutive form of brocco and refers to cabbage sprout. Broccoli is plural and refers to the numerous shoots in this form of Brassica oleracea.
[0008] There are several types of broccoli, the most popular being the sprouting/Italian broccoli that includes the Calabrese-type, Brassica oleracea L convar. bonytis (L.) Alef. var. cymosa Duch. (the name adopted by the Community Plant Variety Office (CPVO)). Heading broccoli has several attributes more commonly attributed to cauliflower (an example being the Romanesco type, which is increasing in popularity). The true Calabrese type is a primitive type with many secondary heads (origination from the axils of the leaves). The heads are also split into smaller parts, that do not form a solid head.
[0009] Another broccoli, “broccoli rabe”, or, “broccoli raab” has loose green sprouting heads (more like loose broccoli than cauliflower) that are harvested and eaten as greens along with surrounding leaves.
[0010] Morphologically, cauliflower and heading broccoli are similar. The broccoli plant, however, generally produces a green head with a longer and more slender floret-stalk than cauliflower. When the main terminal head of a broccoli plant is harvested, the axillary buds lower on the main stem are induced to develop into smaller heads, which can also be harvested.
[0011] Much of the breeding of modern varieties has focused on heading types, which have been bred to produce a single, large head at the plant axis, reducing the number of secondary heads, though in some regions after the harvest of the main head secondary heads are still harvested, sometimes referred to as “asparagus broccoli”.
[0012] The most commonly grown broccoli variety is Marathon, which shows average to good vigor, with the height of the head at about 40-50 cm above the ground, and the height of the canopy at about 60-70 cm. Maturity is medium to late (70 days in the summer from planting), with secondary heads present. The color of the head is grey/green, with the head forming a medium dome in shape. The bead on the heads is fine, the stem diameter is medium, somewhat sensitive to hollow stem, and the variety has intermediate resistance to downey mildew ( Peronospora parasitica ). Marathon is best adapted to cool season cultivation, (fall, winter) and the plant density varieties between 40,000 to 80,000 plants per ha.
[0013] Most broccoli varieties grow best on well-drained soils that hold water. In sandy soils, irrigation is important for optimum plant growth and to maintain proper main head and side shoot development. Flower heads (the edible portion of sprouting broccoli) develop relative to ambient temperatures, and in the heat of summer, broccoli heads maturing in July may produce flowers and seeds more quickly (four to six days) than those maturing in the cooler spring and fall periods.
[0014] To be considered good quality, broccoli heads should be closed, dark green and tight (no yellow petals showing). A deep green, uniform head color is a desirable trait in broccoli. Broccoli heads “green” according to the amount of sunshine reaching the crown of the heads, the crown being the upper surface of the broccoli head covered by the florets. The present commercial heading broccoli varieties all have a high canopy that shades at least portions of the head, particularly at the margin of the crown, resulting in yellowing around the outer extremities of the harvested broccoli heads, sometimes even causing extensive yellowing of individual florets at the center of the crown.
[0015] Broccoli is typically planted in the range of 30,000 to 40,000 plants per hectare, though in North America it is common to plant broccoli at a higher density, of 40,000 to as high 100,000 plants per hectare. At higher densities, the broccoli plants will produce smaller heads. In common with other cole crops, broccoli can be established in the field by direct-seeding or by transplanting. Many factors, such as soil type, organic matter content and soil moisture interact to influence germination and emergence. A more uniform, as well as earlier, broccoli crop can be grown from transplants raised in plugs or flats in a greenhouse. Such transplants can be planted in the field during late April, although the plants must be hardened off before being set out.
[0016] The edible portion of broccoli is the unopened flowering heads. Broccoli heads are susceptible to a number of defects that may relate to climatic or growth aberrations, though some appear to be cultivar related. Many defects can be avoided by harvesting at the correct stage so that the heads do not become overmature. A post-mature crop will show advanced flower development, with yellowing of the heads. Over-mature plants also commonly developing fibrous stems.
[0017] Harvesting at the correct stage and proper handling afterwards are very important with broccoli, as it is a perishable commodity. For this reason, uniformity of maturity and concentrated harvesting have been the most highly desirable characteristics in broccoli varieties.
[0018] Harvested broccoli is often cooled with packed ice or a hydro-cooler immediately after harvest. Broccoli that is cooled and maintained at 32° F. and 95 to 100 percent relative humidity can be stored for 10 to 14 days. If broccoli is stored this long, however, it will begin to lose its dark green color and firmness, affecting its marketability.
[0019] Since harvesting is the single most expensive cultural operation, it is imperative that these costs be kept to a minimum. The present trend is to harvest only the main terminal heads, usually by hand. Certain mechanical harvest aids are used, but complete mechanical harvesting has not been adopted. Use of modern, more uniform hybrids has enabled growers to complete harvesting in two or, at the most, three manual cuts through the field.
[0020] In a study reviewing harvest practices from 1985-1990 in the United States, the time required for cutting broccoli was reported to be on the order of 60 manhours/ha. Overall costs for cut/pack/haul/cool and sell was reported as $2125/ha, with the cost of the cut alone being $500/ha. The labor requirements for harvesting are well over 50% of the total labor costs for growing broccoli.
[0021] Converting from hand to machine harvesting of broccoli could reduce these labor requirements by a great deal. However, in testing different cultivars, transplant times, growing techniques and harvest methods, a recent study determined that once over mechanical harvest of broccoli inflorescences, or heads, compared to the graduated traditional hand-harvest (picking repeatedly 6 to 8 times), results in a yield reduction on the order of 49% to 60%, depending on the variety. A combination of hand harvest for the primary heads, followed by a mechanical picking of the secondary heads was proposed as reducing yield losses, though still on the order of about 23% (Dellacecca, V. 1996, New agrotechniques to promote broccoli picking. Acta Hort. (ISHS) 407:347-352).
[0022] There have been efforts aimed at the improvement of broccoli to produce varieties better suited to mechanized harvesting. One factor limiting the performance of a mechanical harvester is the phenotypic appearance of the broccoli varieties and a lack of uniformity in maturity (Casada, J. H.; Walton, L. R.; Bader, M. J. (1988) Single pass harvesting of broccoli, Am Soc Agr Eng Microfiche Collect. (fiche #88-1041) p. 11; Bon, T. A. (1997) Senior design project development of a non-selective broccoli harvester, American Society of Agricultural Engineers No. 97-1018, pp 17). Generally, there is wider acceptable maturity range for processing broccoli compared with fresh market broccoli, which requires a more uniform product (Shearer, S. A.; Jones, P. T.; Casada, J. H.; Swetnam, L. D. (1991). A cut-off saw mechanism for selective harvest of broccoli. Transactions of the American Society of Agricultural Engineers 34 (4): 16231628.)
[0023] Thus, the selection of appropriate broccoli plant types for uniformity of maturity has been identified as one factor in the success of any broccoli harvester project (Bon, T. A., 1997). Harvesting of broccoli, either by hand or machine, could also be facilitated by an elongated growth habit that results in the protrusion, or exsertion, of the head above the general level of the broccoli foliage (Baggett, J. R., Kean, D., & Kasimor, K. (1995). Inheritance of internode length and its relation to head exsertion and head size in broccoli, J. Am. Society of Hort Sci. 120 (2): 292-296).
[0024] Another issue is that in harvesting broccoli leaves attached to the severed head must be removed manually. Accomplishing this task mechanically presents a further obstacle in the development of full mechanisation of harvest. (Casada Shearer, S. A. and P. T. Jones (1991) Development of a mechanized selective harvester for cole crops, Am Soc of Agr Engineers. Albuquerque, N. Mex., Jun. 23-26, 1991, Paper #91-1018, p 17). In this regard, incorporating mechanical defoliation of the broccoli plants into a harvester design is an area undergoing investigation, in the hope that successful implementation of a defoliation operation into a harvester would improve the overall efficiency of the harvest and packing (Bon, T. A., 1997).
[0025] The successful development of mechanized harvest would greatly improve the overall efficiency of the harvest and packing (Bon, T. A., 1997). However, attempts to develop a broccoli harvester have not been successful with present day broccoli plant types, due in part to the many simultaneous problems that must be overcome in adapting broccoli varieties for mechanization. In one article this problem is presented as requiring the selection of varieties with their heads well above the ground, with a more open leaf posture, and with leaves that are well separated from (or uncover) the bottom of the head. (Chou broccoli:La recolte mecanique devient possible. A&D, 07/2001 #68. Also in UNILET informations, #107-Janvier 2001). To date, the development of a broccoli plant type simultaneously providing these multiple solutions in a commercially acceptable context has presented an insurmountable problem for the breeding community.
SUMMARY OF THE INVENTION
[0026] The present invention provides a broccoli plant adapted for ease of harvest, with the traits of an exerted head having a crown, or top of the head of the broccoli, that is higher than the leaf canopy and a harvestable head of at least about 200 grams when planted at a density of 40,000 plants per hectare, where the harvestable head comprises the top 25 centimeters of the stalk.
[0027] The invention further provides broccoli heads produced by and harvested from such broccoli plants.
[0028] In one preferred embodiment, the broccoli plants have a leafless trait along the stalk, such that within 25 centimeters of the crown the plant produces substantially no leaves or petioles having a surface area greater than about 30 square centimeters, more preferably no greater than about 20 square centimeters.
[0029] In a further improved embodiment, the broccoli plant produces substantially no leaves or petioles within 25 centimeters of the crown having a surface area of greater than about 10 square centimeters, most preferred being such a plant producing substantially no leaves or petioles within 25 centimeters of the crown.
[0030] In another preferred embodiment, the crown of the broccoli plant will be exerted at least about 10 centimeters higher than the topmost leaf of the canopy, more preferably at least about 15 centimeters higher than the topmost leaf of the canopy, and most preferred at least about 25 centimeters higher than the topmost leaf of the canopy.
[0031] In one preferred embodiment, the broccoli plant produces a harvestable head of at least about 250 grams, more preferably at least about 350 grams.
[0032] In a different preferred embodiment the broccoli plant produces a harvestable head of at least about 120 grams when planted at a density of 80,000 plants per hectare, more preferably at least about 150 grams, and most preferably at least about 200 grams when grown at that density.
[0033] The invention also provides a plurality of such broccoli plants grown in a field of broccoli. In a preferred embodiment, substantially all of the plants mature at the same time, and more preferably all of the mature plants grow to substantially the same height.
[0034] The present invention also provides a new method of producing a broccoli crop comprising the step of growing a plurality of broccoli plants and harvesting the heads of the broccoli plants by mechanical means, whereby the plants are characterized in having an exerted head having a crown higher than the leaf canopy and a harvestable head of at least about 200 grams when planted at a density of 40,000 plants per hectare, wherein the harvestable head comprises the top 25 centimeters of the stalk, and wherein the mechanical means comprises means for severing the heads and means for collecting severed heads.
[0035] In one preferred embodiment, the broccoli plant produces a uniformly green head having substantially no yellowing about the margin of the florets, on the order of about 10% or less of any floret surface showing a change from uniform green to yellow.
[0036] In a preferred embodiment of the method of the invention, the mechanical means further comprises means for grasping the heads and guiding the heads to the severing means, more preferably the severing means guided through the plurality of broccoli plants at a substantially constant height above the soil.
[0037] In a further preferred embodiment, there is provided means, and collecting means, for advancing the severing means through the plurality of broccoli plants, which are more preferably provided in a combination.
[0038] The invention also provides seed of inbred broccoli line designated 932779, a sample of such seed having been deposited as NCIMB 41218 Brassica oleracea var botrytis 932779, having a deposit date of 28 Apr. 2004, seed of an inbred broccoli plant designated 970249, a sample of such seed having been deposited NCIMB 41219 Brassica oleracea var botrytis 970249, having a deposit date of 28 Apr. 2004, and seed of an inbred broccoli plant designated 970195, a sample of such seed having been deposited as NCIMB 41216 Brassica oleracea var botrytis 970195, having a deposit date of 28 Apr. 2004.
[0039] The invention further provides hybrid broccoli seed having as one parent a plant grown from such seed, as well as a broccoli plant, or parts thereof, produced by the hybrid seed. The invention thus provides seed of a hybrid broccoli plant designated SVR 4, a sample of such seed having been deposited as NCIMB 41214 Brassica oleracea var botrytis SVR 4, having a deposit date of 28 Apr. 2004, seed of an inbred broccoli plant designated SVR 1, a sample of such seed having been deposited NCIMB 41215 Brassica oleracea var botrytis SVR 1, having a deposit date of 28 Apr. 2004, and seed of an inbred broccoli plant designated SVR 5, a sample of such seed having been deposited as NCIMB 41217 Brassica oleracea var botrytis SVR 5, having a deposit date of 28 Apr. 2004.
[0040] In a preferred such embodiment, the invention provides a plurality of such broccoli plants in a field of planted broccoli, as well as broccoli heads harvested from such a field
[0041] The invention further includes such broccoli plants, or parts thereof, transformed to contain one or more transgenes operably linked to regulatory elements functional in a broccoli plant.
[0042] The invention also includes pollen, ovules or tissue culture derived from cells of broccoli seed or plants of the invention, where the tissue culture comprises cells or protoplasts from a tissue from cells from leaves, pollen, embryos, roots, root tips, anthers, flowers, fruit, and seeds, as well as a broccoli plant regenerated from such tissue culture.
[0043] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0045] Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
[0046] FIG. 1 of the accompanying drawings is a picture showing the typical growth habit of a conventional broccoli line, General, of Seminis Seeds.
[0047] FIG. 2 of the accompanying drawings is a picture showing the growth habit of the hybrid line SVR1.
[0048] FIG. 3 of the accompanying drawings is a pedigree showing the development of the broccoli plant of the invention designated 970195.
[0049] FIG. 4 of the accompanying photographic drawings illustrates a picture of the inbred broccoli plant designated 970192.
[0050] FIG. 5 of the accompanying photographic drawings illustrates a picture of the inbred broccoli plant designated PLH42.
[0051] FIG. 6 of the accompanying photographic drawing illustrates a picture of the hybrid broccoli plant designated SVR 1.
[0052] FIG. 7 of the accompanying photographic drawing illustrates a picture of the hybrid broccoli plant designated SVR 4 growing in a field.
[0053] FIG. 8 of the accompanying photographic drawing illustrates a picture of the hybrid broccoli plants designated SVR 5 growing in a field.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0054] Technical or scientific terms used herein shall have the ordinary meaning accepted by those of skill in the art, unless defined differently herein. Descriptions of botanical terms can be found in numerous texts on the subject. See, for instance; Hickey, M., and King, C., (2001). Cambridge Illustrated Glossary of Botanical Terms , Cambridge, UK: Cambridge University Press.
[0055] Referring now to FIG. 1 , there is shown a conventional broccoli plant of the line General (Seminis Seeds). FIG. 2 shows a broccoli plant made in accordance with the present invention, the hybrid plant SVR1. The plants in FIG. 1 and FIG. 2 were grown in a field trial under similar conditions. In FIGS. 1 and 2 the leaves facing the camera have been cut away to better reveal the growth habit of the respective plants. The components of a harvested broccoli head comprises the floret clusters, the tops of which form an upper, deep green and generally convex surface, also referred to herein as the crown. Commonly, a region of the stalk supporting the floret clusters is harvested with the broccoli, and forms a part of the edible broccoli head.
[0056] The invention provides an inbred line, adapted to 100% mechanical harvest, that combines high head exsertion with a lack of leaf development on the stalk below the head ( FIG. 2 ). Some prior varieties, such as Caravel and Corvet, have shown a relatively raised head but still have large leaves prevalent on the stem directly below the head. There are also purple sprouting varieties with bushy elevated heads, again, that have many leaves on the stem below the head.
[0057] The type of broccoli described herein makes it possible to mechanically harvest a field of broccoli, with the trait of a broccoli plant having head exsertion above the plant canopy combined with a substantial absence of leaves and leaflets along the stalk immediately below the head. The variety also produces broccoli plants showing uniformity for both maturity and height, and that will produce commercially acceptable heads.
[0058] With the present invention a harvester especially adapted for harvesting the high head exsertion types is also provided, with cutting means provided for severing the heads at a point along the stalks and above the canopy, and means for collecting and conveying the severed heads.
[0059] Conventional broccoli typically has large leaves and petioles growing out of the stem up to and just below the head. The improved variety has only a few very small leaves at the same positions below the head.
[0060] The development of commercial broccoli hybrids involves the development of homozygous inbred parental lines through techniques well known to the art. Generally, two or more germplasm sources or gene pools are combined to develop superior breeding lines. Desirable inbred or parent lines are developed by continuous selection, followed up with several generations of selfing until the lines are sufficiently uniform. Alternatively, anther or microspore culture (DH lines) may be used followed by selection of the best breeding lines and testing progeny in various hybrid combinations.
[0061] Once the inbred lines that give the best hybrid performance have been identified, hybrid seed can be produced indefinitely, as long as the homogeneity and the homozygosity of the inbred parents is maintained. The term inbred broccoli plant also includes any single gene conversions of that inbred. The term single gene converted plant as used herein refers to those broccoli plants which are developed by a plant breeding technique called backcrossing wherein essentially all of the desired morphological and physiological characteristics of an inbred are recovered in addition to the single gene transferred from the donor parent into the inbred via the backcrossing technique.
[0062] For large scale hybrid seed production, different systems of cross pollination, based on self-incompatibility, or, alternatively, cytoplasmic male sterility (CMS), are used. These techniques are well known in the art. Large scale increase of the hybrid parents (inbred lines) is done by self-pollination, where necessary facilitated by increasing the concentration of CO 2 to overcome the self-incompatibility, or bud pollination using hand labor. Such large scale increase of inbred lines is most commonly done in a greenhouse or plastic house. This practice of parent line seed production leads to good quality seed and disease control. Inbred plants include broccoli types 970192, 932779, 970249, PLH42 and 970195. FIG. 3 provides a pedigree chart following the selections made in the development of 970195.
[0063] The commercial hybrid seed is produced in the open field by inter-planting rows of the seed parent and the pollinator parent, where self-incompatibility or CMS of the seed parent prevents self pollination and ensures the harvesting of hybrid F1 seed, in methods well known in the art.
[0064] For broccoli hybrid seed production, the most modern system is using CMS that was introgressed into Brassica oleracea from radish. For broccoli hybrid seed production, the modern system uses CMS that was introgressed into Brassica oleracea from radish (Ogura, H. (1968). Studies on the new male sterility in Japanese radish, with special reference to the utilization of this sterility towards practical raising of hybrid seed. Mem Fac Agric Kagoshima Univ. 6:39-78).
[0065] The head exsertion broccoli parent line has shown uniformity and stability for all traits. The parent lines have been maintained by bud-pollination (in case of self-incompatibility of the hybrid parents of the three homozygous lines deposited), or in case of CMS seed parents pollinated by its maintainer, and planted for a sufficient number of generations, with careful attention to uniformity of plant type, to ensure homozygosity and phenotypic stability. No variant traits have been observed or are expected.
[0066] The exerted broccoli type brings the head far above the canopy. The broccoli further has no large leaves in the area of the stalk that is immediately below the head, and so it can be harvested at the level of the stem in a manner that is free of interference of the leaves, including petioles, which not only eases manual harvest but makes possible the efficient once-over mechanical harvesting of the crop, in both cases saving labor costs. Conventional broccoli can only be harvested manually, making it both time consuming and costly as the product sits deep in the crop and the leaves must further be manually stripped from the stem.
[0067] The broccoli provides uniformity in other traits that will maximize yield in once-over harvest, including the timing of maturation and growth characteristics of the broccoli on the plant, as well as head exsertion (raised head) trait. The whole head and/or florets of the broccoli inbred line designated 970192 (plh26/plh33), shown in FIG. 4 , demonstrate these traits.
[0068] A further advantage of the new varieties is the uniformity of color, i.e., that the broccoli plants produce heads that stick out of the canopy and are exposed to sunlight to a higher and more consistent degree than for conventional broccoli plants, resulting in a uniformly deep green color for the product, with substantially no yellowing about the margin of the crown. The reduced canopy means that light can better reach all sides of the heads, as well as individual florets, become uniformly green after floretting, instead of being green with yellow edges as is the case with conventional broccoli being shaded along the edges by the leaf canopy. This is a very desirable characteristic for broccoli processors.
[0069] By substantially no yellowing, it is meant that the harvested heads, even when viewed from the side, show a uniform deep green color, with very little or no lightening or yellowing a the edges of the crown as a whole. This is also true for individual florets, which have greatly reduced yellowing about the floret margins. It has been observed that for the broccoli heads produced by the plants having the exerted head trait, that less than about 10% of any floret will show a change from a uniform green to yellow at the margins.
[0070] The present invention also contemplates a broccoli plant regenerated from a tissue culture of an inbred or hybrid plant of the present invention. Methods are well known in the art for tissue culture regeneration of broccoli, and further that such methods can be used for the in vitro regeneration of broccoli or transformed broccoli (see, e.g., U.S. Pat. No. 5,188,958, Moloney, et al., Feb. 23, 1993).
[0071] The development of the head exsertion broccoli type began as an effort to develop broccoli plants for easier hand or mechanical harvest in combination with good horticultural adaptation. For hand or machine harvesting an elongated growth habit of the main stem bearing the broccoli head and protrusion above the leaf canopy was the goal. This character is defined as head exsertion.
[0072] Other characteristics thought to be important for ease of harvesting were head height, along with short leaf petioles, facilitating the exsertion of the head above the canopy. Another character selected for was uniformity of head height.
[0073] The following examples are intended to illustrate but not to limit the invention.
Example 1
Development of Germplasm
[0074] Both proprietary and available public research lines were available having a raised head (RH) trait. For instance, the Oregon State University (OSU) broccoli breeding program had lines with a moderate raised head, and several accessions were obtained from the OSU breeding program. These lines were designated as OSU-102 and OSU-111. These accessions produced poor head size, poor head quality, generally, and leaves on the stem just below the head which rendered such lines unsuitable as parents for commercially viable hybrids. Selection for better raised head traits and higher internode lengths consistently led to lower head weights. (Baggett, et al., 1995). The present invention has found a solution to this problem, as further described herein.
[0075] Proprietary accessions selected at the start of the breeding project were designated DH-MRE-7, DH MRD1-1, GM1-6, B19, DH E-47, EC-2, SH2, EC-2, SH-2, DH M-84, HCH, GB-7, HBH-6 and DH GV-37. All of these lines were elite parent lines developed in the Seminis breeding program, that were used for the production of commercial hybrids as long ago as the 1970s. These lines were chosen at least partly to compensate for the defects observed of the horticultural characteristics of the OSU lines.
[0076] More specifically, the proprietary lines had very good general combining ability, resistance to disease, particularly to downy mildew ( Peronospora parasitica ), already showed reasonably good RH traits, short leaves about the head, good head height and head-height uniformity, as well as resistance to bacterial soft rot ( Erwinia and Pseudomonas bacteria). The main characteristics of each of these lines are summarized in Table 1, below.
[0000] TABLE 1 Accession or line number Description OSU-102 Compare with OSU111, little more vigor OSU-111 Small plant, average RH, leaves on stem, large bead DH-MRE-7 Downey Mildew resistant, good bead DH MRD1-1 Downey Mildew resistant, good bead GM1-6 Relatively good raised head, fine bead, good combining ability, used in many commercial Seminis hybrids (Corvet, Cruiser etc), leaves on stem below the head. B19 Earliness, combining ability, used in commercial Seminis hybrids. DH E-47 Brings in head weight and color EC-2 Relatively RH, large bead DH GV-37 Firmness and bead quality SH-2 Combining ability, genetic distance, color, vigor, wetrot tolerance HBH-6 Earliness DH M-84 Small bead, quality of head, firmness HCH Compare HBH6 GB-7 Firmness and bead quality
The designation DH designates double haploid, and indicates that this line has been developed through either anther culture or microspore culture, followed by chromosome doubling.
[0077] In general, the better RH lines had little (OSU) or average (GM1.6, EC2) head quality. In the better quality lines, i.e., having good firmness, bead size, color, Downey Mildew resistance, etc., the RH trait was generally missing. There were no lines available that combined the RH trait with suitable quality, and none that added the trait of substantially no leaves present below the head to give an exserted appearance.
[0078] The lines have been continuously crossed and selected in various combinations since the 1980s. Progeny plants (F1) of each cross were selected for their phenotypic appearance for head exsertion in combination with favorable horticultural characteristics for all other important horticultural traits of head traits. The selected plants from the best families were crossed again with other selected plants from other families. Occasionally, between two crossing cycles selected plants were selfed for one or two generations (F2, F3) to obtain better uniformity of the lines.
[0079] The best plants of these lines were crossed again. This breeding procedure is known as the modified family selection, as is described in standard text books of plant breeding, i.e., Allard, R. W., Principles of Plant Breeding (1960) New York, N.Y., Wiley, pp 485; Simmonds, N. W., Principles of Crop Improvement (1979), London, UK, Longman, pp 408; Sneep, J. et al., (1979) Tomato Breeding (p. 135-171) in: Breeding of Vegetable Crops, Mark J. Basset, (1986, editor), The Tomato crop: a scientific basis for improvement, by Atherton, J. G. & J. Rudich (editors), Plant Breeding Perspectives (1986); Fehr, Principles of Cultivar Development-Theory and Technique (1987) New York, N.Y., MacMillan.
[0080] In the course of the selection program several lines showing favorable characteristics were selected which were designated as PLH, and associated with a sequence number. Surprisingly, there is little or no discernible loss in yield in the raised head type of broccoli. This is somewhat surprising given the amount of additional stalk required to attain exsertion of a heavy head from the foliage.
[0081] Only after a succession of years of crossing and selection in combination with one or two generations of selfing was it shown that the genetic linkage that existed between head exsertion and poor horticultural and head quality characteristics could be broken. The progress in any generation was always small and difficult to quantify from generation to generation.
[0082] The best lines now available include 970195 (based on selection from the cross PLH 2546 and PLH 33), 970192 (selected from the cross PLH 26 with PLH 33), 970249 (selected from a cross between DH M 84 and MRD 6), 932779 (selected from a cross between PLH 10 and DC3EC6), and PLH 42 (selected from a cross between DC3EC6 and PLH 10). Seed of lines 932779, 970249, and 970195 are the subject of a NCIMB deposit. PLH 10 was itself a selection from a cross of HBH 6 and OSU-111.
[0083] A pedigree showing the development of the line 970195 is summarized in FIG. 3 , demonstrating a typical series of crosses and selections used in development of the varieties.
[0084] The whole head and/or florets of the broccoli inbred line 970192 (plh26/plh33), FIG. 4 , demonstrates the head exsertion trait in an inbred line. The head exsertion of this broccoli line has shown uniformity and stability for all traits over several years. It has been developed and maintained by bud pollination for five generations with careful attention to uniformity of plant type to ensure homozygosity and phenotypic stability. No variant traits have been observed or are expected.
[0085] Inbred lines 970195 and 970249 have similar raised head traits. Development and maintenance of these lines was analogous to that for line 970195.
[0086] PLH 42 ( FIG. 5 ), shows good head exsertion in accordance with the invention, with few, small leaves present on the stalk below the head. It has been developed and maintained by bud pollination for six generations with careful attention to uniformity of plant type to ensure homozygosity and phenotypic stability. No variant traits have been observed or are expected.
[0087] 932779 has a similar background to PLH42. It is an early maturing line that shows good head exsertion and a good quality head with nice bead and firmness, with a number of smaller leaves on the stalk below the head. The Downey mildew resistance is very high and the color of the head dark green.
Example 2
Production of Exserted Head Broccoli Hybrid
[0088] The favored inbred lines have been used to produce hybrid combinations. SVR 1 was produced by crossing PLH42×DH PLH13 ( FIG. 6 ). It has the traits of extreme RH, extreme early, extreme dark color, fine bead, good heat tolerance, good wetrot tolerance, good uniformity, Downey Mildew Resistance, DMR, fine stem, some leaves below the head, head weight 250-300 gr/head at 40.000 pl/ha, good adaptability to climate and seasons. The leaves below the head are very few, having a very small square area.
[0089] SVR 4 was produced by crossing PLH26/PLH33×NjaECB ( FIG. 7 ). It shows good RH, medium maturity, semi crown, relatively large bead, head weight 300350 gr/head at 40.000 pl/ha, with a cleaner stem than SVR1.
[0090] SVR 5 was produced by crossing PLH2546/PLH33×NjaECB. Its maturity is like SVR4, deeply branched head, medium raised head, also a cleaner stem than SVR1, head weight 350-400 gr/head at 40.000 pl/ha, extremely green floret color, all green floret, more of a processing/floretting type, with a deeply branched head ( FIG. 8 ).
Example 3
Harvesting of Exserted Head Broccoli
[0091] A field of broccoli plants is grown to maturity, and the heads harvested by mechanical means of grasping the heads, severing the heads and collecting the severed heads on a conveyor. It is found that the great majority of broccoli heads can be harvested in this manner from a field of broccoli plants, saving time and expense of hand harvesting. The exserted head trait with little or no foliage below the head allows the running of a mechanized harvest without damage to the broccoli heads or fouling of the harvester.
Deposit Information
[0092] A deposit of the Seminis Vegetable Seeds proprietary inbred and hybrid broccoli lines disclosed above and recited in the appended claims have been made with NCIMB Ltd, 23 St. Machar Drive, Aberdeen AB24 3RY. The date of each of these deposits was 28 Apr. 2004. The deposit of 2500 seeds for each variety were taken from the same deposit maintained by Seminis Vegetable Seeds since prior to the filing date of this application. Upon issuance of a patent, all restrictions upon the deposit will be removed, and the deposit is intended to meet all of the requirements of 37 C.F.R. §1.801-1.809. The NCIMB accession numbers for inbred lines 932779, 970249, and 970195 are, respectively, NCIMB 41218 Brassica oleracea var botrytis 932779, NCIMB 41219 Brassica oleracea var botrytis 970249, and NCIMB 41216 Brassica oleracea var botrytis 970195. Hybrid broccoli seed SVR 4, SVR 1 and SVR 5 have NCIMB accession number, respectively, NCIMB 41214 Brassica oleracea var botrytis SVR 4, NCIMB 41215 Brassica oleracea var botrytis SVR 1, and NCIMB 41217 Brassica oleracea var botrytis SVR 5. These deposits will be maintained in the depository for a period of 30 years, or 5 years after the last request, or for the effective life of the patent, whichever is longer, and will be replaced as necessary during that period.
[0093] The patent or application file contains at least one color drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0094] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity and understanding, it will be obvious that certain changes and modifications may be practiced within the scope of the invention, as limited only by the scope of the appended claims. | A broccoli plant characterized in having an exerted head having a crown higher than the leaf canopy and a harvestable head of at least about 200 grams when planted at a density of 40,000 plants per hectare, where the harvestable head comprises the top 25 centimeters of said stalk. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to a combined reverse osmosis/continuous electrodeionization water treatment system and, more particularly, to a combined reverse osmosis/continuous electrodeionization water treatment system for producing high-purity water.
2. Description of the Prior Art
The requirement for high-purity water with particular properties has evolved in several industries including the electronics industry, the power industry, and the pharmaceutical industry. The water purity requirements of the semiconductor industry are among the most stringent of any industry. Typically these applications require treatment of a source water supply (such as a municipal water supply) to reduce the level of contaminants. High-purity water processing procedures and the hardware required for carrying out the processing are complex and expensive. A current high-purity water specification is available in the ASTM D 5127-99 standard for electronics and semiconductor industry.
Ion exchanging resins have been used to produce deionized water. Other well known processes that can be used for water purification include distillation, electrodialysis, reverse osmosis, and liquid chromatography. These ion exchanging resins generally require chemical regeneration. On-site ion exchange regeneration requires aggressive chemicals that are dangerous to handle. Removal of the spent chemicals must be dealt with in a manner that is safe for the environment. In this respect, attention has been drawn in recent years to a self-regenerating type deionizing apparatus. To avoid the use of aggressive chemicals, a deionizing function of the ion exchanging resins and an electrodialysis function of ion exchange membranes are combined in an electrodeionization apparatus to obtain high-purity deionized water without chemical regeneration (U.S. Pat. No. 6,274,019). Electrodeionization is a water purification technique that utilizes ion exchanging resins, ion exchange membranes, and electricity to deionize water (for a more detailed discussion see Wilkins, F. C., and McConnelee, P. A. “Continuous Deionization in the Preparation of Micro-electronics Grade Water”, Solid State Technology, pp 87-92, August 1988). Electrodeionization is differentiated from electrodialysis by the presence of ion exchange resin in the purifying compartments. Illustrative of other prior art attempts to use the combination of electrodialysis and ion exchanging resins to purify saline from are described in U.S. Pat. Nos. 2,796,395; 2,947,688; 2,923,674; 3,014,855; 3,384,568; and 4,165,273.
The use of electrodeionization is disclosed in U.S. Pat. Nos. 2,689,826; 2,815,320; 3,149,061; 3,291,713; 3,330,750; and many others. A commercially successful electrodeionization apparatus and process is described in U.S. Pat. No. 4,632,745. The basic repeating element, called a cell pair, consists of a purifying compartment, bounded on each side by an anion membrane and a cation membrane, which is filled with a mixed bed ion exchanging resin, and a concentrating compartment (see Wilkins and McConnelee). The feedwater entering the electrodeionization apparatus is separated into at least three parts. A small percentage flows over the electrodes, a majority of the feed water passes through the purifying compartment and the remainder passes along the concentrating compartments. Under the influence of D.C. Potential, ions in the purifying compartment are transferred into the adjacent concentrating compartment. Ions entering the resin-filled purifying compartment transfer through the resin and the ion exchange membranes in the direction of the electrical potential gradient, into the concentrating compartment (See Liang, L. S., Wood, J., and Hass W., “Design and Performance of Electrodeionization System in Power Plant Applications”, Ultrapure Water pp, 41-48, October 1992). As a result, ions in the water will become depleted in the purifying compartments and will be concentrated in the adjacent concentrating compartments. The third stream is the electrode stream that sweeps past the electrodes removing gases from electrode reactions as it flows. The percentage of the incoming feedwater that becomes purified product is referred to as the recovery of the system. In conventional electrodeionization systems with reverse osmosis product as feed, the concentrate stream can typically be recirculated to obtain recoveries in the range of 80 to 95% (see Liang et al.). U.S. Pat. No. 6,193,869 discloses the use of modular system design.
The power supply may be a constant current or a constant voltage power supply. Presently, electrodeionization apparatuses typically operate using a constant voltage power supply, in which the current is varied to maintain a constant voltage. Unfortunately, it has been observed that the electrical impedance of electrodeionization apparatuses increases with the age of the module. This impedance increase means that as the electrodeionization apparatus ages, the current passing through the apparatus decreases when powered with a constant voltage power supply (as described in U.S. Pat. No. 6,365,023). This results in the poor treated water quality from the electrodeionization apparatus. Similarly, a new electrodeionization apparatus having low impedance and run at a constant voltage can produce a very high current. Further, scaling of electrodeionization apparatus can be a problem where there is more current than necessary applied to the apparatus. Impedance of an electrodeionization apparatus increases with decreasing temperature. As a result, the risk of scaling may be low in winter. U.S. Pat. No. 6,365,023 suggests the use of constant-current power supply. Ionic removal is accomplished here by supplying a constant electrical current in the range of about 1.5 to 15 times a theoretical minimum current.
In electrodeionization devices a gasket positioned between anion and cation exchange membranes forms purifying compartments. U.S. Pat. Nos. 4,632,745; 4,747,929; 4,925,541; 4,931,160; 4,956,071; and 5,120,416 describe gasket design in electrodeionization apparatus. A need also exists for a gasket that assures good fluid flow and electrical current distribution and that has a low overall pressure drop for fluid flow (see for example U.S. Pat. No. 6,123,823).
U.S. Pat. No. 4,925,541 discloses a plate and frame electrodeionization apparatus and method. Plate and frame apparatuses are large in size and typically suffer from leaks because of the difficulty in sealing large vessels. Spiral-wound modules (U.S. Pat. No. 5,376,253 and Rychen P., Alonso S., and Alt H. P., “High-purity Water Production with the Latest Modular Electrodeionization Technology”, Ultrapure Water Europe, Amsterdam, 1996) and helical modules (U.S. Pat. No. 6,190,528) are also available.
The ion exchanging materials are commonly mixtures of cation exchanging resins and anion exchanging resins (e.g. U.S. Pat. No. 4,632,745), but alternating layers of these resins have also been described (e.g. U.S. Pat. Nos. 5,858,191 and 5,308,467). Because of their ability to exchange counter-ions, ion exchange resins are electrically conductive (Heymann E., and O'Donnell I. J., Journal of Colloid Science, Volume 4, pp 395, 1949). The resin-filled purifying compartments facilitate ion transfer along contiguous ion exchange beads by creating a low resistance electrical path, even in a highly purified solution with high resistivity (see Griffin C., “Advancements in the Use of Continuous Deionization in the Production of High-purity Water”, Ultrapure Water, pp 52-60, November 1991). A path is developed through the ion exchange resin beads that is much lower in electrical resistance than the path through the surrounding bulk solution, thereby facilitating removal of ions from the device (see Ganzi G. C., “The Ionpure™ Continuous Deionization Process: Effect of Electrical Current Distribution on Performance”, Presented at the 80 th Annual AIChE Meeting, Washington D.C., November 1988). Strongly dissociated ion exchanging resins have specific electrical resistances of order of magnitude about 100 ohm-cm, i.e., about the same as an aqueous solution containing about 0.1 gram-equivalent of sodium chloride per liter. U.S. Pat. No. 5,593,563 discloses the use of electron conductive particles such as metal particle and/or carbon particles in the cathode compartment. U.S. Pat. No. 5,868,915 discloses the use of chemical, temperature, and fouling resistant synthetic carbonaceous adsorbent particles (0.5-1.0 mm diameter) in either electrolyte compartments, purifying compartments, or concentrating compartments. It is important to note that the presence of gases, poor flow distribution, low temperature and/or low conductance liquids within the electrolyte compartments may be detrimental to electric current distribution, thereby reducing the efficiency of deionization.
Undesirably, where mixed bed ion exchanging materials are used, the thickness of the purifying compartments must be necessarily thin to maximize the transport efficiency of impurity ions through the resins to the membranes (U.S. Pat. No. 6,197,174). Thinner diluting compartments dictate higher manufacturing cost. U.S. Pat. No. 4,636,296 discloses an electrodeionization apparatus containing alternating layers of anionic and cationic exchanging resins to mitigate this problem. U.S. Pat. No. 6,197,174 discloses the use of one mixed bed phase of anion and cation resins and at least one single phase, adjacent to the mixed bed phase. U.S. Pat. No. 6,156,180 discloses the use of a continuous phase of a first ion exchanging resin material containing therein a dispersed phase of clusters of a second ion exchanging resin material in the purifying compartments. This arrangement allows an increase in the thickness and size of the purifying compartments thereby permitting more resin to be placed in the purifying compartments and decreasing the necessary membrane area for a given flow rate.
When uniform-bead size resins were placed in the purifying compartments, increased ion exchange rate and accordingly better salt removal was found (see Griffin). This is due to an increase in the resin surface area and also due to an effective increase in the amount of resin active in the electrical circuit within the system. U.S. Pat. No. 5,308,466 discloses the use of low crosslinked ion exchange resin or membrane to lower the resistance of the resin or membrane. Such resins or membranes have greater interstitial water content, a greater pore size, and a decreased charge density as compared to resins and membranes having higher degrees of crosslinking. U.S. Pat. No. 5,858,191 discloses the use of Type II anion exchanging resin material, alone or with Type I anion exchanging resin material, in anion permeable membranes and/or resins to improve the electric current distribution, degree of resin regeneration, and deionization performance. The use of doped cation exchanging resin and Type I anion exchanging resin materials in the purifying compartments to reduce the difference in conductivity between the alternating layers is disclosed in U.S. Pat. No. 6,284,124. U.S. Pat. No. 6,312,577 discloses the use of macroporous ion exchanging resins that are both highly crosslinked and have a high water content. This system provides an improved removal of weakly ionized ions, particularly silica.
When ions are readily present in the feedwater, charge will pass through the purifying compartment as ions migrate into the concentrating compartment. But as these ions are removed, a point will be reached within the electrodeionization system where insufficient ions are available to carry the charge being generated at the electrodes. The resistance across the cells will substantially increase, resulting in an increase in voltage. The voltage differential across the purifying chamber will increase until it is sufficient to split water into its H + ions and OH − ions (see Byrne W., Encyclopaedia of Water Treatment, Volume X: EDR & EDI, Version U 1.0, Wes Byrne and the Company for Educational Advancement (CEA), 1999). In electrodeionization apparatus, H + ions and OH − ions are formed by dissociation of the water to continuously regenerate the ion exchanging resins filled in the purifying compartments so that the electrodeionization apparatus can efficiently deionize water. The high electric voltage in the dilute compartment not only splits water, but also destroys some of the low molecular weight organics that pass through the preceding reverse osmosis system (Auerswald, D., “Optimising the Performance of a Reverse Osmosis/Continuous Electrodeionization System”, Ultrapure Water, pp 35-52, May/June 1996). Electric current more than the theoretical amount required to discharge ions from feedwater is supplied to cause dissociation of water in the purifying compartments so as to continuously regenerate the ion exchanging resins. The passage of 96, 500 coulombs (one Faraday) causes the transfer of one chemical equivalent of a salt theoretically.
It has been shown (see Glueckauf E., “Electro-deionisation Through a Packed Bed”, British Chemical Engineering, pp 646-651, December 1959) that the mechanism of ion removal from purifying compartments to adjacent concentrating compartments involves the diffusion of ions to the resin phase and subsequent electrical conduction within the resin phase to the bounding membranes of the purifying compartment. In order to achieve high rates of ion removal, the cation exchanging resin should be predominantly in the hydrogen form and the anion exchanging resin should be predominantly in the hydroxide form. At the end of the purifying compartments, where water is relatively free off ions, splitting of water occurs in the electric field. This generates hydrogen and hydroxyl ions. The creation of H + ions and OH − ions from water splitting allows the resins to remain in the hydrogen and hydroxide forms. Moreover, the resins in the regenerated forms can react with weakly ionized species, allowing transfer of the species that would not otherwise occur (as described by Ganzi).
The random nature of mixtures of cation and anion exchanging resins tends to cause some portion of the resins to be regenerated to a needlessly high degree and others inadequately regenerated. The achievement of a uniform distribution of water splitting is a more difficult problem and much effort has gone into designing structures that achieve this (for examples see U.S. Pat. Nos. 6,241,867; 5,858,191; 5,868,915 and 5,308,467).
Scaling has been found to occur in localized regions of electrodeionization apparatus, and particularly those where high pH is typically present. It is believed that the pH at the boundary layer increases with current. Therefore, the current needs to be maintained at a sufficiently low level to prevent or, at least ameliorate the incidence of scaling. If the current is too low, poor water quality is obtained. If the current is too high, the incidence of scaling increases (U.S. Pat. No. 6,365,023). One difficulty in utilizing electrodeionization apparatuses is the deposit of insoluble scale within the cathode compartment primarily due to the presence of calcium, magnesium, and bicarbonate ions in the liquid, which contact the basic environment of the cathode compartment. Scaling can also occur in the concentrating compartments under conditions of high water recovery. In order for calcium carbonate to precipitate in solution the Langelier Saturation Index (LSI) has to be positive. In the cathode compartment the pH can be high enough for the LSI to be positive. The LSI of reverse osmosis product water is always negative. The LSI is even negative in the electrodeionization concentrate stream. Thus, on the basis of consideration of LSI alone, one would not expect the precipitation of calcium carbonate that occurs within concentrating compartments. This phenomenon is instead explainable upon local conditions (U.S. Pat. No. 6,296,751). When the electrodeionization apparatus is in operation, pH near a surface of the anion exchange membrane locally becomes alkaline. CO 3 2− or HCO 3 − and OH − permeating the anion exchange membrane from the purifying compartments are concentrated near the anion exchange membrane. In addition, hardness contributing polyvalent cations in water in the concentrating compartments are drawn or driven to the anion exchange membrane, so that CO 3 2− or HCO 3 − and OH − react with Ca 2+ to form scales of calcium carbonate on the anion exchange membrane. Build-up of scale can result in an increase in the resistance to the flows of electricity and water through the stack. When scales are formed, the electrical resistance at the area where the scales are formed increases and less electric current flows at that section. At the extreme condition, sufficient current for ion removal cannot be applied within the maximum voltage of the device, and the quality of the treated water deteriorates. Prevention of scale formation typically focuses on removing polyvalent cations from the supply stream by adding water softener. Vendors of the electrodeionization apparatuses suggest that the concentration of calcium in the feed to the system be limited to very low levels; e.g., less than 0.5 ppm (US Filter Literature No. US2006). U.S. Pat. No. 5,308,466 discloses an electrodeionization apparatus utilizing concentrating compartments containing ion exchanging resins. If the concentrating compartments are filled with the ion exchanging resins, the OH − ions permeating through the anion exchange membrane are easy to move in the concentrating compartments, so that the scale is dispersed (U.S. Pat. No. 6,379,518). Acid may be added to convert some of the alkalinity to carbonic acid, and to increase the solubility of carbonate and sulphate salts. The addition of an acidic solution to the concentrate water is disclosed in U.S. Pat. No. 6,274,019. The use of an acidic solution in the concentrate water increases the solubility of the hardness components within the concentrate water and prevents scale formation. The use of effective amount of antiscalant in the concentrating compartments and anode and cathode compartments to inhibit precipitation of scale is disclosed in U.S. Pat. No. 6,056,878. Physical damage can be inflicted on stack components by severe scaling.
U.S. Pat. No. 6,296,751 discloses the use of first and second stages in the electrodeionization apparatus. The purifying compartments of the first stage include only anion exchanging resin or cation exchanging resin material, and thus remove either anions or cations but not the other. The purifying compartments of the second stage receive the purifying compartment effluent from the first stage and include the other type of exchanging resin or a mixed resin material and remove the oppositely charged ions. The concentrate from the first stage is isolated from the second stage to prevent the scaling of sparingly soluble salts in the concentrating compartments.
The use of opposite flow directions for supply stream and concentrate stream is disclosed in U.S. Pat. No. 6,248,226. In conjunction with the use of opposite flow direction, the introduction of a porous diaphragm or ion conducting membrane to divide the concentrating compartments into first and second compartments is disclosed in U.S. Pat. No. 6,149,788 to inhibit scaling. The porous diaphragm or ion conducting membrane effectively eliminates convective transport of scale-forming metallic cations from the cation exchange membrane side of the concentrating compartments to the anion exchange membrane side of the concentrating compartments, thereby inhibiting scale formation on the anion exchange membrane.
Deposits of colloids, organic contaminants, and other impurities on the surface of the membranes and ion exchanging resins generally result in an increase in electrical resistance: this may also result in an increase in the hydraulic resistance in the compartments of the stack and in a decrease in current efficiency (U.S. Pat. No. 5,026,465).
The use of electrodeionization polarity reversal is disclosed in U.S. Pat. No. 5,026,465 to reduce scaling and fouling tendencies by salt precipitates, colloids, organic contaminants, and other impurities. The use of polarity reversal in electrodialysis processes are disclosed in U.S. Pat. Nos. 2,863,813; 3,341,441; 4,115,225; and 4,381,232.
BRIEF SUMMARY OF INVENTION
It is the object of the invention to provide an improved combined reverse osmosis and electrodeionization system for purifying water, or to at least provide the public with a useful choice.
Accordingly to the present invention there is provided a method of water purification including the steps of passing source water through at least one reverse osmosis unit to produce a product water and reject water, directing the product water from a reverse osmosis unit into the dilution stream of a continuous electrodeionization unit, directing the reject water from the first pass reverse osmosis unit through a softening unit to produce softening unit output water with fewer hardness elements than the reject water from the first pass reverse osmosis unit, directing the softening unit output water into a concentrate stream of the continuous electrodeionization unit, and wherein the continuous electrodeionization unit further purifies the water from the dilution stream to produce purified water.
In the reverse osmosis unit source water is divided into two portions, reject portion water and product portion water. In the reverse osmosis unit the reject portion water becomes more concentrated and the product portion water more dilute as water molecules from the reject portion water pass through at least one membrane into the product portion water. The reject portion water exits the reverse osmosis unit as reject water and the product portion water exits the reverse osmosis operation as product water.
The continuous electrodeionization device has an anode, a cathode, a plurality of cation exchange membranes and a plurality of anion exchange membranes. The anion and cation exchange membranes are arranged to form an anode compartment, a cathode compartment, at least two concentration compartments and at least one purifying compartment. These compartments are formed between the anode and the cathode. A concentrate stream, including reject water from the first pass reverse osmosis operation, is provided to the concentration compartments, the anode compartment and the cathode compartment. A supply stream of reverse osmosis product water provided to the purifying compartment. When sufficient power is provided to the anode and cathode of the electrodeionization device, anions in the supply stream flow through the anion exchange membrane into a concentration compartment and cations in the supply stream flow through the cation exchange membrane into a concentration compartment. This reduces ions in the water in the purifying compartment. Water exits the purifying compartment as pure product water.
Before the reject water from the first pass reverse osmosis unit is provided to the continuous electrodeionization unit it must undergo a process to remove hardness. Four different softening processes are preferred: a standard reverse flow softener containing a uniform particle size strong acid cation resin, a weak acid cation exchanger containing resin with carboxylic acid groups, an ion exchanger containing suitable macroreticular type aminophosphonic functional groups chelating resin, or an ion exchanger containing suitable macroreticular type iminodiacetic acid functional groups chelating resin.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will be further described by way of example only and without intending to be limiting with reference to the following drawings, wherein:
FIG. 1 is a flow diagram of a preferred embodiment of water purification method of the invention;
FIG. 2 is an outline of a basic continuous electrodeionization device;
FIG. 3 is a flow diagram of one embodiment of combined reverse osmosis and continuous electrodeionization device; and
FIG. 4 is a flow diagram of another embodiment of combined reverse osmosis and continuous electrodeionization device.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the high-purity water system used in the present experimental study. The drawing is a flow chart of one embodiment for carrying out this invention, wherein are shown a raw water storage tank 1 , an in-line static mixer 2 , a multimedia filter 3 , an activated carbon filter 4 , a 1 micron nominal cartridge filter 5 , first-pass reverse osmosis membrane filter 6 , an ion exchange unit for the removal of hardness 7 , second-pass reverse osmosis membrane filter 8 , a permeate storage tank 9 , a primary UV TOC (total organic carbon) reducer 10 , a primary membrane degassifier 11 , a continuous electro-deionizer (CEDI) 12 , a primary mixed bed deionizer 13 , a deionized water storage tank 14 , a plate type heat exchanger 15 , a secondary UV TOC reducer 16 , a sacrificial polishing mixed bed deionizer 17 , a secondary membrane degassifier 18 , an UV disinfection unit 19 , a 0.1 micron absolute cartridge filter 20 , an ultrafiltration membrane 21 , an UV disinfection unit 22 in the return line, and pumps P 1 -P 5 .
City water is received in the raw water storage tank 1 and is pumped by a multi-stage vertical centrifugal pump P 1 through the multimedia filter 3 for the reduction of suspended solids. Coagulant (PAC) is added before the multimedia filter 3 for coagulation of suspended solids and an in-line static-mixer 2 is provided to ensure the proper mixing of the coagulant with water. The filtered water from multimedia filter 3 passes through the activated carbon filter 4 for the removal of organics and residual chlorine. Sodium bisulphite dosing is provided prior to the activated carbon filter 4 for the removal of free chlorine and dissolved oxygen. The treated water from the activated carbon filter 4 is then taken through a 1-micron cartridge filter 5 for the removal of fine solids.
The two-pass reverse osmosis (RO) system includes high-pressure flooded suction multi-stage vertical centrifugal pumps P 2 and P 3 , first-pass reverse osmosis membrane filters 6 and second-pass reverse osmosis membrane filters 8 . Caustic soda is added between the two passes to improve the performance of the membrane filters with respect to the rejection of weakly ionized silica, boron, and organics in the second-pass reverse osmosis membrane filter 8 . Spiral-wound polyamide composite reverse osmosis membranes are used for reverse osmosis filters 6 and 8 . The reject stream from the second-pass reverse osmosis membrane filters 8 is recycled back to the first-pass feed stream. Permeate (product water) from the two-pass reverse osmosis system is taken to permeate storage tank 9 . From the permeate storage tank 9 , water is pumped by a multi-stage vertical centrifugal pump P 4 through the primary UV TOC reducers 10 for the reduction of organic content in the water. Water from the primary UV TOC reducer 10 passes through the primary membrane degassifier 11 for the removal of dissolved gases and volatile organics. Finally it passed through the CEDI unit 12 followed by the primary mixed bed deionizer 13 for the reduction of ionic impurities in the water.
From the make-up treatment loop, water is taken to the deionized water storage tank 14 . This tank 14 is nitrogen blanketed to ensure that the water inside the tank is not contaminated from the outside air. Water is pumped by high-pressure flooded suction multi-stage vertical centrifugal pump P 5 through the heat exchanger 15 to reduce the temperature and is then passed through the secondary UV TOC Reducer 16 for the removal of residual organics. The secondary UV TOC Reducer 16 removes TOC down to sub-ppb level at conventional 33% recirculation rate in the polishing loop. The water from the outlet of this secondary UV TOC Unit 16 passes through a sacrificial polishing mixed bed deionizer 17 followed by a secondary membrane degassifier 18 . The resin in the sacrificial polishing mixed bed deionizer 17 is a non-regenerable type. The sacrificial polishing mixed bed deionizer 17 removes ionic impurities down to ppt levels. The secondary membrane degassifier 18 removes dissolved oxygen down to sub-ppb level. Water from the secondary membrane degassifier 18 passes through an UV disinfection unit 19 followed by a 0.1 micron absolute cartridge Filter 20 . The UV disinfection unit 19 is used as a sterilant in the preparation of high-purity water. The sterilized water from the UV disinfection unit 19 is then taken to a 0.1-micron absolute cartridge filter 20 for the removal of ultra-fine particles. The Ultrafiltration (UF) Unit 21 is the final equipment in the polishing loop and the product water from this UF unit 21 is monitored continuously for flow, pressure, temperature, resistivity, particle count, TOC, and dissolved oxygen. This UF unit 21 at the Point-of-use (POU) further reinforces the ultra-fine particle removal action to achieve a particle count down to less than 300/liter of 50 nm size particles. Return water from POU is taken back to the deionized water storage tank 14 through a return UV disinfection unit 22 to maintain the sterile condition.
Although FIG. 1 shows a two pass reverse osmosis system, these reverse osmosis systems can each be single or multiple arrays of units in series depending upon the necessity of the use of concentrate staging to improve the recovery of each system. More or fewer reverse osmosis systems may be used. For example, only one reverse osmosis system may be used.
Before the first pass reverse osmosis reject stream is provided to the continuous electrodeionization unit the reject stream passes through ion exchange unit 7 to remove hardness elements. Ion exchange unit 7 removes polyvalent cations from the reject stream. This assists in achieving adequate concentrate stream conductivity in the electrodeionization apparatus. In this case it is preferable to remove polyvalent cations in the first pass reject stream so as to make the local Langelier Saturation Index (LSI) in the concentrate stream negative. In preferred embodiments of the invention one of four systems is used to remove hardness elements from the first pass reverse osmosis reject stream: standard reverse flow softening, softening by passage through/past a weak acid cation resin, softening with a suitable aminophosphonic or iminodiacetic acid functional group chelating resin.
In a preferred embodiment when the water softening system uses a standard reverse flow softener containing a uniform particle size strong acid cation resin, the strong acid cation resin is in the sodium form.
In a preferred embodiment when the water softening system uses passage through or past a weak acid cation resin to soften the water, the weak acid cation resin is in the sodium form.
Water softening is used for the removal of calcium and magnesium ions, which are the hardness (scale) forming constituents of water. The standard reverse flow softener is highly effective, yet relatively simple. Hard water is passed through a column of sodium form strong acid cation exchange resin, which replaces the objectionable calcium and magnesium ions with non-objectionable sodium ions. When the capacity of the resin for absorbing calcium and magnesium ions is exhausted, the column is regenerated with salt solution in a direction opposite to the service flow. For most first pass reverse osmosis reject waters after passing through the reverse flow softener the output water has hardness below about 1.5 ppm as calcium carbonate. Once the reverse flow softener is exhausted it needs to be regenerated. Regeneration can be achieved with a 10% brine solution at a regeneration level in the vicinity of 150 grams per liter of resin.
The use of the weak acid cation resin in the sodium form for the removal of hardness is equivalent to carbosoft process. In order to effectively soften waters, which contain high total dissolved solids (TDS), it is necessary to employ a weak acid cation resin in the sodium form. This technique, involving a two-step regeneration, has been called the carbosoft process. In the sodium form, there is a higher selectivity for calcium and magnesium than is shown by the conventional strong acid cation exchangers. The exhausted resin is first regenerated with relatively high levels of acid and this is followed by sodium hydroxide. Softening in the sodium cycle requires that the acid-regenerated form be converted directly to the working sodium form. The resins have an expansion of around 50-60% when converted from hydrogen form to the sodium form. The ion exchange vessel needs to be large enough to allow for this expansion. Using a weak acid cation resin in the sodium form output water can be provided with hardness below about 0.5 ppm as calcium carbonate for most first pass reverse osmosis reject waters. The feed water entering the weak acid cation resin may require pH adjustment using either sodium hydroxide or sodium carbonate to increase the alkalinity of the feed water up to a total hardness level. When the weak acid cation resin has been exhausted it requires regeneration. The regeneration may comprise a 5% hydrochloric acid at a regeneration ratio of about 110% followed by conditioning with a 5% sodium hydroxide solution. To avoid bed compression the weak acid cation resin may use an upflow technique for sodium conversion.
Macroreticular type chelating resins with aminophosphonic or iminodiacetic acid functional groups possess a high selectivity for calcium, magnesium, and strontium as well as heavy metal cations over alkali metal ions, such as sodium. The selective nature of such resins allow the removal of hardness from water streams down to ppb levels as well as the removal of heavy metals from solution. The exhausted resin is first regenerated with relatively high levels of acid and this is followed by sodium hydroxide. Softening in the sodium cycle requires that the acid-regenerated form be converted directly to the working sodium form. Such resin has an expansion of around 40-45% when converted from hydrogen form to the sodium form. The ion exchange vessel needs to be large enough to account for this expansion.
When the softening operation using macroreticular type aminophosphonic functional groups chelating resin the output water from the softening operation achieves hardness of below about 25 ppb as calcium carbonate for most first pass reverse osmosis reject waters. The macroreticular type aminophosphonic functional groups chelating resin runs at space velocity of about 15 BV/h for optimum operating efficiency. The macroreticular type aminophosphonic functional groups chelating resin uses an upflow technique to prevent bed compression for sodium conversion.
When the softening operation using macroreticular type iminodiacetic functional groups chelating resin the output water from the softening operation achieves hardness of below about 25 ppb as calcium carbonate for most first pass reverse osmosis reject waters. The macroreticular type iminodiacetic functional groups chelating resin runs at space velocity of about 15 BV/h for optimum operating efficiency. The macroreticular type iminodiacetic functional groups chelating resin uses an upflow technique to prevent bed compression for sodium conversion.
FIG. 2 is a cross-sectional illustration of a portion of the CEDI apparatus 12 used in the present experimental study. The CEDI Unit 12 comprises the anode compartment 23 provided with an anode 24 and the cathode compartment 25 provided with a cathode 26 . A plurality of cation exchange membranes 27 and anion exchange membranes 28 are alternately arranged between the anode compartment 23 and the cathode compartment 25 to form purifying compartment 29 and concentrating compartment 30 . The purifying compartment 29 is bounded on the anode side by an anion permeable membrane 28 and on the cathode side by a cation permeable membrane 27 . The adjacent concentrating compartments 30 are each correspondingly bounded by a cation permeable membrane 27 on the anode side and an anion permeable membrane 28 on the cathode side. The electroactive media utilized in the purifying compartment 29 includes a mixture of anion 31 and cation 32 ion exchange resin beads. The ion exchange materials 31 and 32 preferably are ion exchange resin particles in the form of beads. The second pass reverse osmosis product water is further treated by the primary UV TOC reducer 10 and the primary membrane degassifier 11 prior to entering the purifying compartment 29 which contains substantially uniform size resin beads. Similarly, the first pass reverse osmosis reject water is further treated by the ion exchange unit 7 for the removal of hardness prior to entering the concentrating compartments 30 and the anode and cathode compartments 23 , 25 .
It should be noted that the continuous electrodeionization unit may include more than one purifying compartment and more than two concentrating compartments.
Ion exchange membranes are made of ion exchange resins manufactured in sheet form. Membranes of a particular fixed charge are permeable to counter-ions and impermeable to co-ions. Ion exchange membranes are also impermeable to water, and therefore act as a barrier to bulk liquid flow while allowing the transfer of counter-ions under the influence of an electric potential.
By circulating and reusing the concentrate water, the water utilization rate is improved and a reasonable ion concentration in the concentrating compartment is maintained. The concentrate flowrate through its compartment must be sufficient to maintain turbulence, and to keep pressure drops within their desired range. Little flexibility is available for reducing flow as a means of obtaining better water recovery from the system. A certain percentage of the concentrate flow must go to the drain. The increase in the electric current flow due to higher electrical conductivity of the concentrate water reduces the power consumption of the device because the applied voltage can be made smaller. Higher conductivity in the concentrate stream facilitates the transfer of current while back-diffusion can limit effluent quality. Increasing the flowrate of the concentrate stream prevents scales from forming in the concentrate compartments. In a conventional system, it is desirable to limit the recovery to reduce the rate of scale formation in the concentrating compartments, or possibly to reduce the effects of back diffusion.
Referring to FIG. 3 , the CEDI Unit 12 in accordance with the present invention is described in more detail. The feed to the electrodeionization system is split into two streams, the supply stream 33 and the make-up stream 37 to the concentrating loop 34 . Water to be treated is introduced into the purifying compartments 29 from supply stream 33 . The supply stream 33 is deionized as it flows through the purifying compartments 29 in the system. In order to achieve the target effluent water quality, the water in the concentrating loop 34 must be sufficiently conductive for the required current to be passed. The concentrating loop 34 comprises a pump P 6 to recycle concentrate solution, a concentrate bleed-off line 35 to drain 36 , a make-up stream 37 from supply stream 33 , and another high conductivity softened water make-up stream 38 from an ion exchange unit 7 . Ion exchange equipment 7 can be either standard reverse flow softener or weak acid cation exchanger in the sodium form, or ion exchanger containing macroreticular type aminophosphonic or iminodiacetic functional groups chelating resin. A pressure reducing valve (PRV) 41 is used in the make-up stream 38 to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments. A suitable antiscalant is injected into the outlet stream from the softening equipment to prevent scaling due to supersaturation of silica. An in-line static mixer 42 is provided to ensure the proper mixing of the antiscalant with the outlet stream from the softening equipment. The make-up stream 37 is blended with the high conductivity softened water make-up stream 38 from an ion exchange unit 7 to provide a sufficiently conducting concentrate stream 39 . The resulting concentrate stream 39 is introduced into the concentrating compartments 30 and into the anode and cathode compartments 23 and 25 respectively. The electrode bleed-off stream 40 is diverted to drain 36 because it contains trace amounts of chlorine, hydrogen, and oxygen gases.
Referring to FIG. 4 , the CEDI Unit 12 is described without the concentrate recirculation. This configuration was utilized in the present experimental studies. It is important to note that hardness components, which originally exist in the concentrate water in small amounts, become increasingly concentrated as the concentrate water is circulated and reused and over time more rapidly deposit in the concentrate chambers or in the electrode chambers to form scales. The use of a once-through operation in the concentrate loop in accordance with the present invention prevents such scaling. The feed to the electrodeionization system is split into two streams, the supply stream 33 that flows into the purifying chamber and the make-up stream 37 that joins the concentrate stream 39 . Water to be treated is introduced into the purifying compartment(s) 29 from supply stream 33 . The supply stream 33 is deionized as it flows through the purifying compartment(s) 29 in the system. The make-up stream 37 is blended with the high conductivity softened water make-up stream 38 from ion exchange unit 7 to provide a sufficiently conducting concentrate stream 39 . Ion exchange equipment 7 can be either standard reverse flow softener or weak acid cation exchanger in the sodium form, or ion exchanger containing macroreticular type aminophosphonic or iminodiacetic functional groups chelating resin. A pressure reducing valve (PRV) 41 is used in the make-up stream 38 to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments. A suitable antiscalant is injected into the outlet stream from the softening equipment to prevent scaling due to supersaturation of silica. An in-line static mixer 42 is provided to ensure the proper mixing of the antiscalant with the outlet stream from the softening equipment. The resulting concentrate stream 39 is introduced into the concentrating compartments 30 and into the anode and cathode compartments 23 and 25 respectively. The concentrate bleed-off stream 35 and electrode bleed-off stream 40 are diverted to drain 36 .
In previous CEDI units to provide an adequate concentration of ions in the concentrate stream a chemical, for example a brine solution, was added. Reject water from the first pass reverse osmosis unit provides water for the concentrate stream of the CEDI with high conductivity. The conductivity of the first pass reverse osmosis reject water is high enough that chemicals do not need to be added to the CEDI concentrate stream. This provides a savings in costs and chemical handling. A further advantage of using the first pass reverse osmosis reject water as part of the CEDI concentrate stream is that the higher conductivity of the concentrate stream allows the CEDI to be run at low temperatures. The higher conductivity of the concentrate stream keeps the total voltage drop across the electrodeionization cells within the maximum voltage limit of the device. Yet another advantage is a general increase in electric current flow due to the increased conductivity in the concentration chambers of the CEDI unit.
EXAMPLES
The invention is further described and elucidated in the following examples and teach one how to make use of the invention. These examples are not intended, however, to limit or restrict the scope of the invention in any way and should not be construed as providing conditions, parameters or values which must be utilized exclusively in order to practice the present invention.
A typical characteristic of the municipal water supply used in the present experimental study is as follows:
Average feed pH
7.5
Average feed water temperature
28 degree Celsius
(82 degrees Fahrenheit)
Average Total Dissolved Solids (TDS)
240 ppm
Average feed silica
10 ppm
Average feed boron
50 ppb
Average Total Organic Carbon (TOC)
3.0 ppm
City water was received in the raw water storage tank and is pumped by a multi-stage vertical centrifugal pump through the multimedia filter for the reduction of suspended solids. Coagulant (PAC) is added before the multimedia filter for coagulation of suspended solids and an in-line static-mixer is provided to ensure the proper mixing of the coagulant with water. Turbidity, silt density index (SDI) 15 minutes, and zeta potential are measured to determine the performance of the multimedia filter.
Turbidity is a measurement of the lack of clarity in a water sample. Turbidimeter measures the scattering of light caused by various particles and suspended solids in the water sample. These readings are typically given in Nephelometric Turbidity Unit (NTU). As turbidity readings exceed 1.0, they are indicative of a greater tendency for membrane fouling. Like the SDI test, turbidity is only an indicator of fouling potential. In fact, there are some foulants that are clear to the passage of light, and would not show up in a turbidity measurement. Although they are less than perfect as tools of analysis, turbidity and SDI measurements are useful for characterizing an RO feed water.
Experimental results indicate that the effluent turbidity is approximately about 0.1 NTU at the 2 ppm PAC dosing. The Accu4™ Low-range Turbidimeter System from GLI was used for the on-line monitoring of Turbidity at the outlet of the multimedia filter. This system has an auto-ranging measuring scale, enabling continuous monitoring over a 0-100 NTU range. The Filter Plugging Analyzer Model FPA-3300 from Chemetek (Portland, USA) was used for the on-line monitoring of SDI at various PAC dosing levels at the outlet of the Multimedia Filter. Experimental results indicate that the effluent 15 minutes SDI is approximately about 2.5 at the 2 ppm PAC dosing. A zetasizer 3000 HS from Malvern Instrument was used for the off-line monitoring of zeta potential at the inlet of the multimedia filter. At a PAC dosage of about 2 ppm, the zeta potential at the multimedia filter inlet approaches zero.
The filtered water from multimedia filter passed through the activated carbon filter for the removal of organics and residual chlorine. Sodium bisulphite dosing was provided prior to the activated carbon filter for the removal of free chlorine and dissolved oxygen. The treated water from the activated carbon filter was then taken to a 1-micron cartridge filter for the removal of fine solids. Sodium bisulphite removed chlorine completely and also reduced the dissolved oxygen level in the vicinity of 2.5-3.0 ppm. Total organic carbon (TOC) level in the activated carbon product water decreased from 3.0 ppm to below 1.8 ppm.
The following unit operations in the preferred embodiment are involved in the removal of ionic impurities prior to the electrodeionization apparatus 12 .
First-pass reverse osmosis membrane filters 6 . The membrane filters comprise 3:2 arrays of CPA2-4040 membrane elements (manufactured by Hydranautics) with 4 elements per vessel. First pass reverse osmosis elements are operating at an average flux rate of 12 gallons per square foot per day (GFD) and recovery ratio of 70%.
Second-pass reverse osmosis membrane filters 8 . The membrane filters comprise 2:1 arrays of CPA2-4040 membrane elements (manufactured by Hydranautics) with 4 elements per vessel. Second pass reverse osmosis elements are operating at an average flux rate of 17 gallons per square foot per day (GFD) and recovery ratio of 85%. As a result, the overall recovery ratio is approximately 66.5%.
To ensure a negative LSI in the reject stream from the first pass reverse osmosis system, 2.0 ppm hydrochloric acid dosing was provided in the first pass feed water. A typical characteristic of the double pass product water obtained in the present experimental study is as follows:
Average product pH
5.2
Average Total Dissolved Solids (TDS)
0.3 ppm
Average product silica
10 ppb
Average product boron
8 ppb
Average Total Organic Carbon (TOC)
50 ppb
Using the preferred embodiment described above, a series of experiments were conducted around combined reverse osmosis/electrodeionization apparatus using various softening equipment for the first pass reverse osmosis reject stream at different recoveries around the electrodeionization apparatus. The D. C. Electric current through the electrodeionization apparatus was set at 4.6 Amps using a rectifier capable of a maximum output voltage of 600 Volts.
It was found in our experimental work that the type of softening equipment, the type and concentration of antiscalant strongly affect the performance of the electrodeionization apparatus. Operational results of the pilot test unit may be better appreciated by reference to Examples 1 through 5.
Finnigan Element 2 was used during this study for trace element analysis of boron, silica, sodium, potassium, calcium, and magnesium. Element 2 is a high-resolution inductively coupled plasma mass spectrometry which can analyze compounds—especially trace elements—in many different matrices. Dionex DX 500 ion-exchange chromatography (IC) was used in this study for the analysis of anionic impurities in the deionized water. Sievers 800 TOC analyzers were utilized in this study for online monitoring of the TOC levels (Ionics Instrument Business Group, Boulder, USA) at the inlet and outlet of the double pass reverse osmosis system.
Municipal water of a quality as shown in Table 1 was treated with double pass reverse osmosis equipment to obtain permeate water of a quality as shown in the same Table. This permeate water was used as feed water and partly concentrating water to be passed through purifying compartments and concentrating compartments, respectively, in electrodeionization water production equipment. The first pass reject stream from the reverse osmosis equipment passes through either standard reverse flow softener or weak acid cation resin preferably in the sodium form, or suitable chelating resin to remove the hardness elements. The first pass reject stream quality is also shown in Table 1. Adequate concentrate stream conductivity in the electrodeionization water production equipment was achieved by using softened first pass reject stream after the application of a suitable antiscalant to prevent scaling due to supersaturation of silica.
TABLE 1
Average performance of a double pass reverse osmosis equipment
Municipal
RO permeate
First pass
Parameter
water
water
reject water
pH
7.5
5.2
7.6
TDS, ppm
240
0.3
713
Electrical conductivity,
438
0.7
1335
microsiemens/cm
Temperature, ° C.
28 (82° F.)
28 (82° F.)
28 (82° F.)
Calcium, ppm
20.0
ND
59.7
Magnesium, ppm
2.4
ND
7.2
Sodium, ppm
50.0
0.1
149.4
Potassium, ppm
3.0
ND
9.0
Sulphate, ppm
50.0
ND
149.3
Chloride, ppm
65.0
0.1
201.0
Bicarbonate, ppm
36.6
0.1
99.1
Nitrate, ppm
3.0
0.1
8.8
Silica, ppm
10.0
0.01
29.9
Note:
ND indicates that the actual value is below the instrument detection limit.
Details of the electrodeionization water production equipment used in the present experimental study are given below in Table 2:
TABLE 2
Performance of Electrodeionization equipment
Parameter
Value
Design flowrate
12.5 gallons per minute
Supplier
GE Water Technologies
52 Royal Road, Guelph
Ontario, Canada N1H 1G3
Model Number
E-Cell MK - 1E
Allowable pH
5-9
Maximum total exchangeable anion
25 ppm as CaCO 3
Maximum hardness in feed
0.25 ppm as CaCO 3
Maximum hardness in concentrate
5.0 ppm as CaCO 3
Maximum reactive silica in feed
500 ppb
Maximum reactive silica in concentrate
10 ppm
Maximum TOC in feed
500 ppb
Maximum TOC in concentrate
10 ppm
Maximum free chlorine in feed
0.05 ppm
Range of operating temperature
40-100° F.
Range of operating pressure
45-100 psig
Observed feed water parameters for the electrodeionization apparatus are given below in Table 3:
TABLE 3
Observed electrodeionization average feed water parameters
Parameter
Observed value
Accepted range
Total exchangeable anion
2.9
0-25.0
(TEA), ppm as calcium carbonate
Total exchangeable cation
0.4
0-25.0
(TEC), ppm as calcium carbonate
Carbon dioxide, ppm
1.2
0-13.2
Alkalinity, ppm as calcium carbonate
0.1
0-20.0
Hardness, ppm as calcium carbonate
<0.02
0-1.0
Silica, ppb
10
0-500
Conductivity, microsiemens/cm
0.7
0-62.0
In this case, the use of softening equipment for the first pass reverse osmosis reject stream were varied as shown below for effecting deionization treatment. Throughout this experimental study, the flowrate through the concentrating compartments were kept constant at 4.5 gpm. Operating the concentrate stream at such a high flowrate prevents scales from forming in the concentrate compartments. Moreover the concentrate water was not recirculated, as adequate concentrate flowrate is available from the softened first pass reverse osmosis reject stream. It is important to note that hardness components, which originally exist in the concentrate water in small amounts, become increasingly concentrated as the concentrate water is circulated and reused and over time more rapidly deposit in the concentrate chambers or in the electrode chambers to form scales. The use of a once-through operation in the concentrate loop prevents such scaling. In the present experimental study, the product water flowrate was also kept constant at 12.5 gpm. The flowrate of the softened first pass reject stream from the reverse osmosis equipment through the concentrating compartments were varied to obtain different recoveries around the electrodeionization water production equipment. The results were evaluated by measuring the stack voltage, electrical resistivity of the treated water and observing any scale deposits within the concentrating chambers and the electrode chambers after 30 days of continuous operation. The presence of scales reduces the electric current flows at the respective sections when the necessary applied voltage exceeds the maximum voltage of the device. In this case, sufficient current for ion removal cannot be applied, and the quality of the treated water deteriorates.
The D.C. Electric current through the electrodeionization apparatus was set at 4.6 Amps using a rectifier capable of a maximum output voltage of 600 Volts.
Example 1
A standard reverse flow softener was used to remove the hardness elements from the first pass reverse osmosis reject stream. The ion exchange resin was of a sulphonic acid type cation exchange resin (trade name: Amberjet 1200 Na manufactured by Rohm and Haas). A 250 mm external diameter reverse flow softener was used in the present experimental study for a maximum water flowrate of 7.0 gpm and a cycle time of 8.0 hours. The resin volume was 50 liters. Space velocity through the vessel was 32.4 BV/h at 7.0-gpm flowrate. Regeneration was conducted with 10% brine solution at a level of 150 grams per liter of resin. This standard reverse flow softener achieved an outlet hardness of about 1.5 ppm as calcium carbonate. The conductivity of the softened water was in the range of 1300-1600 microsiemens/cm. This conductivity of the softened water was about 3 times that of the source water supply because the reverse osmosis system was operating at an overall recovery ratio of 66.5%. A pressure reducing valve (PRV) Type V 82 (manufactured by George Fischer) was used in the outlet stream from the standard reverse flow softener to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments in the electrodeionization apparatus.
Pretreat Plus™ 0100 antiscalant (manufactured by King Lee Technologies) was injected into electrodeionization concentrate stream using a static mixer to retard polymerization and precipitation of silica. This antiscalant does not flocculate dissolved iron/aluminum oxide/silica complexes. It was useful at a dosage level of 4.5 ppm.
Recovery around the electrodeionization water production equipment was set at 90%. At the start of the experiment, the maximum applied voltage of 600 Volts produced a current of 2.9 Amps, but this current increased to the set point of 4.6 Amps while the voltage dropped to 480 Volts and remained at this level for the duration of the experiment (720 hours). The product water maintained a resistivity value over 17.1 megaohm-cm for the duration of the experiment. The silica level in the product water decreased from 10 ppb to below 100 ppt. The boron level in the product water decreased from 8 ppb to below 100 ppt. The constant voltage and consistently high product water resistivity indicate the absence of significant scaling within the concentrating chambers and the electrode chambers.
Example 2
A comparative experiment was conducted with the use of above standard reverse flow softener with the exception of operating the electrodeionization apparatus at a recovery of 95%. This standard reverse flow softener achieved an outlet hardness of about 1.5 ppm as calcium carbonate. The conductivity of the softened water was in the range of 1300-1600 microsiemens/cm. This conductivity of the softened water was about 3 times that of the source water supply because the reverse osmosis system was operating at an overall recovery ratio of 66.5%. A pressure reducing valve (PRV) Type V 82 (manufactured by George Fischer) was used in the outlet stream from the standard reverse flow softener to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments in the electrodeionization apparatus. Any suitable pressure reducing valve may be used. The injection of Pretreat Plus™ 0100 antiscalant (manufactured by King Lee Technologies) at a dosage level of 4.5 ppm was maintained in this experimental study. The target operating current of 4.6 Amps was passed with the available 600 Volts D. C. For the first few hours, and the current then decreased steadily to 1.8 Amps over the duration of the experiment (720 hours). The product water resistivity has an initial value of 16.8 megaohm-cm, but decreased to 9.0 megaohm-cm after 160 hours of operation, and further decreased to less than 1.2 megaohm-cm after 720 hours of operation. This result clearly indicates the formation of scale on the concentrate chamber side of the anion membranes. Some scale deposition was observed and a part of the flow line was blocked.
Example 3
A weak acid cation resin in the sodium form was used to remove the hardness elements from the first pass reverse osmosis reject stream. Sodium hydroxide was added to the feed stream so that alkalinity exceeded the total hardness. The ion exchange resin was of a carboxylic acid type cation exchange resin (trade name: Amberlite IRC 86 manufactured by Rohm and Haas). A 300 mm external diameter weak acid cation exchanger was used in the present experimental study for a maximum water flowrate of 8.0 gpm and a cycle time of 20.0 hours. The resin volume was 75 liters. Space velocity through the vessel was 24.0 BV/h at 8.0-gpm flowrate. Regeneration was conducted with 5% hydrochloric acid at a level of 78 grams per liter of resin, which is equivalent to 110% regeneration ratio. Subsequently, sodium hydroxide conditioning was performed to convert the regenerated resin to the sodium form. This sodium conversion was performed in the upflow manner to avoid bed compression. Because resin (delivered in hydrogen form) swells 50 to 60% to the sodium form, vessel sizing was done accordingly. This weak acid cation exchanger in the sodium form achieved an outlet hardness of about 0.5 ppm as calcium carbonate. The conductivity of the softened water was in the range of 1300-1600 microsiemens/cm. This conductivity of the softened water was about 3 times that of the source water supply because the reverse osmosis system was operating at an overall recovery ratio of 66.5%. A pressure reducing valve (PRV) Type V 82 (manufactured by George Fischer) was used in the outlet stream from the weak acid cation exchanger to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments in the electrodeionization apparatus.
The injection of Pretreat Plus™ 0100 antiscalant (manufactured by King Lee Technologies) at a dosage level of 4.5 ppm was maintained in this experimental study.
Recovery around the electrodeionization water production equipment was set at 95%. At the start of the experiment, the maximum applied voltage of 600 Volts produced a current of 3.1 Amps, but this current increased to the set point of 4.6 Amps while the voltage dropped to 460 Volts and remained at this level for the duration of the experiment (720 hours). The product water maintained a resistivity value over 17.0 megaohm-cm for the duration of the experiment. The silica level in the product water decreased from 10 ppb to below 100 ppt. The boron level in the product water decreased from 8 ppb to below 100 ppt. The constant voltage and consistently high product water resistivity indicate the absence of significant scaling within the concentrating chambers and the electrode chambers.
Example 4
A suitable chelating resin was used to remove the hardness elements from the first pass reverse osmosis reject stream. The ion exchange resin was of a macroreticular type with aminophosphonic functional groups resin (trade name: Amberlite IRC 747 manufactured by Rohm and Haas). The chemical nature of these groups is such that they form complexes with metal ions. Amberlite IRC 747 is an efficient resin for the removal of hardness elements and other metals in the water streams. The ion exchanger was operated at a space velocity of 15 BV/h. This ion exchanger containing macroreticular type aminophosphonic functional groups chelating resin in the sodium form achieved an outlet hardness of about 25 ppb as calcium carbonate. The conductivity of the softened water was in the range of 1300-1600 microsiemens/cm. This conductivity of the softened water was about 3 times that of the source water supply because the reverse osmosis system was operating at an overall recovery ratio of 66.5%. A pressure reducing valve (PRV) Type V 82 (manufactured by George Fischer) was used in the outlet stream from the ion exchanger containing macroreticular type aminophosphonic functional groups chelating resin to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments in the electrodeionization apparatus.
The injection of Pretreat Plus™ 0100 antiscalant (manufactured by King Lee Technologies) at a dosage level of 4.5 ppm was maintained in this experimental study.
Recovery around the electrodeionization water production equipment was set at 98%. At the start of the experiment, the maximum applied voltage of 600 Volts produced a current of 3.2 Amps, but this current increased to the set point of 4.6 Amps while the voltage dropped to 450 Volts and remained at this level for the duration of the experiment (720 hours). The product water maintained a resistivity value over 17.4 megaohm-cm for the duration of the experiment. The silica level in the product water decreased from 10 ppb to below 100 ppt. The boron level in the product water decreased from 8 ppb to below 100 ppt. The constant voltage and consistently high product water resistivity indicate the absence of significant scaling within the concentrating chambers and the electrode chambers.
Example 5
A suitable chelating resin was used to remove the hardness elements from the first pass reverse osmosis reject stream. The ion exchange resin was of a macroreticular type iminodiacetic acid functionally chelating resin in the sodium form (trade name: Amberlite IRC 740 manufactured by Rohm and Haas). The chemical nature of these groups is such that they form complexes with metal ions. Amberlite IRC 748 is an efficient resin for the removal of hardness elements and other metals in the water streams. The ion exchanger was operated at a space velocity of 15 BV/h. This ion exchanger containing macroreticular type iminodiacetic acid functionality chelating resin in the sodium form achieved an outlet hardness of about 25 ppb as calcium carbonate. The conductivity of the softened water was in the range of 1300-1600 microsiemens/cm. This conductivity of the softened water was about 3 times that of the source water supply because the reverse osmosis system was operating at an overall recovery ratio of 66.5%. A pressure reducing valve (PRV) Type V 82 (manufactured by George Fischer) was used in the outlet stream from the ion exchanger containing macroreticular type iminodiacetic acid functionality chelating resin to ensure that the concentrate and electrode feed stream is introduced at a pressure of 5 to 10 psig below that of the inlet stream of the purifying compartments in the electrodeionization apparatus.
The injection of Pretreat Plus™ 0100 antiscalant (manufactured by King Lee Technologies) at a dosage level of 4.5 ppm was maintained in this experimental study.
Recovery around the electrodeionization water production equipment was set at 98%. At the start of the experiment, the maximum applied voltage of 600 Volts produced a current of 3.1 Amps, but this current increased to the set point of 4.6 Amps while the voltage dropped to 460 Volts and remained at this level for the duration of the experiment (720 hours). The product water maintained a resistivity value over 17.3 megaohm-cm for the duration of the experiment. The silica level in the product water decreased from 10 ppb to below 100 ppt. The boron level in the product water decreased from 8 ppb to below 100 ppt. The constant voltage and consistently high product water resistivity indicate the absence of significant scaling within the concentrating chambers and the electrode chambers.
Use of a macroreticular resin as described in examples 4 and 5 has the advantages of high resistance to osmotic shock and improved kinetics of ion exchange over gel-type resins (for example those used in Examples 1 to 3).
The foregoing describes the invention including preferred forms thereof. Alterations and modifications as will be obvious to those skilled in the art are intended to be incorporated in the scope hereof as defined by the accompanying claims. | A method of water purification including the steps of passing source water through at least one reverse osmosis unit to produce a product water and reject water, directing the product water from a reverse osmosis unit into the dilution stream of a continuous electrodeionization unit, directing the reject water from the first pass reverse osmosis unit through a softening unit to produce softening unit output water with fewer hardness elements than the reject water from the first pass reverse osmosis unit, directing the softening unit output water into a concentrate stream of the continuous electrodeionization unit, and wherein the continuous electrodeionization unit further purifies the water from the dilution stream to produce purified water. | 8 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to a loop antenna used for a portable, compact radio device.
2. DESCRIPTION OF THE PRIOR ART
Antennas excellent in portability and free from degradation of antenna gains even upon being carried by users have been used in conventional portable, compact radio devices. Among these antennas, a loop antenna disclosed in, e.g., Japanese Unexamined Utility Model Publication No. 5-2425 is most popular. For example, as shown in FIG. 1, this antenna is obtained by forming a band-like antenna conductor 1 into a loop. The loop antenna is disposed in a plastic housing 2 of a radio device such that the opening of the antenna conductor 1 faces outward. At the same time, the loop antenna is coupled to a parts board 4 of the radio device through a feeder 3. This antenna is excellent in portability because it can be incorporated in the housing 2. When the device is carried by a user, a higher antenna gain than that in a free space can be advantageously obtained due to a human body image effect. The human body image effect implies such phenomenon that an image loop is produced when the radio device is carried by a user, so that current in phase with an actual loop will flow and a peak of electromagnetic intensity will appear in the vicining of a human body by the image antenna in phase with the actual loop.
Since the loop antenna, however, is a magnetic field type antenna, the effective opening surface decreases upon receiving the influence of a metal object located close to the antenna opening. A radiation resistance decreases with respect to the loss resistance of the antenna. As result, in a portable, compact radio device in which an antenna is located very close to a radio unit, the influences of the device board and device parts undesirably lower the antenna gain.
To solve the above problem, the loop antenna must be located at a physically remote position from the radio unit. As the radio unit is, however, basically connected to the loop antenna through only the feeder, the strength of the antenna itself cannot be assured at the physically remote position from the radio unit.
To solve the above problem, it is desirable to arrange the antenna at the inner surface portion of the housing. The physical size of the antenna must be reduced due to the layout of the antenna at the inner surface portion of the housing, higher performance of a recent radio device, and an increase in packing density which result from downsizing. As a result, it becomes difficult to maintain conventional reception characteristics because the reception characteristics can be improved in proportion to an increase in effective size of the antenna. That is, in a conventional loop antenna, downsizing of the antenna is the direct cause for degrading the antenna characteristics.
SUMMARY OF THE INVENTION
The present invention has been made to solve the conventional problems described above, and has as its object to provide a compact loop antenna having a high gain and a high mechanical strength in a portable, compact radio device.
In order to achieve the above object of the present invention, there is provided a band-like loop antenna disposed along an inner surface of a housing of a portable, compact radio device, wherein the loop antenna is bent such that a side surface of the loop antenna which is located on the inner side of the radio device is located at a position outward in a radial direction of a loop of the loop antenna with respect to a side surface of the loop antenna which is located on the outer side of the radio device.
In this case, the side surface of the loop antenna which is located on the inner side of the radio device may be inclined outward in the radial direction of the loop, or the side surface of the loop antenna which is located on the inner side of the radio device may be bent 90° outward in the radial direction of the loop.
The housing can include a support structure engaging with the loop antenna to support the loop antenna in the housing. In addition, the bent portion of the loop antenna is preferably in contact with the inner surface of the housing. In this case, the ridge portion of the housing may be chamfered.
The following effects can be obtainers by the present invention.
1. The band-like loop antenna is partially bent in contact with the housing. For this reason, the strength of the loop antenna can be assured even if the loop antenna must be conventionally mounted in a place where the strength of the antenna cannot be assured. That is, when the antenna is bent in contact with the inner surface of the housing, the contact portion of the antenna with the housing increases to result in an increase in strength.
2. The band-like loop antenna is partially bent outside the opening surface of the loop antenna. For this reason, a small space can be efficiently used to increase the effective area of the opening surface of the antenna. As compared with a conventional loop antenna having no bent portion, the radiation resistance increases without changing the loss resistance, thereby increasing the antenna gain. That is, although the loss resistance does not change due to the unchanged peripheral length of the loop antenna, bending of the antenna results in an apparent increase in effective area of the opening surface of the antenna.
The above and many other advantages, features and additional objects of the present invention will become manifest to those versed in the art upon making reference to the following detailed description and accompanying drawings in which preferred structural embodiments incorporating the principles of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing the layout of a conventional loop antenna;
FIG. 2 is a perspective view showing the shape of a loop antenna according to an embodiment of the present invention when viewed from the top;
FIG. 3 is a sectional view showing the layout of the loop antenna of the embodiment shown in FIG. 2;
FIG. 4 is a sectional view showing the layout of a loop antenna according to another embodiment of the present invention; and
FIG. 5 is a graph showing the relationship between an increase in opening area by inclination of the loop antenna and an increase in antenna gain.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the accompanying drawings. The same reference numerals as in FIG. 1 denote the same parts, and a detailed description thereof will be omitted.
FIGS. 2 and 3 show a structure in which a band-like loop antenna 11 disposed at the inner surface of a housing 2 is partially bent such that side surfaces 14 of the loop antenna 11 which are located on the inner side of a radio device are inclined outward in the radial direction of the loop of the loop antenna 11. The loop antenna 11 is coupled to a parts board 4 through a feeder 3. The loop antenna 11 is inclined such that their side surfaces are bent outward so as not to close its opening surface.
The inclined or curved chamfered portions are formed on the outer surface portions of the housing, and the inner surface portions of the housing 2 are so inclined as to conform to the outer surface portions. As shown in FIG. 3, the bent portions of the loop antenna 11 are brought into contact with the inner surface portions to assure the strength of the loop antenna. In this case, the bent portions of the loop antenna 11 are supported in contact with the inner surface portions such that the end faces of the respective bent portions engage with support structures 12 formed to interpose the inner surface portions in the housing 2.
With the above structure, the number of contacts between the housing 2 and the loop antenna 11 increases to obtain a higher strength. The loop antenna 11 is formed such that the band width of a portion to be bent in band-like loop antenna is set larger than that of the remaining portion and the portion having a larger width is bent in contact with the corresponding inner surface portion of the housing 2. That is, the structure of the present invention can be realized by simply bending part of the conventional band-like loop antenna.
FIG. 4 shows another embodiment of the present invention. In the embodiment shown in FIGS. 2 and 3, each side of the band-like loop antenna 11 is entirely bent outward. However, in the embodiment shown in FIG. 4, a side surface portion of each side of a band-like loop antenna 13, which is located on the inner side of the radio device, is bent 90° outward in the radial direction of the loop, thereby obtaining the same effect as in FIGS. 2 and 3.
The radiation gain of a small loop antenna as in the present invention is determined mainly depending on the radiation efficiency. A radiation efficiency η is generally defined as follows:
η=radiation resistance/radiation resistance+loss resistance
In fact, the radiation efficiency of the small loop antenna is about several %. The loss resistance is large relative to the radiation efficiency, and therefore this antenna is very low in radiation efficiency. To increase the radiation efficiency, the radiation resistance must be increased, and the loss resistance must be suppressed. The loss resistance mainly depends on the conductivity of an antenna conductor, increases in proportion to an increase in peripheral length of the antenna, and decreases in proportion to an increase in conductivity per unit length.
According to the present invention, the peripheral length of the antenna is kept unchanged to suppress the loss resistance. At the same time, the antenna conductor is partially bent outward to result in an apparent increase in effective area of the opening surface of the antenna. The relationship between an increase in opening area by inclination of the loop antenna and an increase in antenna gain is shown in FIG. 5. | A loop antenna for a portable, compact radio device, which has a high gain and a high strength according to this invention, is realized such that side surfaces of the loop antenna are inclined or bent along the inclined or curved outer surface portions of a housing. | 7 |
FIELD OF THE INVENTION
The present invention relates to the synchronization of digital equipment and more particularly to a novel method for planning the synchronization distribution of a communications network. The invention is applicable to optical telecommunications networks spanning various administrative domains, such as local exchange carriers (LECs) and inter-exchange carriers (IECs).
BACKGROUND OF THE INVENTION
A typical optical communications network can be topologically broken down into a combination of ring ADM (add-drop multiplexer) systems, linear ADM systems and linear point-to-point systems. While it is possible to define other system categories, it is generally accepted that most optical telecommunications networks consist of one or more of these three classes.
A ring ADM system generally comprises a collection of network elements, each of which is connected to two adjacent network elements by respective segments of optical fiber that usually carries bidirectional traffic according to a standard such as SONET (synchronous optical network) or SDH (synchronous digital hierarchy). Incidentally, while such a ring system is commonly referred to as a ring ADM system, the network elements themselves may be add-drop multiplexers, regenerators, multi-wavelength optical repeaters or switches.
A linear ADM system resembles a broken and unravelled ring ADM system, having a pair of terminal network elements (to each of which only one other network element is connected). A point-to-point linear system, on the other hand, comprises a single pair of network elements joined by optical fiber carrying SONET or SDH traffic.
Network elements are placed at physical locations known as sites. A site generally comprises one or more network elements that belong to various systems (ring ADM, linear ADM, linear point-to-point, etc.), which may or may not communicate information amongst each other. Synchronous operation of the network is achieved through the transmittal of data by the network elements at each site at a precise rate controlled by an electronic clock signal. This clock signal may be generated at the site itself or received from a neighbouring site.
Prior to the advent of SONET, it was common to distribute timing between adjacent sites through the use of a DS1 (digital signal first level) signal. In more recent networks employing SONET, DS1 clock signals are still used for intra-office timing distribution but are derived from incoming optical carrier (OC-N) signals, where N is a multiple of 51.84 Megabits per second and represents the bit rate of the optical signal. A suitable method for deriving DS1 from SONET overhead is described in Bellcore's GR-253 specification, which is hereby incorporated by reference herein.
It is known that the precision of the clock signal used at a site directly influences performance of the network elements at that site when measured in terms of data errors. In general, the higher the precision, the better the performance. In a typical network, the most precise (and expensive) type of clock available is a so-called primary reference source (PRS) clock. The frequency of a PRS clock is usually obtained from an atomic clock or a satellite-based system such as GPS or LORAN-C. A PRS clock is designated as having stratum level 1 (ST1) and its quality is typically measured in terms of its free-run accuracy, as defined in ANSI standard T1.101.
Since PRS clocks are relatively expensive, most sites in the network do not comprise their own PRS clocks. Rather, these "intermediate sites" rely on external timing references from neighbouring upstream sites and also distribute timing to neighbouring downstream sites.
Aside from those intermediate sites which comprise a single network element that terminates a linear ADM system or a chain of linear point-to-point systems, intermediate sites can receive timing signals via at least two potential timing references (PTRs). Derived DS1 synchronization reference signals are extracted from the overhead portion of SONET frames arriving on one of the PTRs known as a "primary" timing reference, which is used under normal circumstances as the preferred timing reference for that site. A second derived DS1 synchronization reference (extracted from another PTR) is used as a "secondary" timing reference in case of failure of the primary timing reference. Since the site typically comprises multiple network elements, timing would ordinarily be distributed to all network elements at the site by means of a building-integrated timing supply (BITS), so that at any given time, a single timing reference provides timing to all the signals leaving the site.
To better explain timing distribution using a BITS, FIG. 1 shows an intermediate site 100 comprising a network element 101 which belongs to a ring system and two network elements 102,103 which join two linear point-to-point systems in a back-to-back configuration. Network element 101 is connected to bidirectional fiber segments 105 and 106, network element 102 is connected to a bidirectional fiber segment 107 and network element 103 is connected to a bidirectional fiber segment 108.
The intermediate site 100 also comprises a BITS 104 for timing distribution, and the site is therefore referred to as an "intermediate BITS site". There are four PTRs provided by the fiber segments 105-108, among which only two are selected as the timing inputs to the BITS 104. Specifically, the SONET frames arriving on fiber segments 105 and 108 are used for the derivation of DS1 timing signals, becoming DS1 timing inputs 115,118 that are fed to the BITS 104. The selection of which two among the four potential timing references arriving on fiber segments 105-108 are to be used for deriving the timing inputs to the BITS 104 is usually effected quite arbitrarily, and the significance of such a selection is often overlooked by network planners.
From its two timing inputs 115,118, the BITS 104 selects, by means of a switch 114, one of these as a timing signal 124 to be distributed to the network elements 101,102,103 at the intermediate BITS site 100. One of the two timing inputs 115,118 is the so-called primary timing reference and under normal conditions is more reliable than the other (secondary) timing reference, e.g., by virtue of being closer to a PRS. Under normal circumstances, therefore, the selected default timing input to be redistributed by the BITS 104 to the network elements 101-103 is the primary timing reference. Under other circumstances, e.g., during fault conditions, the BITS 104 switches over to the secondary timing reference. Assigning one of the timing inputs as the primary timing reference and the other as the secondary timing reference is a system-level decision.
It is also usual to install a BITS at a PRS site, in which case no derivation of DS1 signals from incoming fiber systems is necessary as the highest quality clock is generated at the PRS site itself.
Ensuring a timely switchover from the primary timing reference to the secondary one is an important issue affecting all intermediate sites, regardless of whether or not these sites are BITS-equipped. For example, suppose that a site Y is located between a site X and a site Z, site Y taking its primary clock from site X and its secondary clock from site Z.
If site Y switches from its primary clock to its secondary clock immediately upon detecting degradation of the primary clock (from site X), then the secondary reference (from site Z) is not guaranteed to be reliable. In fact, the clock signal produced by site Z may be a redistribution of a clock signal already distributed to site Z by site Y, in which case site Y would then be relying on an internally generated non-PRS clock. In the network synchronization art, this is known as a timing loop, and has deleterious consequences that include the loss of data.
One straightforward technique which remedies the problem of timing loops is the placement of a PRS clock at every or every second site in the network. While this "solution" is attractive due to its simplicity, it carries with it a hefty price tag for the telecommunications service provider in the form of a multitude (on the order of hundreds) of expensive PRS clocks.
Another way to help reduce the risk of creating timing loops is to use so-called synchronization status messaging (SSM) between neighbouring sites, whereby the quality of a redistributed clock is transmitted to adjacent sites as part of the timing signal itself. Thus, a network element or a BITS equipped with SSM capability reads synchronization-related messages at its two inputs, which control the instant at which the switchover to the secondary timing reference is to be performed. A more complete description of SSM may be found by consulting Bellcore's GR-436-CORE document, revision 1, June 1996, Section 5.4.6, which is hereby incorporated by reference herein.
However, choosing to employ SSM at all the network elements and BITSes in a complex network is expensive and still does not guarantee the elimination of all possible timing loops. In fact, in order to obliterate timing loops entirely, it is necessary to consider the enabling of selected sites with SSM in a joint fashion with the placement of PRS clocks and the installation of BITSes. At the same time, consideration must be given to the cost of installing PRSs and BITSes, and that of enabling sites with SSM. Since the prior art teaches no economical method for jointly considering the above three factors, it is usually the case that network planners apply empirical design methodologies based on years of personal experience with a narrow range of network types, which is a serious disadvantage when the planner is faced with a new, large and entirely different network configuration.
SUMMARY OF THE INVENTION
It is an object of the present invention to mitigate or obviate one or more disadvantages of the prior art.
It is a further object of the present invention to provide a cost-effective design method which eliminates the risk of creating timing loops in an optical telecommunications network using a combination of selective placement of PRS clocks, selective installation of BITSes and enabling SSM at selected sites.
Therefore, the invention may be summarized according to a first broad aspect as a method of synchronizing a communications network having a plurality of interconnected sites, each site comprising at least one network element and being connected to at least one other site via a respective network segment providing a potential timing reference (PTR) for the site, the method comprising the steps of: (1) selecting the sites at which primary reference source (PRS) clocks are to be deployed;(2) selecting the sites at which building integrated timing supplies (BITSes) are to be installed; and (3) at sites not comprising a PRS, selecting primary and secondary timing references for the site from among the PTRs and selecting which sites to enable with synchronization status messaging (SSM).
According to a second broad aspect, the invention may be summarized as a computer-readable storage medium containing software that, when running on a processor, follows a sequence of steps to synchronize a communications network having a plurality of interconnected sites, each site comprising at least one network element and being connected to at least one other site via a respective network segment providing a potential timing reference (PTR) for the site, the steps comprising: (1) selecting the sites at which primary reference source (PRS) clocks are to be deployed; (2) selecting the sites at which building integrated timing supplies (BITSes) are to be installed; and (3) at sites not comprising a PRS, selecting primary and secondary timing references for the site from among the PTRs and selecting which sites to enable with synchronization status messaging (SSM).
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the present invention will now be described with reference to the following figures, in which:
FIG. 1 shows an example prior art intermediate BITS site with four synchronization distribution paths;
FIG. 2 depicts an example telecommunications network which is used to illustrate applicability of the present invention;
FIG. 3A shows the network of FIG. 2 with PRS clocks placed at selected sites in accordance with the present invention;
FIG. 3B shows the network of FIG. 4A with BITSes placed at selected sites in accordance with the present invention;
FIGS. 4A to 4C help to illustrate the concept of a synchronization distribution path (SDP);
FIG. 5 is a flowchart describing timing distribution to intermediate sites in accordance with the present invention;
FIG. 6 is a flowchart expanding box 505 from FIG. 5;
FIG. 7 is a flowchart expanding boxes 610 and 622 from FIG. 6; and
FIG. 8 illustrates application of the inventive method to an inter-PRS span from FIG. 3B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In order to explicitly describe the invention, it is important to first develop a precise terminology that will be used throughout the description and claims. To this end, FIG. 2 shows an example optical telecommunications network 200 comprising a plurality of sites 201-214 interconnected by bidirectional fiber optic segments 301-319. In the example network 200, each site 201-214 is seen to comprise one, two or three network elements, each of which is connected to either one or two fiber optic segments.
Generally, it is helpful (and usually possible) to view each network element as part of a ring ADM system, a linear ADM system or a linear point-to-point system. For example, at site 201, network element 201A can be considered part of a ring ADM system consisting of network elements 201A, 202A, 203A, 204A, 205A and 206A. Similarly, at site 212, network element 212A can be considered as part of a ring ADM system consisting of network elements 212A, 213A, 204B, 203B, 207A, 208A, 210A and 211A. If any one fiber optic segment in a ring ADM system were missing from FIG. 2, then the corresponding network elements, formerly members of a ring ADM system, could be viewed as forming a linear ADM system.
Site 212 further comprises both a network element 212B, considered part of a linear point-to-point system joining this network element with network element 214A at site 214 via segment 317, and a network element 212C, considered part of another linear point-to-point system joining this network element to network element 211B at site 211 via segment 315. Network elements 212B and 212C are linked together at site 212 in a so-called back-to-back configuration.
Both network elements 212B, 212C are also seen to be connected to network element 212A via two internal links 402. In telecommunications networking terminology, site 212 would be better known as a "junction office". Other sites that are junction offices include site 204, at which network elements 204A and 204B are joined by an internal link 401 and site 210, at which network elements 210B and 210C are joined to network element 210A by a pair of internal links 403.
It is to be appreciated that the topology of the example network 200 in FIG. 2 is completely arbitrary, and has been created with the aim of illustrating the applicability of the present invention. The use or designation of junction offices therefore serves only as an example. Furthermore, pairs of fiber optic segments each devoted to a single direction of traffic flow may substitute each of the bidirectional fiber optic segments 301-317 shown in the example network 200.
As previously discussed, timing for each site can either be generated at the site (by a PRS clock) or it can be derived from network elements at neighbouring sites. For the purposes of understanding the present invention, it is important to introduce the notion of the number of potential timing references (PTRs) that are available to a site that does not generate its own timing. Among these PTRs, a certain number will be "independent". An ideal manner of illustrating the concept of an independent PTR is by way of example, with continued reference to FIG. 2.
Considering site 214, for instance, it is clear that a timing reference is only derivable from segment 317, i.e., there is but one PTR which is independent by default.
Next, one can consider site 201, which is shown connected to segments 301 and 307. Clearly, only two PTRs are available. Similarly, sites 202, 205, 206, 207, 209 and 213 also have access to exactly two PTRs. In each of these cases, the two available PTRs are independent, since they are derived from segments arriving from completely different directions of the network.
For the remaining sites the situation is quite different. At site 204, for example, timing is derivable from four PTRs, provided by segments 303, 304, 305 and 319. However, segments 303 and 304 are connected to a common site, namely site 203, while segments 305 and 319 diverge from site 204 in completely different directions. As a result, site 204 in fact has only three independent PTRs, which is also true of sites 203 and 212.
Similarly, it is determined that site 211 has only two independent PTRs, respectively originating from neighbouring sites 210 and 212. Regarding site 210, although it is connected to three other sites (208, 209 and 211), it too will have only two independent PTRs (the PTR from site 209 is not independent because in fact it leads from site 208 along the same general direction). Similarly, site 208 has two independent PTRs.
Having described the notion of a PTR, and in particular that of an independent PTR, the present invention may be compactly summarized by three principal steps, each of which is described in detail hereunder. Incidentally, it is to be understood that the method disclosed herein may be executed by a computing device or by a human network planner in a straightforward manner.
STEP I: Selection of the Sites at Which PRS Clocks are to be Deployed
FIG. 3A shows the distribution of PRS clocks placed at selected sites (as indicated by "PRS" symbols) in accordance with STEP I of the present invention. A site comprising a PRS clock is aptly named a "PRS site", and, as already mentioned, a site not comprising a PRS clock is referred to as an "intermediate site".
According to STEP I, therefore, and with reference to FIG. 3A, the installation of a PRS clock at a given site can be mandatory or desirable. It is required when the number of independent PTRs is not equal to two. This obviously includes sites which have only one PTR (e.g., site 214) as well as sites which have three or more independent PTRs (e.g., sites 204, 212). PRS clocks are not mandatorily placed at the remaining sites, which have exactly two independent PTRs.
It is to be understood that it is possible for a site to have two PTRs but which come from the same general direction, as would be the case with site 208 if segment 309 did not exist. In that case, site 208 would have access to only one independent timing reference, forcing the installation of a PRS clock in accordance with the present invention.
If, however, a given site has access to exactly two independent potential timing references, then placement of a PRS is still considered, being preferable if the site is considered significant for strategic business reasons. For instance, a site providing services to a large number of important business customers is eligible to become a PRS site, as is a site which would help shorten an extremely long chain of intermediate sites.
Accordingly, in the example network 200 in FIG. 3A, placement of an additional PRS clock would be preferable at site 201, minimizing the number of intermediate sites in the arc between site 201 and both of sites 203 and 204 already comprising respective mandatory PRS clocks. Also, if it is determined, for example, that site 208 is serving strategic customers, then it would be seriously impacted by a synchronization failure, prompting the placement of a PRS clock at this site, as illustrated in FIG. 3A.
STEP II: Selection of the Sites at Which BITSes are to be Installed
In addition to showing the PRS clocks installed in accordance with STEP I, FIG. 3B indicates by means of a "BITS" symbol the sites in the example network 200 at which respective BITSes are required to be installed in accordance with the inventive method. An intermediate site comprising a BITS is aptly named an "intermediate BITS site" and a PRS site with a BITS is called a "PRS BITS site".
Specifically, a BITS is to be deployed at a given site if there are (or are expected to be) two or more network elements physically located at that site. It follows that in the example network 200, BITSes are to be deployed at PRS sites 203, 204, 208 and 212, making them "PRS BITS sites". Similarly, BITSes are to be installed at intermediate sites 209, 210, 211, making them "intermediate BITS sites".
For each PRS BITS site, the inventive method simply requires that the ST1 PRS clock becomes the reference for the BITS. On the other hand, for intermediate BITS sites, the quality required of timing signal supplied by the BITS is preferably determined according to the (possibly expected) requirement that the site provide DS1 termination or synchronization for customers. If this is the case, a stratum 2 clock is to be deployed; otherwise, it is acceptable to use a stratum 3E clock. In either case, the BITS at an intermediate BITS site will rely on two timing inputs from the available PTRs.
STEP III: At Each Intermediate Site, Selection of Two Synchronization References From the Available PTRs and Selecting the NE's That Require SSM Enabling
The third step of the inventive method is most easily described by introducing the notions of an inter-PRS span and a synchronization distribution path, or "SDP". An inter-PRS span can be defined as the collection of (intermediate) sites and interconnecting segments which are located between two PRS sites. An example of an inter-PRS span can be found in FIGS. 3A and 3B, between PRS sites 212 and 208, consisting of sites 209, 210 and 211, as well as segments 310-316.
An SDP can be defined as a path belonging to a system (ring ADM, linear ADM, linear point-to-point, etc.) which exists between two adjacent intermediate BITS sites or PRS BITS sites for potentially delivering synchronization. An SDP can be either bidirectional or unidirectional, and is more suitably illustrated by way of FIGS. 4A to 4C. Specifically, FIG. 4A shows two intermediate BITS sites 11,12 connected as a linear point-to-point system by a fiber optic segment 14, which forms a bidirectional SDP delivering timing from one intermediate BITS site to the other. If site 11 were a PRS BITS site, then synchronization would only be deliverable from site 11 to site 12, and the SDP associated with segment 14 would be classified as unidirectional.
In FIG. 4B, there are shown three intermediate BITS sites 21,22,23 arranged as a linear ADM system or as part of a ring ADM system. There is a first bidirectional SDP between intermediate BITS sites 21 and 22 formed by a fiber optic segment 24 and a second bidirectional SDP between intermediate BITS sites 22 and 23 formed by a fiber optic segment 25. If site 22 were a PRS BITS site, then both SDPs would reduce to unidirectional ones. If only site 23 were a PRS site, then the SDP associated with segment 25 would reduce to a unidirectional one, while the SDP associated with segment 24 would remain bidirectional.
In FIG. 4C, there is shown a linear ADM system or part of a ring ADM system comprising three intermediate sites 31,32,33 interconnected by fiber optic segments 34,35. Among intermediate sites 31-33, only sites 31 and 33 are also intermediate BITS sites. Site 32 is void of a BITS and comprises a line-timed or through-timed network element. While there are certainly two PRTs available at site 32, derivable from data arriving on segments 34 and 35, these are part of the same bidirectional SDP 36 formed between the two intermediate BITS sites 31 and 33. With respect to directionality, the SDP 36 can be rendered unidirectional if a PRS clock is installed at either intermediate BITS site 31,33. On the other hand, if a PRS clock were installed at site 32, then the SDP 36 would be broken into two individual unidirectional SDPs.
Having defined what is meant by an inter-PRS span and a unidirectional or bidirectional SDP, it now is appropriate to break down STEP III of the present invention, which is concerned with selecting the two timing references (primary/secondary) for each intermediate site from among all the SDPs available at that site and also with enabling selected network elements with SSM. By administering STEP III, the number of network elements that need to be provided with SSM functionality is minimized, while the risk of creating timing loops is eliminated.
The execution of STEP III is best illustrated by referring to the flowchart in FIG. 5, which begins in box 501 with the consideration of a first inter-PRS span. The next step (box 502) determines whether the span being considered comprises exactly one intermediate site. If so, then two (independent) PRS clocks are available to this lone site, in which case the enabling of SSM at this site is not required (box 503). Next, the primary and secondary timing references for this site, which may or may comprise a BITS, are chosen arbitrarily from between the two neighbouring PRS sites (box 504).
However, in most cases, there will be more than one intermediate site in the inter-PRS span, and in this case (the "NO" path following box 502), the present invention calls for a slightly more sophisticated selection algorithm to be applied (box 505), which is illustrated in more detail in FIG. 6.
Specifically, with reference to FIG. 6, the first intermediate site from either PRS site terminating the inter-PRS span is considered (box 601). Box 602 determines whether or not the intermediate site is equipped with a BITS. If not, then the implication is that only one network element is present at that site, and its software or firmware is to be SSM-enabled (box 603). As for timing derivation, box 604 instructs the network element to take its primary and secondary timing references from its two available PRTs emanating from adjacent sites, i.e., the network element is "line timed" or, in the case of a regenerator, "through timed".
Box 605 determines whether there are any further intermediate sites to be considered and if so, box 606 requires that a new intermediate site be considered. The loop consisting of boxes 602-605 is performed on the new intermediate site, and the procedure continues until it is determined in box 605 that all intermediate sites in the inter-PRS span have been considered. Box 607 then dictates that SSM should also be enabled at all network elements (in adjacent sites) connected directly to any line or through timed network elements.
(In certain cases, box 607 may cause some overlap with previous execution of box 603. For example, when none of the intermediate sites in the inter-PRS span are intermediate BITS sites, these sites will already be enabled with SSM according to box 603 prior to execution of box 607, which will require that these same network elements be enabled with SSM. This is not inconsistent, and simply serves to cover all possible combinations of network element interconnections.)
Continuing with box 608, the first intermediate BITS site from one of the terminal PRS sites of the inter-PRS span is considered. (This PRS site need not be identical to the one chosen in box 601.) The next step (box 609) is to identify all SDPs between the current intermediate BITS site and the newly chosen PRS site. Such SDPs will be unidirectional, and effectively represent the number of PTRs originating from the PRS site and available to the first intermediate BITS site. One of the two timing inputs to the BITS at the first intermediate BITS site will be chosen from only one of these SDPs.
To ensure that only one such SDP is drawn from by the intermediate BITS site in question, box 610 applies a technique that is further described in FIG. 7. With reference to FIG. 7, therefore, box 701 performs a basic check to see whether there is in fact more than one available synchronization distribution path. If not, if there is only one SDP, then obviously that path is selected (box 702) as the timing input to the BITS at the first intermediate BITS site.
When there are multiple SDPs leading from the chosen PRS site to the BITS still in question, box 703 determines whether or not one of the paths belongs to a system (ring or linear point-to-point) that is already being used for timing distribution. For the first intermediate BITS site to be considered, there is no such path.
Accordingly, the flowchart leads to box 705, which determines whether one or more of the SDPs is part of a ring system. If so, box 706 indicates that the SDP selected to provide the first of two timing references to the first intermediate BITS site is the one which belongs to the ring system with network elements in the largest number of sites. If not, box 707 dictates that the desired SDP is to be chosen as the one which belongs the system comprising the fewest network elements between the current intermediate BITS site and the previous intermediate BITS site (or PRS site, if applicable). In the case of a linear point-to-point system with no intervening regenerators, for example, this number will be equal to two. In the case of a "tie" any one of the SDPs which meet the selection criteria may be chosen as the one used by the intermediate BITS site as the first timing input to the corresponding BITS.
Following the selection of the synchronization distribution path to be used by the intermediate BITS site, box 708 requires that SSM is to be enabled on all network elements that form this path. (This may cause some overlap with box 607 in FIG. 6 if the network element being enabled with SSM has already been so enabled because it is connected to a line timed or through timed network element.)
Still in relation to the first intermediate BITS site in the first inter-PRS span, the last step in FIG. 7 provides, in box 709, connection of the DS1 timing signal derived from one end of the SDP to one of the two BITS timing inputs of the intermediate BITS site in question. (At the other end of the unidirectional SDP is the chosen terminating PRS site and since a PRS clock does not require a timing reference input, there is no need to derive a DS1 timing signal from the SDP at this end.)
At this point, box 610 in FIG. 6 is complete, and the next step is to enable SSM on the BITS itself (box 611) and to select the external timing option for all network elements at the intermediate BITS site (box 612). The latter step simply ensures that the network elements receive their timing from the BITS. Next, it is determined whether or not there is at least one more intermediate BITS site in the inter-PRS span (box 613) and if so, to proceed with the next intermediate BITS site (box 614).
In box 615, it is necessary to determine all SDPs between the newly selected intermediate BITS site and the previous intermediate BITS site, the SDPs being bidirectional. Next, steps 610-612 are followed exactly as when the first intermediate BITS site was considered, although the path taken through FIG. 7 may be slightly different. Most notably, the answer to the question posed in box 703 may be "yes", i.e., there may actually be an SDP belonging to a system that is already being used for timing distribution. In that case, box 704 would dictate that the SDP corresponding to this system be chosen as the SDP used by the intermediate BITS site currently under consideration, thereby to reduce the number of network elements that would require SSM support and reduce the overall cost of synchronization distribution.
Another difference in flow will be encountered when passing through box 709, since neither end of the SDP will in general be a PRS site, and therefore a DS1 timing signal derived from the SDP by sites located at either end of the SDP will be connected to one of the two timing inputs of the corresponding BITS.
Finally, once it is determined in box 613 that the last intermediate BITS site in the first inter-PRS span has been considered, timing will have been distributed in both directions between one of the PRS sites and all BITSes in the inter-PRS span. However, there remains the final selection of a timing reference from the other PRS site to the last intermediate BITS site. To this end, box 616 requires the identification of all (unidirectional) SDPs between the last intermediate BITS site and the other PRS site. In box 622, the chosen SDP is determined in a manner identical to the procedure outlined in FIG. 7 and already used in box 610. As provided by box 709 in FIG. 7, it will obviously not be necessary to connect the chosen SDP to any timing inputs at the second PRS site.
At this point, the flowchart in FIG. 6 is complete and further description of the flow of the inventive method continues with reference to FIG. 5. Specifically, having now selected which two from the possible plurality of SDPs are to be used by each intermediate site in an inter-PRS span, it is verified whether all inter-PRS spans have been considered (box 506). If not, the next such span is considered (box 507), and the inventive procedure is reapplied, starting with box 502 in exactly the same way as previously described.
Of course, after each and every inter-PRS span has been considered, the answer to the question in box 506 is "YES" and the synchronization distribution algorithm in FIG. 5 ends. Each intermediate site in the entire network now has two timing references and STEP III of the inventive method is complete.
As an example of how the inventive method is applied, it is useful to refer to FIG. 3B and to the inter-PRS span between PRS sites 208 and 212 consisting of sites 209-211 and segments 310-316. FIG. 8 illustrates this inter-PRS span, as well as the BITSes 809-811 used for distributing timing to sites 209-211, respectively. By first considering site 211, it is observed that it is an intermediate BITS site, and that there exist two (unidirectional) SDPs leading from PRS site 212, as formed by segments 315, 316.
According to box 706 in FIG. 7, the selected SDP is the one formed by segment 316, i.e., it is associated with the ring system having network elements in the largest number of sites. Subsequently, according to box 709, the BITS timing input 801 of the BITS 811 at site 211 is derived from the chosen SDP.
Next, considering intermediate BITS site 210, box 703 dictates that the chosen SDP be associated with segment 314, as both segments belong to the same ring system. Box 709 then dictates that the first BITS timing input 803 to the BITS 810 at site 210 and that the second BITS timing input 802 to the BITS 811 at site 211 be derived from the chosen SDP.
The following step involves consideration of site 209, which is also happen to be an intermediate BITS site. Here, box 702 dictates that the only available SDP be used, namely, the one associated with segment 312. Thus, box 709 indicates that the first BITS timing input 805 to the BITS 809 at site 209 and that the second BITS timing input 804 to the bits 810 at site 210 be derived from this chosen SDP. Finally, the second BITS timing input 806 to the BITS 809 at site 209 is derived from the SDP selected according to boxes 616 and 702 as the one associated with segment 311.
It is then left as a simple exercise for the network system designer to establish the initial synchronization distribution configuration by assigning one of the two timing references as the primary and the other as the secondary. This can be done on the basis of proximity from the PRS, for example, for an inter-PRS span comprised of 6 intermediate sites arranged along an east-west axis, the 3 "eastern" intermediate sites would be getting their primary reference from the east-end PRS clock, while the other 3 intermediate sites would get their primary reference from the west-end PRS clock. It is understood, however, that due to the use of SSM, this initial configuration may change as faults occur on the fiber segments and synchronization distribution becomes rearranged under SSM control. However, by having applied the inventive design methodology described herein, timing loops will not be created.
While the preferred embodiment of the present invention has been described and illustrated, it will be apparent to one skilled in the art that numerous modifications and variations are possible. The scope of the invention, therefore, is only to be limited by the claims appended hereto. | A method for distributing synchronization in an optical communications network is disclosed. In order to keep costs to a minimum, the method consists of deploying requisite primary reference source (PRS) clocks only at those sites having access to more or less than two independent synchronization distribution paths (SDPs). PRS clocks are also preferably installed at sites located substantially far from a site already equipped with a PRS clock. As a result, a small number of PRS clocks end up being installed, leading to substantial cost savings for the telecommunications service provider. Subsequently, a building integrated timing supply (BITS) system is deployed at all sites comprising more than one network element. The BITS has two timing inputs, a primary and a secondary timing reference, selected from two of the accessible SDPs. Synchronization status messaging (SSM) is then enabled at selected network elements in order to prevent the occurrence of timing loops while the number of network elements that need to be equipped with SSM by appropriately choosing which SDPs are used for the primary and secondary timing references. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention generally relates to an airflow diverter. More specifically, the present invention relates to an aquarium airflow diverter.
[0003] 2. Description of Related Art
[0004] Air stones are employed frequently for aerating the water of an aquarium to provide oxygen for fish and other marine life that may be present in the aquarium. The air stone is constructed of a body of porous material through which air can propagate. In a typical installation in an aquarium the air stone is connected via a flexible air tubing to an air pump located outside of the aquarium. The pump pumps air via the tubing into the air stone. The air stone then disperses the air to form a stream of bubbles that migrate upwardly through the water. The air stone can also be placed within the lift tube of an aquarium undergravel filter to allow an entrained stream of bubbles to draw water through the lift tube and, thereby, circulate water through the filter.
[0005] The construction of the air stone permits its use in situations, other than that of the fore-going aquarium, in which it is desired to disperse a gas within a fluid. However, for purposes of demonstrating the use of the invention, it is presumed that the air stone is to be employed for aeration of water in an aquarium.
[0006] A problem arises in the construction of air stones in that air forced into the stone tends to propagate through a portion of the porous material of the stone located generally in the vicinity of the air inlet to the stone, while the remaining portion of the body of porous material is essentially inactive in the process of dispersing the air. As a result, there is a significant diminution in the esthetic appearance to the paths of bubbles emanating from the air stone because the bubbles emanate only from the upper portion of the stone rather than emanating uniformly from the entire exterior surface of the stone. In addition, there is usually a mineral build up at the end of the air inlet into the stone that starts to clog after a while. Also, since the path of air is only through the upper part of the stone, the underutilization of the lower portion of the air stone results in a more rapid clogging and wearing of the upper portion of the air stone resulting in a more frequent need for replacing the air stone.
[0007] It would therefore be useful to develop a device for altering the flow of air from an air stone. It would also be useful to develop a device that improves the appearance of the air stone, thus making the air stone more attractive.
SUMMARY OF THE INVENTION
[0008] According to the present invention, there is provided a method of altering airflow of an aquarium air supply by placing a bottle over the air supply and altering the airflow. Also provided is a decorative attachment assembly for use in an aquarium. The assembly including a bottle having at least a first hole and a second hole, wherein the first hole is capable of accepting an aerating device, and the second hole is of a size sufficient to allow air to flow from the aerating device into the aquarium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention are readily appreciated, as the invention becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0010] [0010]FIG. 1 shows the bottle of the present invention; and
[0011] [0011]FIG. 2 shows a side view of the bottle of the present invention positioned at an angle within the aquarium.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Generally the present invention provides a method and device for altering the airflow in an aquarium. The present invention also provides a device for covering an air stone. The device is preferably an attractive bottle 10 that disguises the presence of the air stone while directing the flow of air from the air stone in a desired direction.
[0013] It is well known to those of skill in the art that aerating devices are used in aquariums. One problem with such aerating devices is that they do not evenly distribute the flow of air bubbles and are unattractive to view in the aquarium. Since many individuals who have aquariums in their homes include in the aquariums other display pieces for making the aquarium more attractive, it is more desirable to have a product that is capable of at least partially blocking the view of the aerating device and any filters associated therewith. The present invention accomplishes this by covering the aerating device with a bottle 10 or other container capable of having a first hole 12 and a second hole or spout 14 spaced therefrom. The aerating device is placed within the bottle 10 and the air is allowed to escape from the top of the bottle 10 .
[0014] The airflow altering device is preferably a bottle 10 . The bottle 10 is placed within the aquarium and the aerating device is placed within the bottle 10 . The bottle 10 is then partially buried in the gravel found on the bottom of the aquarium. This can be at any angle desired by the individual placing the bottle 10 . Thus the bottle 10 can appear to be part of buried treasure or can be standing upright within the aquarium.
[0015] The bottle 10 can be any type of bottle. The bottle 10 can be made from glass, plastic, or of any other material that can withstand the rigors of a water environment. Examples of such bottles can be liquor bottles, wine bottles, decorative bottles, or artistic bottles available to individuals. The bottle 10 of the present invention can be of any color that glass can be formed, it can be clear, opaque, or completely tinted thus preventing light to shine through. Therefore, any bottle can be utilized. All that is required is that the bottle 10 be able to withstand having a hole made in the bottle 10 that enables the insertion of an aerating device into the bottle 10 .
[0016] The bottle 10 of the present invention includes at least two holes. The first hole 12 is a hole into which an aerating device is placed. The first hole 12 is typically located at the base of the bottle 10 . Alternatively, the first hole 12 can be located anywhere on the bottle 10 that will be in close proximity to the bottom of the aquarium in which the bottle 10 is placed. In other words, the bottle is modified so that there are two holes in the bottle while not altering the general appearance of the bottle. The bottle 10 is not required to have an actual base, therefore if one does not wish to drill a hole, they can remove the bottom of the bottle 10 and the aerating device can be placed into the bottle 10 from the lack of base. The second hole 14 is at the end of the bottle 10 that is facing upward. It is through the second hole or spout 14 that the air bubbles are allowed to escape, thus aerating the aquarium.
[0017] The aerating device can be any aerating device known to those of skill in the art. Such a device can be as simple as a hose pumping air into the aquarium to an air stone or more complicated system. The air stone that can be used in conjugation with the present invention can be any aerating device that is known to those of skill in the art. The aerating device is typically continually connecting to an aerating processor through an airline tubing. The aerating processor maintains a constant flow of air to the aerating device thus maintaining the proper aeration of the water present in the aquarium. An example of such an aerating device can be used in an aquarium as disclosed below.
[0018] An aerating device can be used in aquarium tank constructed of transparent glass walls and holding water for support of marine life. A layer of gravel is typically disposed on a bottom wall of the tank. An air stone rests upon the gravel, and is connected by a connector to an air inlet conduit constructed as flexible plastic tubing. An air pump located outside of the tank is connected to the tubing for pumping air into the air stone. The air stone is fabricated of a porous material that is held together by cement, such as a one part acrylic adhesive material. The air stone is permeable to air. The density of the air stone can be varied. However, generally, the greater the density the more air pressure will be needed. Air delivered by the pump through the tubing permeates through the pores of the material of the air stone to be dispersed and to emit bubbles along the outer surface of the air stone. The bubbles migrate upwards through the water to aerate the water and to introduce a movement to the water by virtue of entrainment of the bubbles within the water.
[0019] An under gravel aquarium filter is installed in the bottom of the aquarium tank. The filter comprises a perforated plate having depending leg portions along the outer edges of the plate for supporting the plate parallel to and spaced apart from the bottom wall to form therewith a chamber. A layer of gravel is disposed along the top surface of the perforated plate. An airlift tube submerged within the water is oriented vertically, and passes through the layer of gravel to be seated within an aperture of the plate. The aperture allows the tube to communicate with the chamber. The air stone with the air-supply tubing are disposed within the lift tube with the air stone being located adjacent the bottom of the lift tube.
[0020] In operation of the filter, bubbles emanate from the air stone, become entrained in a column of water within the lift tube, and introduce an upward flow of water within the lift tube as the bubbles migrate upwards through the lift tube. As the water flows upward through the lift tube, water from the chamber enters the bottom of the lift tube, and other water from the central region of the tank moves downward through the layer of gravel and through perforations of the plate into the chamber. Thus, there is circulation of water about the tank, with circulated water passing through the filter to produce clear water within the chamber. The gravel and the perforated plate serve to filter debris and pollutants from the aquarium water while the air stone aerates the water to provide oxygen for marine life which may be placed in the aquarium tank.
[0021] The bubbles emanate from the upper portion of the air stone in the vicinity of the air output of the stem. This occurs because the propagation path of air through the porous material as shown by the arrows is relatively short in the vicinity of the stem, and relatively long in a direction downward from the stem towards the bottom of air stone. Resistance to passage of air through the porous material of the stone increases with propagation distance. Thus, all or nearly all of the bubbles appear in the upper portion of the stone while virtually no bubbles appear at the lower portion of the stone.
[0022] The extent from which the bubbles leave from the exterior surface of the air stone depends upon a combination of factors including the density of the air stone and the amount of air pressure supplied. For a denser air stone, and with sufficient air supply, bubbles can be forced to leave from a lower portion of the air stone. However, this requires considerable additional pressure that is often not available in aquarium systems. This is especially a problem where large air stones are utilized. Frequently, such large air stones are desirable in order to keep the air tubing down and prevent it from bobbing upward. However, with such large air stones being very dense, the amount of air pressure required to drive the air out of the lower portions of the air stone becomes impractical to achieve with regular air pumps and, would tend to damage the air pump if driven so hard. Accordingly, typically with standard air stones the bubbles only leave from the upper part of the air stone.
[0023] This presents a poor aesthetic appearance to the air stone. Additionally, since only the upper portion is being utilized, it tends to clog and once it clogs, it retards the flow of air. It also presents a non-uniform utilization of the material of the air stone since the bottom half is hardly used. This becomes a further problem since at the exit of the stem, there tends to be a mineral build-up as a result of the content of the water and this further clogs the flow of air so that after a while the standard air stone becomes a poor supply of air to the aquarium tank.
[0024] In the construction of the air stone, the stone comprises a cylindrical sidewall that encloses and defines the chamber, and a lower end wall, which closes off the lower end of the chamber. Preferably, the thickness of the lower end wall is equal to the thickness of the sidewall so as to provide for equality of propagation paths for air propagating from the chamber through the porous material of the stone. This enables the air to exit in dispersed fashion as the bubbles from an outer surface of the stone.
[0025] In inserting the stem into the port of the chamber, the stem is coated with a barrier layer, typically adhesive material and secured within the chamber. The adhesive material can be of the same type of cement that is used to retain the air stone material together which can be a one part acrylic material without the use of any catalyzers. The entire length of the stem is coated and then inserted into the chamber. However, as will be described hereinafter, the extent of the coating can vary dependent upon the density of the air stone material.
[0026] As a result of the barrier layer, the flow of air it receives a greater resistance to flow in the upper half of the air stone material. As a result, the air leaving from the stem enters into the plenum formed within the chamber and disperses through the walls of the air stone in the lower half of the air stone. Because the sidewalls and bottom wall thickness of the air stone material surrounding the plenum is substantially equal, air will leave equally from the sidewalls below the stem and the bottom wall.
[0027] The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation.
[0028] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention can be practiced otherwise than as specifically described. | A method of altering airflow of an aquarium air supply by placing a bottle over the air supply thus, altering the airflow. The method can be accomplished using a decorative attachment assembly that covers an air stone in an aquarium. The assembly includes a bottle having at least a first hole and a second hole, wherein the first hole is capable of accepting an aerating device, and the second hole is sized to allow air to flow from the aerating device into the aquarium. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel process for producing an antibiotic KA-6643-A or a salt thereof.
2. Description of the Prior Art
The present inventors have found that a new strain KC-6643 belonging to the genus Streptomyces can prepare a novel antibiotic possessing potent antibacterial activity against gram-positive and gram-negative bacteria. As a result of this finding, they have succeeded in isolating antibiotics KA-6643-A and KA-6643-B as novel antibiotics from culture broths of such strain, as disclosed in co-pending United States patent application Ser. No. 137,259 in the names of the present inventors and other joint inventors.
In general, these novel antibiotics are represented by the formula (III): ##STR3##
The formula (III) represents the KA-6643-A antibiotic when R is a hydrogen atom and the KA-6643-B antibiotic when R is a sulfonic acid group. Both the KA-6643-A antibiotic (hereinafter referred to as "KA-6643-A") and the KA-6643-B antibiotic (hereinafter referred to as "KA-6643-B") exhibit marked antibacterial potency. It has been found that the former is superior in the potency to the latter.
In various studies leading to the present invention, it has now been found that KA-6643-A can be easily obtained from conversion of KA-6643-B by hydrolysis.
SUMMARY OF THE INVENTION
Therefore, one object of the present invention is to provide a novel technique of producing KA-6643-A of excellent antibacterial characteristics with operationally and economically satisfactory results.
This object and other objects of the invention as hereinafter will become more readily apparent can be attained by a process for producing KA-6643-A or a salt thereof represented by the formula (I): ##STR4## by hydrolyzing KA-6643-B represented by the formula (II): ##STR5##
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A KA-6643 substance exists in two isomeric forms, i.e., cis and trans forms because the substance contains a double bond in its side chain. The cis isomer is represented as the Z form and has the formula (IV): ##STR6## wherein R is a hydrogen atom or a sulfonic acid group, and the trans isomer is represented as the E form and has the formula (V): ##STR7## wherein R is the same as defined above.
As a metabolic product obtained is the E form. When reacted with a mercuric salt, however, the E form is convertible to the Z form, as taught in Japanese Patent Application No. 55-86989. Accordingly, it is possible to utilize either one of the E and Z forms as a raw material for the process of the present invention. Instead of isolating the KA-6643 substance either from a filtrate of a culture broth of a strain belonging to the genus Streptomyces and being capable of preparing the substance or from a crude active fraction obtained by culturing the strain, KA-6643-B may also be converted to KA-6643-A by hydrolyzing such culture broth filtrate or crude active fraction.
For the practice of the process according to this invention, the hydrolysis reaction is effected by acid hydrolysis, alkali hydrolysis or a similar type of reaction, or by contact with an ion-exchange resin.
Suitable acids for use in acid hydrolysis include inorganic acids such as phosphoric acid and sulfuric acid, and organic acids such as citric acid and oxalic acid. Suitable alkalis for use in alkali hydrolysis include sodium hydroxide, barium hydroxide and aqueous ammonia. Suitable ion-exchange resins include strong acid cation exchange resins such as Amberlite IRA-410, Amberlite IR-120 (Rohm and Haas Co.) and Dowex 50 (Dow Chemical Co.), and weak acid cation exchange resins such as Amberlite IRC-50, Amberlite IRC-84, Amberlite CG-50, Diaion WK-10 and Diaion WK-20 (Mitsubishi Chem. Ind., Ltd.).
An antioxidant such as acidic sodium sulfite, if desired, may be added to the hydrolysis reaction system.
The hydrolysis reaction is suitably carried out at temperatures of room temperature to 100° C. for periods of time for 1 to 10 hours.
The isolation of the desired product or KA-6643-A from the reaction mixture and subsequent purification of the product are achieved by any commonly used technique, preferably by gel filtration, column chromatography, reversed phase chromatography or freeze-drying, or any combination thereof.
If it becomes preferable, KA-6643-A may be converted to an alkali metal salt; an alkaline earth metal salt; a primary, secondary or tertiary amine salt; a quaternary ammonium salt; or a lower alkyl ester or fatty acid ester.
Having generally described the invention, a further understanding can be obtained by reference to Reference Example and certain specific Examples which are provided herein for purposes of illustration only and not intended to be limiting unless otherwise specified.
REFERENCE EXAMPLE
(i) Into a medium which had a composition of 2% of starch, 1.5% of soybean flour, 0.28% of potassium phosphate monobasic, 0.18% of sodium phosphate dibasic.dodecahydrate, 0.005% of cobalt chloride.hexahydrate, 0.05% of magnesium sulfate.heptahydrate and 0.001% of ferrous sulfate and which had been adjusted to a pH of 6.0 and sterilized were inoculated mycelia of a KC-6643 strain, followed by pre-culture at 27° C. for about 48 hours to give a first seed culture. Into each of two tanks each having a volume of 200 l was charged 100 l of another medium of the same composition as used above but having 1% of cotton seed oil added. The first seed culture was inoculated into each tank in an amount of 500 ml and cultured at 30° C. for 4 days by an aerated agitation system (rpm: 300, flow rate of air: 50 l/min).
(ii) After completion of the culture, 10 v/v % of Dicalite Perlite 4109 (Dicalite Orient Co., Ltd.) was added to the culture broth (170 l) as a filter aid, and the mycelia were removed by filtration. The resulting filtrate (150 l) was adjusted in its conductivity to 1.5 m /cm and passed through a column (21.5×45 cm) of a strong basic anion exchange resin, Diaion PA316 (Cl - type: Mitsubishi Chem. Ind., Ltd.) at a flow rate of 200 ml/min. After being washed with a 0.01M phosphate buffer solution (pH: 7.0), the resin was subjected to elution with a 0.01M phosphate buffer solution (pH: 7.0) containing 2M of sodium chloride in 2 v/v % of aqueous methanol at a flow rate of 150 ml/min to collent an active fraction. The resulting active fraction was passed through a column (16×10 cm) of Diaion HP-20, which had been adjusted with a 10 w/v % sodium chloride solution, at a flow rate of 400 ml/min and, after being washed with a 10 w/v % sodium chloride solution, was eluted with dionized water a flow rate of 200 ml/min to collect an active fraction.
(iii) The active fraction obtained in (ii) above was passed through a column (6×70 cm) of a strong basic anion exchange resin, Amberlite IRA-458 (Cl - type: Rohm & Haas Co.), at a flow rate of 50 ml/min and eluted with a 0.01M phosphate buffer solution (pH: 7.0) containing 0.15M sodium chloride to collect a fraction in which KA-6643-A was included. Thereafter, the fraction was eluted with a 0.01M phosphate buffer solution (pH: 7.0) containing 2M sodium chloride to yield an active fraction.
(iv) The active fraction obtained in (iii) above was passed through a column (6×70 cm) of Diaion HP-20 which had been pre-treated with a 20 w/v % aqueous sodium chloride solution, and eluted with deionized water at a flow rate of 20 ml/min to collect an active fraction. The active fraction was diluted with deionized water to have an electroconductivity of about 700 μ /cm and passed through a column (3×30 cm) of a weak basic anion exchange resin, DEAE-Sephadex A-25 (Pharmacia Fine Chemicals), which had been adjusted to a pH of 7.0 using a 0.01M phosphate buffer solution, followed by washing with water and by elution with a phosphate buffer solution (pH: 7.0) containing 0.15M of sodium chloride at a flow rate of 35 ml/min to collect an active fraction. The active fraction was concentrated under reduced pressure at below 30° C., passed through a column (3.5×40 cm) of Diaion HP-20 which had been pre-treated with a 10 w/v % aqueous sodium chloride solution, and then eluted with deionized water at a flow rate of 20 ml/min to collect an active fraction. The resulting active fraction was concentrated under reduced pressure to about 2 ml and freeze-dried to yield 190 mg of a crude powder of KA-6643-B. The thus obtained crude powder was dissolved in 1 ml of deionized water, passed through a column (2×30 cm) of Diaion HP-20 and thereafter eluted with deionized water at a flow rate of 1 ml/min to collect an active fraction. The active fraction was concentrated under reduced pressure and passed through a column of Sephadex G-10, followed by development with deionized water at a flow rate of 2.0 ml/min. The resulting active fraction was collected, concentrated under reduced pressure to about 2 ml and then freeze-dried to yield 80 mg of a crude powder.
(v) 80 mg of the crude powder obtained in (iv) above was dissolved in 0.1 ml of a 0.1M phosphate buffer solution (pH: 6.8) and passed through a column (0.8×120 cm) of Bondapack C 18 /Polasil B (Waters Associates, Inc.) which had been pretreated with a 0.1M phosphate buffer solution, followed by elution with the same buffer solution at a flow rate of 6 ml/min to collect an active fraction. The active fraction was passed through a column (0.9×5 cm) of active carbon, washed with deionized water and then eluted with 50 w/v % aqueous acetone to collect an active fraction. The resulting active fraction was concentrated under reduced pressure to about 1 ml and freeze-dried to yield 35 mg of a pure powder of KA-6643-B.
EXAMPLE 1
80 mg of a sodium salt of KA-6643-B was dissolved in 2 ml of 0.1M phosphate buffer solution (pH: 7.0), and the solution was allowed to stand in a water bath at 70° C. for 4 hours. After being cooled to room temperature, the solution was passed through a column (8×1,200 mm) of Bondapak C 18 for adsorption. Elution was performed at a flow rate of 6 ml/min by use of a 0.05M phosphate buffer solution (pH: 6.8) containing 3% methanol. KA-6643-B was eluted after a retention time of 35 minutes, whereas KA-6643-A was eluted after a retention time of 120 minutes. The fraction containing KA-6643-A was collected and concentrated to about 5 ml under reduced pressure. The concentrate was passed through a column (20×200 mm) of Diaion HP-20 which had been pre-treated with a 10% sodium chloride solution and eluted with deionized water. The active fraction was collected and concentrated to about 2 ml. The concentrate was passed through a column (25×1,000 mm) of Sephadex G-10 and eluted with deionized water. The resulting active fraction was collected and freeze-dried to yield 2.2 mg of a sodium salt of KA-6643-A. The ultimate substance was identical with the authentic product derived from fermentation in terms of the physicochemical and biological properties.
EXAMPLE 2
60 mg of a sodium salt of KA-6643-B was dissolved in 10 ml of 0.1M acetate buffer solution (pH: 6.0), and the solution was allowed to stand in a water bath at 60° C. for 2.5 hours. After being cooled to room temperature, the solution was passed through a column (20×150 mm) of QAE-Sephadex A-25. Elution was performed by a concentration gradient method using a 0-0.9% sodium chloride solution. The active fraction was collected and concentrated to about 3 ml under reduced pressure. The concentrate was passed through a column (20×200 mm) of Diaion HP-20 pre-treated with a 10% sodium chloride solution and eluated with deionized water. The active fraction was collected and concentrated to about 2 ml under reduced pressure. The concentrate was passed through a column (25×1,000 mm) of Sephadex G-10 resulting and eluted with deionized water. The resulting active fraction was collected and freeze-dried to yield 1.8 mg of a sodium salt of KA-6643 -A.
Having now fully described this invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made to the invention without departing from the spirit or scope of the appended claims. | An antibiotic KA-6643-A or a salt thereof having the formula: ##STR1## is produced by a process comprising the step of hydrolyzing an antibiotic KA-6643-B of the formula: ##STR2## | 2 |
The present invention relates to a support device for a furnace, particularly the bottom furnace of a flash smelting furnace.
DESCRIPTION OF THE PRIOR ART
Typically furnaces used in the production of metals, for example flash smelting furnaces, comprise a furnace space with walls typically lined with fire-resistant material. Around the furnace walls, there is typically arranged a supporting construction comprising, among others, vertical support pillars that are spaced apart and provide support for the furnace walls, among others. The pillars are arranged to be flexibly attached to other support structures, so that they allow the movement of the furnace walls that is caused by thermal expansion. The furnace is arranged on top of a foundation that also supports the rows of vertical support pillars. A flash smelting furnace has a bottom part preferably provided with a curved top surface, which is curved, starting from the centre part, upwardly towards the side walls. The side walls are typically structural elements arranged at the bottom part edges by means of a joint that allows the shifting of the walls caused by thermal expansion. Underneath the furnace wall support pillars, there are provided so-called base plates bedded in a concrete foundation. At the bottom part, the side wall support pillars have extended as far as the base plates. The support pillars are attached to the support structures by means of flexible elements. When the furnace temperature is high, the side wall support pillars have shifted, along with the side walls, when the flexible elements have allowed, both up and away from the furnace, so that an aperture has formed between the support pillar and the base plate. The support structures according to the prior art require a foundation extending to underneath the vertical support pillars, which in addition to space also requires a lot of construction material. The aperture created between the pillars and the base plate collects dirt and is a drawback also from the esthetical point of view.
BRIEF SUMMARY OF THE INVENTION
The object of the invention is to realise a completely new support device arrangement, whereby the drawbacks of the prior art are avoided.
The arrangement according to the invention is characterised by what is set forth in the appended claims.
The arrangement according to the invention has several remarkable advantages. Now the furnace foundation does not have to extend underneath the vertical support pillars, in which case both concrete and steel needed in the base plates is saved. Cleaning is easier, because underneath the furnace pillars there are not left small apertures that are difficult to keep clean. When the arrangement according to the invention is applied to the renewing of old furnaces, a new and a larger furnace can be built on top of the old foundation. The direction of the wall pillar, caused by the movement of the furnace walls, is easier to control than before. By making the support surface in the form of a slot, there is obtained a simple and secure solution for controlling the motion of the support pillar. When a pin element is used as a counterpart, there is realised an easily attachable and simple arrangement that is particularly well suited to be used together with the slot serving as the support surface. Said counterpart can also advantageously be used as a fastening point for the pull bar of the fastening device.
The invention is explained in more detail below with reference to the appended drawings, where
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art arrangement provided in connection with the bottom furnace of a flash smelting furnace,
FIG. 2 illustrates a support device according to the invention, provided in connection with the bottom furnace of a flash smelting furnace, fitted at point A of FIG. 1, and
FIG. 3 illustrates a support device according to the invention, seen in the direction B—B of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows, in simplified illustration, part of a prior-art smelting furnace support structures seen at the furnace end. Around the furnace walls, there is typically provided a support structure that comprises, among others, vertical support pillars 21 that are spaced apart and support the furnace walls 20 , among others. The pillars are fastened, by means of flexible elements 23 of fastening device 22 , flexibly to the support structures, so that they allow for instance the motion of the furnace walls 21 caused by thermal expansion. The furnace is arranged on top of a foundation 24 , which also supports the rows of vertical support pillars 21 . Underneath the support pillars 21 , there are used so-called base plates 25 that are bedded in the concrete foundation 24 . The flash smelting furnace comprises a bottom part 26 preferably provided with a curved top surface 27 that is curved from the center part upwardly towards the side walls 20 , so that there is formed a concave furnace bottom surface. Typically the side walls 20 are structural elements arranged at the edges of the bottom part 26 by means of a joint that allows the shifting of the walls caused by thermal expansion. The pillars are also fixed at their top part, for instance by means of pull bars and flexible elements. The fastening of the top part is not dealt with here, but it is assumed to represent technology known as such for a man skilled in the art.
FIGS. 2 and 3 illustrate an arrangement according to the invention when applied in connection with the bottom furnace of a flash smelting furnace, within the area A marked with a dotted line in FIG. 1 . In FIGS. 2 and 3, the reference numbers for various parts differ from those used in FIG. 1 . The support device according to the invention comprises a pillar part 1 and a pillar part fastening device 2 , provided with at least one flexible element 3 . In the pillar part 1 , there is arranged at least one support part 4 comprising a support surface 5 for at least one counterpart 6 provided in the furnace structures. The supporting part 4 extends from the level of the side surface on the furnace wall 20 to a distance towards the furnace. In the embodiment according to FIG. 2, the supporting part 4 is a lug that is typically attached, for example by means of welding, to the pillar part 1 , preferably to its bottom part. In the embodiment according to the drawing, the support surface 5 is the side surface of the slot 7 formed in the supporting part 4 . In connection with each pillar element 1 , there can be several adjacent supporting parts 4 . For instance the counterpart 6 is a pin element that is typically arranged in a transversal direction with respect to the pillar element 1 , so that it fits into the slot of the supporting part 4 . The contacting surfaces of the slot 7 and the counterpart 6 control the motion of the pillar element, at least partly. In the embodiment according to FIG. 2, the pin element is a bar that is round in cross-section and attached to the support structure 28 of the bottom part. The pin element is arranged somewhat towards the furnace from the level of the outer wall of the wall element, and underneath the junction surface 11 between the wall and the bottom.
At least in one cross-sectional direction, the support surface 5 of the supporting part 4 is essentially parallel to the junction surface 11 between the wall element and the bottom element 20 . According to a preferred embodiment, the support surface 5 is parallel to a line tangent of the junction surface 11 . Thus the motional direction of a pillar element can be affected by means of the shapes of the support surface 5 and the counterpart.
In the embodiment according to FIG. 2, the counterpart 6 provides a fastening point for the pull bar 8 of the fastening device 2 . The pull bar 8 is attached, by a fastening loop 12 , to the pin element. In the pillar element, there is arranged a second support surface 9 , against which the flexible element 3 of the fastening device 2 is tightened and locked by tightening means 13 , 14 . In the support surface 9 , there is provided an aperture for the pull bar 8 of the fastening device 2 . In the case of FIG. 2, the pull bar 8 is provided at both ends with flange elements 15 , 16 .
In the pillar element 1 , preferably at the bottom part thereof, there is arranged at least one compartment 10 in order to protect the fastening device 2 . The adjacent support pillars 1 are interconnected by at least one transversal support pillar 13 . In the embodiment according to FIG. 3, each support pillar 1 is at the bottom part attached to the furnace structures by two fastening devices 2 . Thus the compartments 10 are arranged symmetrically with respect to the pillar 1 . The transversal support beam 13 is preferably arranged at the compartments 10 , in between the compartments 10 of adjacent pillars. The compartments 10 protect the fastening device 1 , particularly its flexible element 3 , against possible melt leaks, among others.
In the installation step, the pillar elements 1 are supported, at their inclined slots 7 , against the pins serving as counterparts 6 , which pins also function as fastening points for the pull bars 8 of the fastening device 2 . Later during operation, the pillar elements 1 move along their inclined slots 7 , and the support of the pillars is at least partly shifted to depend on the friction between the pillar elements 1 and the wall elements 20 .
The support device according to the invention can also be used in connection with the end walls of a flash smelting furnace. In that case the motional direction of the walls is mainly horizontal, which means that the support surface of the support element can also be horizontal.
It is obvious for a man skilled in the art that the invention is not restricted to the above described embodiments only, but it can be modified within the scope of the appended claims. | A support device for a furnace, particularly the bottom furnace of a flash smelting furnace, includes a fastening device flexibly connecting a pillar element to a support structure. The pillar element includes a support part having a slot for receiving a counterpart attached to the support structure. The engagement of the counterpart with the slot controls the horizontal motion of the pillar element as the furnace walls move caused by thermal expansion. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §120 as a continuation of U.S. patent application Ser. No. 11/423,873, filed Jun. 13, 2006, and titled “AUTOMOTIVE ECU MOBILE PHONE INTERFACE,” the entire contents of which are incorporated herein by reference.
[0002] Name of Applicant: Hendalee Wilson
FEDERALLY SPONSORED RESEARCH
[0003] Non applicable
SEQUENCE LISTING OR PROGRAM
[0004] Non applicable
BACKGROUND OF INVENTION
[0005] The present invention relates to use of a mobile phone to extract automotive data from an automobiles engine control unit (ECU) and translate it into human readable form on the phones display, while simultaneously broadcasting the information internet-based system for immediate repair and roadside assistance.
BACKGROUND OF THE INVENTION-PRIOR ART
[0006] The Environmental Protection Agency (EPA) requires vehicle manufacturers to install on-board diagnostics (OBD-II) for monitoring light-duty automobiles and trucks beginning with model year 1996. OBD-II systems (e.g., microcontrollers and sensors) monitor the vehicle's electrical and mechanical systems and generate data that are processed by a vehicle's engine control unit (ECU) to detect any malfunction or deterioration in the vehicle's performance. Most ECUs transmit status and diagnostic information over a shared, standardized electronic bus in the vehicle. The bus effectively functions as an on-board computer network with many processors, each of which transmits and receives data. The primary computers in this network are the vehicle's electronic-control module (ECM) and power-control module (PCM). The ECM typically monitors engine functions (e.g., the cruise-control module, spark controller, exhaust/gas recirculator), while the PCM monitors the vehicle's power train (e.g., its engine, transmission, and braking systems). Data available from the ECM and PCM include vehicle speed, fuel level, engine temperature, and intake manifold pressure. In addition, in response to input data, the ECU also generates 5-digit ‘diagnostic trouble codes’ (DTCs) that indicate a specific problem with the vehicle. The diagnostic trouble codes need to be coupled with OBD-II documentation so the fault code produced by the vehicle can be conceptualized by the auto owner. For instance a DTC of P0118 can be translated to the text ‘Engine coolant temperature circuit high input.’ The presence of a DTC in the memory of a vehicle's ECU typically results in illumination of the ‘Service Engine Soon’ light present on the dashboard of most vehicles.
[0007] Data from the above-mentioned systems are made available through a standardized, serial 16-cavity connector referred to herein as an ‘OBD-II connector’. The OBD-II connector typically lies underneath the vehicle's dashboard. When a vehicle is serviced, data from the vehicle's ECM and/or PCM is typically queried using an external engine-diagnostic tool (commonly called a ‘scan tool’) that plugs into the OBD-IL connector. The vehicle's engine is turned on and data are transferred from the engine computer, through the OBD-II connector, and to the scan tool. The data are then displayed and analyzed to service the vehicle. Scan tools are typically only used to diagnose stationary vehicles or vehicles running on a dynamometer.
[0008] Some vehicle manufacturers also include complex electronic systems in their vehicles to access and analyze some of the above-described data. For example, General Motors includes a system called ‘On-Star’ in some of their high-end vehicles. On-Star collects and transmits data relating to these DTCs through a wireless network. On-Star systems are not connected through the OBD-II connector, but instead are wired directly to the vehicle's electronic system. This wiring process typically takes place when the vehicle is manufactured.
[0009] Prior to this invention, connecting to the OBDII interface required large costly hardware, which utilized proprietary software. In addition, many of the tools used to access automobile information returned native codes, which are not in a descriptive form and does not offer the any indication of the vehicles malfunction. Furthermore, a vehicle would have to be transported to a location in which the automobile information could be retrieved. Also, instances arise in which vehicles have stored information that state the vehicle should not be driven any further. This cannot be derived until the vehicle is brought to a location that has the expertise, hardware, and software to tell the owner that this is the case. This could cause extreme and irreversible damage to the vehicle. Lastly, the information about vehicles information is local. This information is compiled locally and not compiled into a database.
[0010] The current state of automotive repair service is one where organization must wait for an individual to come in and try to explain symptoms that they perceive the vehicle as having. Automotive repair services must allocate time and resources after the technician have checked the vehicle. This leads to much inefficiency in resource allocation at these organizations.
BACKGROUND OF THE INVENTION—OBJECTS AND ADVANTAGES
[0011] The Automotive Cellular Interface is a system that uses cellular phones to access automobile computer systems, interpret the information and shows the text on the cellular phones display. Simultaneously transiting the retrieved information, as well as characteristic and states of the cellular phone used to access the vehicle computer system, to a global network that would alert parties who could assist or benefit from the retrieval automobile information. An example could be, but not limited to the following scenario:
SUMMARY
[0012] The invention is a system for interfacing mobile phones with an on-board diagnostic computer in a vehicle, wherein the on-board diagnostic computer monitors a set of operational characteristics of a vehicle. The information derived from this system will be processed on the mobile phone coupled with additional information and displayed on the mobile phones screen, while simultaneously transmitting this information over the internet to be stored in a database.
DRAWINGS FIGURES
[0013] FIG. 1 is a schematic drawing of system of the invention featuring a single vehicle making contact with the vehicle via a microcontroller:
[0014] FIG. 2 is an example of the mobile phone display after information has been extracted from the vehicles ECU.
[0015] FIG. 3 is a schematic of the flow of information through system of the invention. It shows the dialogue between the users, the system, and organizations connected to the system.
DETAILED DESCRIPTION
[0016] Description FIG. 1 —shows a cellular phone with software application that can establish a connection with the automobile. In addition, at the point of communication negotiation the application on the cellular phone extracts position location and transmits the response from the vehicle and the location to a server ready to receive this information.
[0017] Operation FIG. 1 —the standard for the automotive industry for vehicles is the SAE J1850 communications protocol which utilizes variable pulse width modulation and pulse width modulation. This means that the width of the pulse determines whether it's a 1 or a 0. Most phones form communication with serial connections (RS-232, Infrared . . . etc) and wireless connection protocols (Bluetooth, Infrared . . . etc). These two protocols must be converted or bridged by some sort of microprocessor so the two communication methodologies can communicate with each other. This can be accomplished by using an 8-pin integrated circuit that can be used to convert the OBDII signal (which includes different protocols such as, but not limited to: J1850 VPW, J1850 PWM, ISO 9141-2, ISO 14230, ISO 15765) to one of the aforementioned phone communication formats. This can be accomplished by creating an integrated circuit with a Microchip Technology PIC12C5XX 8 pin 8-bit CMOS micro controller (1). The circuit should have end a male (GM part #12110252) ODBII connector, and male terminals (GM Part #12047581) on one end and a DB9 serial port connector at the other. It is recommended pins are configured in such a manner that serial hardware handshaking is not required.
[0018] The following configuration the microcontroller makes this communication possible:
[0019] Pin 1 —This pin should be the positive supply pin and should always be the most positive point in the circuit. Internal circuitry connected to this pin should be used to provide power on the reset of the controller, so an external reset signal is not required.
[0020] Pin 2 and Pin 3—A 3.57 MHZ NTSC television colourburst crystal is connected between these two pins. Crystal loading capacitors (27 pF) will also be connected between the pin and the common circuit.
[0021] Pin 4—The OBD data is input to this pin with a high logic level representing an active state, and a low logic level indicating a passive state. No Schmitt trigger input is provided so the OBD signal should be buffered to minimize transition time for the internal CMOS circuitry.
[0022] Pin 5—The transmit signal can be connected directly to this pin as long as a current limiting resistor is installed in series. Internal signal inversion and Schmitt trigger wave shaping provide necessary signal conditioning.
[0023] PIN 6—The data output pin
[0024] PIN 7—This is the active low output signal, which is used to drive the OBD bus to its active state.
[0025] Pin 8—Circuit common is connected to this pin. This is the most negative point in the circuit.
[0026] There are many ways to program this microcontroller for our purpose. Please refer to document 2 for documentation on programming the microcontroller.
[0027] These microcontroller aides this process by negotiating timing and voltage differences between automobiles and mobile phones. This is the preferred method as to no damage the automobile computer system and the mobile phone.
[0028] Description FIG. 3 shows a method describing how the system in FIG. 1 typically operates. The mobile phone operates software that acts as a data-collection agent that connects to a microcontroller connected to the vehicles OBDII port that formats that OBDII data into a communication protocol that the mobile phone can decipher with its native hard and software.
[0029] In one mode of function, the information extracted from the ECU's memory is used to query an information source that has the DTC translation from SAE standard to textual description of information.
[0030] At this point other information about the mobile phone and the vehicles location is being gathered by software housed on the phone. No additional hardware will be added to the phone because federal law mandates that mobile phone have location based services. Further, information about the mobile phone user such, such as phone number, can also be extracted from the phone.
[0031] A connection is established to the internet and the above information (The DTC, The location of the malfunctioning vehicle, and the users contact information) is broadcasting to a server which receives the information and stores the information into a database.
[0032] Parties interesting in this information can and will be notified when a broadcasts happen in there area.
[0033] Other embodiments are also within the scope of the invention. The information that is collected in these broadcasts can be utilized for many different purposes, for instance, this information can be used to discover trends in malfunctions or sensor readings in a geographic location. Many organizations (i.e. automobile manufacturers) could use this information to improve there operations. An example of this could be an automobile manufacturing noticing that cars in cold or hot geographic areas have a common component failure and infer that temperature plays a role in the failure. This information could help auto manufacture enact costly recalls sooner than later.
[0034] In addition the information received by organization could be integrated and/or imported into there existing computer information systems to improve operations and increase efficiency. For instance, information that arrives at the repairing organization could be used to automatically order parts necessary for the repair. Also, incoming information could be integrated into the repairing organizations scheduling system so repairs are executed more efficiently.
[0035] Furthermore information derived from this system can be used to increase competition between repairing organizations. Since geographic information is part of the transmitted dataset local repair shops will have indications on who is broken down and there current location. Repair shops will also have the capacity to contact these individuals (because there cell phones numbers will also be part of the dataset) and offer there services. Organizations will have to realize that automobile malfunctions are now public knowledge and structure the prices of there services accordingly. Automobile owners will have the opportunity to receive bids for many service providers and pursue the most economically viable.
[0036] Lastly users of this system will be able to form more meaningful dialogues with repairing parties because the technical information will be translated into terminology that even the novice would find comprehendible. Instead, of the user viewing fault code “P1358” they will see “P1358: Misfire during start cylinder 9.” This will form a check and balance when conversations about the extent of the repair occur. A user who sees “P1358: Misfire during start cylinder 9” will instantaneously know they do not need to replace the transmission, thereby avoiding costly, as well as, unnecessary repairs. | The invention is a system for interfacing mobile phones with an on-board diagnostic computer in a vehicle, wherein the on-board diagnostic computer monitors a set of operational characteristics of a vehicle. The information derived from this system will be processed on the mobile phone coupled with additional information and displayed on the mobile phones screen, while simultaneously transmitting this information over the internet to be stored in a database. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the recovery of carbon dioxide from gaseous streams containing it.
BACKGROUND OF THE INVENTION
[0002] Conventionally, merchant liquid CO 2 is produced from feed streams with high CO 2 content (>95%) using distillation technology. Examples of such sources include ammonia and hydrogen plant off-gases, fermentation sources and naturally-occurring gases in CO 2 -rich wells. Typically, liquid CO 2 is produced at a central plant and then transported to users that could be hundreds of miles away; thereby incurring high transportation costs. The lack of high quality sources and their distance from customers provides motivation to recover CO 2 from low concentration sources, which are generally available closer to customer sites. Predominant examples of such sources are flue gases, which typically contain 3-30% CO 2 depending upon the fuel and excess air used for combustion.
[0003] To produce merchant liquid CO 2 from such sources, the CO 2 concentration in the feed gas needs to be first upgraded significantly and then sent to a distillation unit. A variety of technologies, including membranes, adsorptive separation (e.g. pressure swing adsorption (“PSA”), vacuum pressure swing adsorption (“VPSA”) and temperature swing adsorption (“TSA”)), physical absorption and chemical absorption, can be used for upgrading the CO 2 purity. The economics (capital and operating costs) of the overall scheme depends upon the purity of the feed, the product purity specifications and recovery obtained. For membranes, adsorptive separations and physical absorption, the cost to obtain a given high product purity is a strong function of the feed purity. On the other hand, chemical absorption provides a convenient means of directly obtaining high purity (>95%) CO 2 vapor in a single step because the costs of this technology are relatively insensitive to the feed CO 2 content. This vapor can be used as is for applications at the site of CO 2 separation or further compressed for downstream recovery, as merchant liquid CO 2 , or for disposal/sequestration.
[0004] Chemical absorption can be performed through the use of alkanolamines as well as carbonate salts such as hot potassium carbonate. However, when using carbonate salts, it is necessary for the partial pressure of CO 2 to be at least 15 psia to have any significant recovery. Since flue gases are typically available at atmospheric pressure, use of chemical absorption with carbonate salts would require compression of the feed gas. This is highly wasteful because of the significant energy expended in compressing the nitrogen. On the other hand, there exist alkanolamines that can provide adequate recovery levels of CO 2 from lean sources at atmospheric pressure. Thus for recovery of high purity (>95%) CO 2 vapor from sources such as flue gases, chemical absorption with alkanolamines would be the preferred choice. The pressure of CO 2 -rich vapor recovered from such an absorption process is generally around 15-30 psia. Compression of the gas will typically be needed for further use, processing or disposal.
[0005] Historically, alkanolamines have found widespread use for CO 2 absorption in processes such as natural gas purification and hydrogen production. As the literature indicates (Kohl and Nielsen, “Gas Purification”, 5 th Edition (1997), pp.115-117, 123-125, 144-149), the feed gas is typically in excess of 200 psia and CO 2 -rich vapor is typically obtained at pressures of 15-30 psia. U.S. Pat. No. 5,853,680 discloses a process for the removal of carbon dioxide from high pressure (>425 psia) natural gas. There is no pumping of the CO 2 -rich alkanolamine liquid. By carrying out the regeneration step without significant depressurization, the disclosed process facilitates recovery of a CO 2 -rich vapor stream at pressures of 140 psia or higher.
[0006] However, there still exists a need for a more efficient process that can directly recover high pressure carbon dioxide from low pressure source streams.
BRIEF SUMMARY OF THE INVENTION
[0007] One aspect of the present invention is a process for recovering carbon dioxide, comprising (A) providing a gaseous feed stream comprising carbon dioxide, wherein the pressure of said feed stream is up to 30 psia; (B) preferentially absorbing carbon dioxide from said feed stream into a liquid absorbent fluid comprising an organic amine absorbent to form a carbon dioxide enriched liquid absorbent stream; (C) in any sequence or simultaneously, pressurizing said carbon dioxide enriched liquid absorbent stream to a pressure sufficient to enable the stream to reach the top of the stripper in step (D) at a pressure of 35 psia or greater, and heating the carbon dioxide enriched liquid absorbent stream to obtain a heated carbon dioxide enriched liquid absorbent stream; and (D) stripping carbon dioxide from said carbon dioxide enriched liquid absorbent stream in a stripper operating at a pressure of 35 psia or greater and recovering from said stripper a gaseous carbon dioxide product stream having a pressure of 35 psia or greater. In some preferred embodiments, the pressure in the stripper, and the pressure of the gaseous carbon dioxide product stream, are up to 70 psia.
[0008] In other aspects of this process, the stripped liquid absorbent fluid from the stripper is recycled to step (B).
BRIEF DESCRIPTION OF THE DRAWING
[0009] [0009]FIG. 1 is a flowsheet showing an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following description refers to FIG. 1 which depicts a flowsheet of an improved alkanolamine-based absorption process of the present invention for the recovery of CO 2 at high pressure from a low pressure stream such as flue gas. Variations in the flowsheet and equipment used are possible. Further, the temperature and pressure values included in the following description are simply indicative of typical operating conditions.
[0011] Gaseous feed stream 1 comprises a stream containing carbon dioxide. Typically, feed stream 1 also contains nitrogen and oxygen. The carbon dioxide content is generally up to 30% (all percentages herein being volume percents unless stated otherwise) and is typically 3 to 30 vol. %, which is typical of flue gas. Feed stream 1 has usually been suitably cooled, and pretreated for removal of particulates and impurities such as SOx and NOx. Feed stream is fed to blower 2 which directs it through line 3 to absorber 4 where the feed stream is contacted (preferably, countercurrently) with a liquid absorbent fluid for the carbon dioxide.
[0012] The liquid absorbent fluid is preferably a solution or dispersion, typically in water, of one or more absorbent compounds, that is, compounds which in water create an absorbent fluid that compared to water alone increases the ability of the fluid to preferentially remove carbon dioxide from the feed stream. Examples of such compounds are well known in this art and can readily be ascertained by the practitioner. Preferred for use are organic amine absorbents, and more preferably one or more alkanolamines. Organic amines can be classified into primary (monosubstituted with a group other than hydrogen), secondary (disubstituted with groups other than hydrogen) and tertiary (trisubstituted with groups other than hydrogen) amines. Useful alkanolamines include amines substituted with one, two or three groups each of which is alkanol containing 1, 2, 3, 4, 5 or 6 carbon atoms, wherein the amine is otherwise substituted with hydrogen or with alkyl containing 1, 2, 3, 4, 5 or 6 carbon atoms. Useful organic amines other than alkanolamines include (1) amines substituted with one, two or three alkyl groups each containing 1, 2, 3, 4, 5 or 6 carbon atoms which amines are otherwise substituted with hydrogen; (2) cyclic amines containing one or two nitrogen atoms and a total of 5, 6, 7 or 8 carbon and nitrogen atoms; and (3) diamines containing two nitrogen atoms and 2 through 8 carbon atoms (including diamines wherein each nitrogen is primary, secondary or tertiary). Specific examples of useful alkanolamines include monoethanolamine (primary), diethanolamine (secondary) and methyldiethanolamine (tertiary). Examples of useful organic amines include piperazine and pyrrolidine.
[0013] The absorber can be of any construction typical for providing gas-liquid contact and absorption. The temperature in the absorber can typically vary from around 40-45° C. at the top to around 50-60° C. at the bottom. The absorber can operate at slightly above ambient pressure. A mist eliminator at the top of the absorber traps any entrained amine in the absorber vent gas 5 , which often is essentially enriched nitrogen. CO 2 from the feed gas is preferentially absorbed by the absorbent (i.e., the percentage of the carbon dioxide in the feed gas that is absorbed is greater than the percentage of other gases present in the feed gas), producing a CO 2 -enriched liquid absorbent stream 7 which emerges from the bottom of the absorber 4 and is fed to the rich solvent pump 8 .
[0014] Pump 8 compresses the carbon dioxide enriched liquid absorbent stream to a pressure which is sufficient to enable the stream to reach the top of stripper 12 at a pressure of 35 psia or greater. The CO 2 -rich stream in line 9 is then heated in a countercurrent heat exchanger 10 by the hot regenerated or lean absorbent stream 29 to a temperature of 100-110° C. and is subsequently fed via line 11 to the top of the stripper 12 . Alternatively, this stream can be heated before it is compressed in pump 8 .
[0015] Stripper 12 is a pressurized unit in which carbon dioxide is recovered from the carbon dioxide enriched liquid absorbent stream. In the process of the present invention, the pressures in the reboiler and in the stripper column are maintained at values of around 35 psia or more. This would render the carbon dioxide product at a corresponding pressure of around 35 psia or more. One preferred mode for practice of the present invention is to use an absorbent comprising monoethanolamine and to maintain the pressure in the stripper and reboiler in the range of 40 to 55 psia. Correspondingly, pump 8 would need to pressurize the carbon dioxide enriched absorbent stream to a pressure high enough for it to reach the top of the stripper at a pressure of 40 to 55 psia. Also carbon dioxide product recovered in this process will have a pressure of around 40 to 55 psia.
[0016] Higher pressures in the reboiler would correspondingly increase the reboiler temperature. However, care should be taken to ensure that the temperature does not exceed much beyond 140° C., since higher temperatures would accelerate thermal degradation of the absorbent, the products of which can eventually cause significant corrosion of the equipment and overall deterioration in process performance. For example, typical alkanolamines such as monoethanolamine and methyldiethanolamine are known to degrade much faster at the higher temperatures. The temperature at the top of the stripper is typically between 100 and 110° C. while the bottom can be as high as 119-135° C. Chemical inhibitors could be used to reduce the rate of degradation. The optimal pressure in the stripper/reboiler and consequently the pressure at which CO 2 is recovered will be determined by the following factors—1) reboiler heat duty, 2) downstream compression requirements, and 3) corrosion behavior at the higher temperatures.
[0017] The heated carbon dioxide enriched absorbent stream in line 11 passes into the upper portion of stripping column 12 , which is operating at a temperature typically within the range of from 100 to 110° C. at the top of the column and at a temperature within the range of from 119 to 135° C. at the bottom of the column. As the absorbent flows down through stripping column 12 , carbon dioxide within the absorbent is stripped into upflowing vapor, which is generally steam, to produce carbon dioxide rich top vapor 13 and carbon dioxide lean absorbent 20 . Stream 13 is passed through reflux condenser 47 wherein it is partially condensed. Resulting two phase stream 14 is fed to reflux drum 15 where the product CO 2 stream 16 is separated from the condensate 17 . The reflux pump 18 pumps the condensate, which primarily consists of absorbent (e.g. alkanolamine) and water, to the stripper 12 . The solvent 20 from the bottom of the stripper 12 is heated indirectly in the reboiler 21 , which typically operates at a temperature of around 119-135° C. Saturated steam 48 at a pressure of 30 psig or higher can provide the necessary heating. The heated solvent vapor 22 , which is primarily steam, is recirculated to the stripper.
[0018] The stripped carbon dioxide-lean absorbent solution 23 from the reboiler is pumped back by the lean solvent pump 35 to the heat exchanger 10 . A small portion of the stream 23 is withdrawn as stream 24 and fed to a reclaimer 25 , where the solution is vaporized. Addition of soda ash or caustic soda to the reclaimer facilitates precipitation of the degradation byproducts and heat stable amine salts. Stream 27 represents the disposal of the degradation byproducts and heat stable amine salts. The vaporized amine solution 26 can be reintroduced into the stripper as shown in FIG. 1. It can also be cooled and directly mixed with the lean stream 6 entering the top of the absorber. Also, instead of the reclaimer shown in FIG. 1, other purification methods such as ion-exchange or electrodialysis could also be employed.
[0019] Makeup amine 33 is pumped by pump 32 from storage tank 30 and combined with the lean stream 34 , which exits the heat exchanger 10 at a temperature of around 65-75° C., to form stream 36 , which is further cooled in cooler 37 to around 40° C. From the cooled lean stream 38 , a small portion is withdrawn and purified (removal of impurities, solids, degradation byproducts and heat stable amine salts) through the use of mechanical filters 41 and 45 as well as a carbon bed filter 43 . The purified lean stream 46 is added to stream 38 to form stream 6 that is fed to the top of the absorption column 4 .
[0020] CO 2 recovered from flue gas or other feed streams using the above process can be directly used as vapor for onsite applications. Several CO 2 applications such as pH control of wastewater can use CO 2 vapor directly from the absorption process. However the CO 2 vapor would generally need to be delivered at pressures of around 35 psia or more for use in the respective application. The conventional amine based chemical absorption process typically recovers CO 2 at pressures of 15-25 psia, thus necessitating compression prior to the onsite application. However, the process described in this invention facilitates recovery of CO 2 at pressures of 35 psia or more. This eliminates the need for compression and results in significant capital and operating cost savings.
[0021] Alternatively, the CO2 recovered from flue gas or other feed streams using the chemical absorption process may need to be compressed for downstream recovery or sequestration. Merchant liquid CO 2 is typically obtained by compression of the CO 2 rich vapor stream to pressures of around 300 psia, purification and distillation. Typically the required compression is accomplished in two stages. Recovering CO 2 at pressures in excess of 35 psia with the present invention, instead of 15-25 psia, will reduce the compression costs. In some cases, the first stage of compression in the CO 2 production plant could be eliminated. For sequestration, CO 2 would need to be compressed to pressures of around 1500 psia or higher. By providing the CO 2 at a higher pressure using the present invention, e.g. at 50 psia instead of 20 psia, the net compression ratio reduces from 75 to 30. This correspondingly translates into a reduction in the number of stages of compression, thus decreasing compression costs as well as the overall cost to sequester CO 2 from flue gases.
[0022] This invention is superior to prior recovery processes for several reasons:
[0023] Earlier processes for recovery of CO 2 from flue gas yield a CO 2 -rich vapor at 15-25 psia. This CO 2 vapor would need to be compressed prior to further use or disposal. For example, the CO 2 vapor would need to be compressed to ˜300 psia if it is to be used as feed to the standard CO 2 plant for production of merchant liquid CO 2 . Compression from around 15 psia to 300 psia is typically achieved in two stages. Another instance could involve the direct use of CO 2 vapor at a slightly elevated pressure (˜30-65 psia), as is the case for some onsite applications. By contrast, the high pressure CO 2 recovery scheme, presented in this invention, facilitates recovery of CO 2 at pressures in excess of 35 psia. Thus, if the CO 2 vapor needs to be compressed to ˜300 psia, a single stage of compression would potentially suffice as compared to two for the base absorption process. For cases where CO 2 vapor is required at pressures of around 35 psia or higher, this new absorption process allows direct recovery of CO2 at the required pressure, thus eliminating the need for any further compression. Finally, for sequestration applications CO 2 would typically need to be compressed to pressures of the order of 1500 psia or higher. Recovering CO 2 at pressures of 35 psia or higher as opposed to 15-25 psia would reduce the downstream compression costs through a decrease in the number of compression stages and in the energy consumption. Consequently the overall cost of sequestering CO 2 from flue gas is reduced.
[0024] The process described in U.S. Pat. No. 5,853,680 recovers CO 2 -rich vapor at pressures of around 140 psia. However, the feed streams to the process are at much higher pressures, e.g. the natural gas feed in the described patent is at a pressure of 425 psia or higher. There is no pumping of the CO 2 -rich absorbent liquid. Also, the stripper operating pressure is significantly less than the operating pressure in the absorber. By contrast, the process of the present invention essentially works as a CO 2 -recovery and compression unit. The absorbent liquid selectively absorbs CO 2 from a stream at a low pressure (˜14.7 psia). The absorber typically operates at a pressure of around 15 psia The CO 2 -rich absorbent solution is then pumped to pressures of 35 psia or higher. Stripping at an elevated pressure facilitates recovery of CO 2 -rich vapor at a correspondingly high pressure of about 35 psia or higher. Also, the stripper operating pressure is greater than the operating pressure of the absorber in this process.
[0025] Operating the stripping section at higher pressures enables recovery of CO 2 -rich vapor at pressures of around 35 psia or greater, thereby reducing or eliminating downstream compression costs. While it is also necessary to pump the CO 2 -rich alkanolamine liquid in pump 8 to higher pressures to match the new operating pressure of the stripper, the incremental energy requirements for pumping the CO 2 -rich absorbent liquid are much less than compressing CO 2 vapor, thereby providing a net advantage for production of higher pressure enriched CO 2 vapor. | Disclosed is process for recovering carbon dioxide, comprising (A) providing a gaseous feed stream comprising carbon dioxide, wherein the pressure of said feed stream is up to 30 psia; (B) preferentially absorbing carbon dioxide from said feed stream into a liquid absorbent fluid to form a carbon dioxide enriched liquid absorbent stream; (C) in any sequence or simultaneously, pressurizing said carbon dioxide enriched liquid absorbent stream to a pressure sufficient to enable the stream to reach the top of the stripper at a pressure of 35 psia or greater, and heating the carbon dioxide enriched liquid absorbent stream to obtain a heated carbon dioxide enriched liquid absorbent stream; and (D) stripping carbon dioxide from said carbon dioxide enriched liquid absorbent stream in a stripper operating at a pressure of 35 psia or greater and recovering from said stripper a gaseous carbon dioxide product stream having a pressure of 35 psia or greater.
In another aspect of this process, the stripped liquid absorbent fluid from the stripper is recycled to step (B). | 1 |
FIELD
[0001] The present specification relates generally to light sensors and more particularly relates to a wave guide for improving angular response in a light sensor.
BACKGROUND
[0002] Flat panel displays such as liquid crystal displays (LCD) are now commonplace in portable electronic devices, computers, televisions, cellular telephones, and in other display applications. Ambient light conditions, however, can dramatically impact the display characteristics, resulting in poor display visibility. To compensate for varying ambient light conditions, and to take opportunities to reduce power consumption, ambient light sensors may be included in the displays. Such ambient light sensors attempt to detect the amount of ambient light and provide input to control circuitry which can automatically adjust the brightness of the display, according to the amount of sensed ambient light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is an isometric representation of a display assembly.
[0004] FIG. 2 is a schematic cross-sectional representation of the light sensor of the assembly of FIG. 1 , the cross-section being taken along the dashed-lines indicated as 2 - 2 in FIG. 1 .
[0005] FIG. 3 shows the window, wave guide and photodetector of FIG. 2 in greater detail.
[0006] FIG. 4 shows an idealized response curve of the intensity of light that reaches the sensor of FIG. 3 as a result of the configuration of the wave guide of FIG. 3 .
[0007] FIG. 5 shows a first exemplary configuration of the wave guide of FIG. 3 .
[0008] FIG. 6 shows a second exemplary configuration of the wave guide of FIG. 3 .
[0009] FIG. 7 shows a third exemplary configuration of the wave guide of FIG. 3 .
[0010] FIG. 8 shows a fourth exemplary configuration of the wave guide of FIG. 3 .
[0011] FIG. 9 shows a plurality of further response curves.
[0012] FIG. 10 shows a light sensor assembly as a variation on the assembly of FIG. 2 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] An aspect of this specification provides a display assembly comprising: a display; a light sensor module mounted proximally to said display; a controller connected to said light sensor module and configured to receive an electronic signal representing a measurement of ambient light incident on said display; said controller connected to said display and configured to adjust brightness of said display based on said electronic signal; said light sensor module comprising a window for transmitting ambient light; a light sensor for receiving said ambient light and configured to generate said electronic signal; a wave guide comprising a textured surface disposed between said window and said light sensor; said textured surface having a geometric structure; said geometric structure configured according to a material and a thicknesses of said window; said geometric structure further configured to guide ambient light travelling through said window onto said light sensor such that an intensity of ambient light that strikes said sensor varies substantially proportionally according to a function comprising a cosine of an angle of incidence of ambient light striking said window.
[0014] The geometric structure can be further configured such that said ambient light strikes said sensor at an angle that is substantially normal to said sensor regardless of said angle of incidence.
[0015] The display assembly can further comprise a substrate; said textured surface applied to said substrate; said substrate for mechanically affixing said wave guide to said window. The substrate can be affixed via an adhesive. The geometric structure can be further configured according to a material and thickness of said substrate.
[0016] The textured surface can be integrally formed into said window.
[0017] The textured surface can comprise a plurality of bosses.
[0018] The bosses can be trapeziums, partial-spheroids, or four-sided pyramids.
[0019] The bosses can be regularly spaced, or irregularly spaced.
[0020] The textured surface can be made from one of polymethyl methacrylate, polyethylene terephthalate, acrylic, or epoxy.
[0021] The wave guide can be made from a material having a refractive index of between about 1.4 and about 1.7.
[0022] The light sensor module can further comprise a light emitter configured to emit light at a first angle; said wave guide configured to scatter light emitted from said light emitter out of said window at angle wider than said first angle.
[0023] The display assembly can be configured for incorporation into a portable electronic device and said light emitter is configured to indicate a status of said portable electronic device.
[0024] Another aspect of the specification provides a light sensor module according to any of the foregoing.
[0025] Another aspect of the specification provides a wave guide according to any of the foregoing.
[0026] Referring now to FIG. 1 , a display assembly is indicated generally at 50 . Display assembly 50 comprises a display 54 , a light sensor module 58 , and a controller 62 . Display assembly 50 can be incorporated into any electronic apparatus having a display, including but not limited to portable electronic devices, computers, televisions, cellular telephones, desktop telephones, and major appliances.
[0027] Display 54 comprises one or more light emitters such as an array of light emitting diodes (LED), liquid crystals, plasma cells, or organic light emitting diodes (OLED). Other types of light emitters are contemplated. Such light emitters, when activated by controller 62 , produce emitted light, as indicated by the arrows labeled “EL” in the Figures. Emitted light EL is shown as being emitted substantially normally from the surface of display 54 , although the actual viewing range can be much wider.
[0028] Display 54 is also subject to incident ambient light AL. In FIG. 1 , ambient light AL is shown as incident in a direction that is substantially normal to the surface of display 54 . Those skilled in the art will appreciate that ambient light AL can reduce the visibility of emitted light EL. Controller 62 is therefore configured to receive an electrical signal from sensor module 58 representing an intensity of ambient light AL and to adjust the brightness of emitted light EL to compensate for reduced visibility of emitted light EL due to ambient light AL. As will be discussed further below, display assembly 50 is configured to respond to ambient light AL that is incident from a range of different angles.
[0029] As best seen in FIG. 2 , light sensor module 58 comprises a light sensor or other type of photodetector 66 that is configured to convert ambient light AL that is incident on photodetector 66 into an electrical signal ES. Electrical signal ES has a voltage or other electrical characteristic that is generally proportional to the intensity (expressed as, for example, in units of lux) of ambient light AL that lands on photodetector 66 . Electrical signal ES is received at controller 62 which is configured to brighten or dim display 54 accordingly.
[0030] Light sensor module 58 also comprises a housing 70 and a cover 74 . Housing 70 comprises a chassis 72 that is shaped so as to define a light transmissive chamber 78 , and photodetector 66 is disposed within the end of chamber 78 that is opposite to cover 74 . Chamber 78 , in a present embodiment, contains air and is therefore transmissive of ambient light EL.
[0031] Cover 74 comprises a frame 76 that overlays chassis 72 . Frame 72 is also shaped to define a window 82 . A wave guide 86 is disposed within chamber 78 between window 82 and photodetector 66 . In a present embodiment, wave guide 86 abuts window 82 . As will be discussed in greater detail below, wave guide 86 can be a separate item from window 82 , or wave guide 86 can be integrally formed into window 82 .
[0032] Chassis 72 and frame 76 are substantially mechanical in function and therefore can be of any suitable material to achieve the desired mechanical characteristics of the corresponding display assembly 50 application. For example, where display assembly 58 is part of a display in a portable electronic device, chassis 72 and frame 76 will be made from materials and dimensioned to be rugged enough to mechanically support window 82 , wave guide 86 and photodetector 66 , within light sensor module 58 , and also be rugged enough to withstand dropping or other types of physical blows to which a portable electronic device can be commonly subjected.
[0033] By the same token, window 82 , wave guide 86 , chamber 78 and photodetector 66 are substantially optical in function, (or in the case of photodetector 66 , electro-optical), and as will be discussed further below, are therefore selected from materials that provide the desired optical, (or electro-optical) characteristics. Again, within the context of display assembly 58 being used within a portable electronic device, window 82 , wave guide 86 and photodetector 66 are also configured to provide a certain degree of mechanical ruggedness, again so that the entire display assembly 50 can withstanding the physical blows to which a portable electronic device can be commonly subjected.
[0034] As will be discussed further below, wave guide 86 can be physically integrated into window 82 , or each can be separate items which are mechanically affixed to each other (e.g. via an adhesive) at the time of assembly.
[0035] FIG. 3 shows an embodiment of window 82 , wave guide 86 and photodetector 86 in greater detail. In FIG. 3 , wave guide 86 includes a substrate 88 and a textured surface 90 . FIG. 3 also shows two separate representative beams of ambient light AL- 1 , and AL- 2 .
[0036] Ambient light AL- 1 is shown as incident at an angle AI 1 that is normal to the surface of window 82 . Angle AI 1 is assigned the variable Θ 1 in FIG. 3 , where Θ 1 equals ninety degrees. Ambient light AL- 1 is also shown as having intensity I 1 when ambient light l 1 strikes the surface of window 82 . Intensity I 1 is assigned the variable X in FIG. 3 . I 1 can be expressed in units of lux. For purposes of explaining this embodiment, X can be any value associated with ambient light conditions.
[0037] Ambient light AL- 2 is shown as incident at an angle AI 2 that is less than ninety degrees to the surface of window 82 . Angle AI 2 is assigned the variable Θ 2 in FIG. 3 . Ambient light AL- 2 is also shown as having intensity I 2 when ambient light l 2 strikes the surface of window 82 . For purposes of explaining this embodiment, I 2 is deemed to equal I 1 , and therefore I 1 =X.
[0038] Window 82 can be characterized in terms of its material with an associated index of refraction n 1 , and having a particular thickness T 1 . The index of refraction n 1 of window 82 is represented in FIG. 3 by the change in angle of ambient light AL- 2 as ambient light AL- 2 travels through window 82 .
[0039] Substrate 88 can be also characterized in terms of its material with an associated index of refraction n 2 , and having a particular thickness T 2 . The index of refraction n 2 of substrate 88 is represented in FIG. 3 by the change in angle of ambient light AL- 2 as ambient light AL- 2 travels through substrate 88 .
[0040] What is not represented in FIG. 3 , but will occur to those of skill in the art, are the reflections at the junctions between different adjacent materials. Thus, a certain amount of ambient light AL- 1 will be internally reflected as ambient light AL- 1 enters and exits window 82 , and enters and exits substrate 88 , and enters and exits textured surface 90 . Accordingly, in an actual implementation, the actual intensity of ambient light AL- 1 and ambient light AL- 2 entering chamber 78 will be less than intensity I 1 and intensity I 2 due to attenuation and losses resulting from passing through window 82 and wave guide 86 . Such attenuation is not represented in FIG. 3 for purposes of simplifying explanation.
[0041] Textured surface 90 is defined by a three-dimensional geometric structure that is configured based on the materials and thicknesses of window 82 and substrate 88 , such that the intensity of ambient light that strikes photodetector 66 varies substantially proportionally to the cosine of the angle of incidence of the ambient light striking window 82 . Additionally, the three-dimensional geometric structure of textured surface 90 is configured such that ambient light strikes photodetector 66 at an angle that is substantially normal to photodetector 66 , regardless of the angle that the ambient light actually strikes window 82 .
[0042] (It should now be apparent that in certain configurations, textured surface 90 can be integrally formed with window 82 , thereby obviating the need for substrate 88 . In this configuration, the same principles as the previous paragraph apply, except that only the material and thickness of window 82 need be considered.)
[0043] In FIG. 3 , the intensity of ambient light AL that strikes the surface of sensor 66 is represented by the variable Y. Thus, in mathematical terms, the geometric structure of textured surface is configured according the following function:
[0000] Y=I (cos( AI )) Function 1:
Where:
[0044] Y is the intensity of ambient light that strikes the surface of photodetector 66
[0045] I is the intensity of light that strikes the surface of window 82
[0046] AI is the angle of incidence of light as it strikes the surface of window 82 .
[0047] A graph of plotting Function 1, where I=1, is shown in FIG. 4 .
[0048] Various materials for wave guide 86 are contemplated, including polycarbonate, polymethyl methacrylate, polyethylene terephthalate, acrylic, and epoxy. As desired for a particular configuration, such materials can also be used for window 82 .
[0049] Presently, any material can be chosen that has suitable mechanical properties and has a refractive index of between about 1.4 and about 1.7.
[0050] Presently, textured surface 90 is configured for range of the visible electro-magnetic spectrum, and certain wavelengths at the periphery of that spectrum, specifically wavelengths of between about 350 nanometers and about 900 nanometers.
[0051] FIG. 5 shows a non-limiting exemplary embodiment of a specific geometric structure for textured surface 90 , although in FIG. 5 the textured surface of this specific embodiment is indicated at reference 90 A, within a specific wave guide 86 A. Textured surface 90 A is thus comprised of a plurality of bosses in the form of trapeziums 94 A. While FIG. 5 shows each trapezium 94 A as aligned, in variations the trapeziums can be irregularly aligned.
[0052] The thickness of textured surface 90 A is, in the present embodiment, between about 0.001 millimeters and about five millimeters, and the material for textured surface 90 A can be polycarbonate, polymethyl methacrylate, polyethylene terephthalate, acrylic, or epoxy. In a present embodiment substrate 88 A is integral with window 82 A. In the present embodiment, substrate 88 A is etched directly onto window 82 A. Substrate 88 A has a thickness of about 0.05 millimeters to about two millimeters. Window 82 A has a thickness of about 0.1 millimeters to about five millimeters. Table I shows the various dimensions for each trapezium 94 A.
[0000]
TABLE I
Dimensions for Trapezium 94A
Dimension
reference
Type
Dimension
Unit
Tolerance
98A
Angle
48
Degree
+/−12
100A
Length
0.01
mm
+5/−0.01
104A
Radius
0.01
mm
+0.5/−0.01
108A
Length
0.05
mm
+5/−0.04
[0053] FIG. 6 shows another non-limiting exemplary embodiment of another specific geometric structure for textured surface 90 , although in FIG. 6 the textured surface of this specific embodiment is indicated at reference 90 B, within a specific wave guide 86 B. Textured surface 90 B is thus comprised of a plurality of bosses in the form of partial-spheroids 94 B. While FIG. 6 shows each semi-spheroid 94 B as aligned, in variations the partial-spheroids 94 B can be irregularly aligned.
[0054] The thickness of textured surface 90 B is, in the present embodiment, between about 0.001 millimeters and about five millimeters, and the material for textured surface 90 B can be polycarbonate, polymethyl methacrylate, polyethylene terephthalate, acrylic, or epoxy. In a present embodiment substrate 88 B is integral with window 82 B. In the present embodiment, substrate 88 B is etched directly onto window 82 B. Substrate 88 B has a thickness of about 0.05 millimeters to about two millimeters. Window 82 B has a thickness of about 0.1 millimeters to about five millimeters. Table II shows the various dimensions for each partial-spheroid 94 B.
[0000]
TABLE II
Dimensions for Partial-Spheroid 94B
Dimension
reference
Type
Dimension
Unit
Tolerance
98B
Angle
44.91
Degrees
+/−15
100B
Length
0.03
mm
+5/−0.03
104B
Radius
0.01
mm
+5/−0.01
[0055] FIG. 7 shows another non-limiting exemplary embodiment of another specific geometric structure for textured surface 90 , although in FIG. 7 the textured surface of this specific embodiment is indicated at reference 90 C, within a specific wave guide 86 C. Textured surface 90 C is thus comprised of a plurality of bosses in the form of four-sided pyramids 94 C. While FIG. 7 shows each four-sided pyramid 94 C as aligned, in variations the four-sided pyramids 94 C can be irregularly aligned.
[0056] The thickness of textured surface 90 C is, in the present embodiment, between about 0.001 millimeters and about five millimeters, and the material for textured surface 90 B can be polycarbonate, polymethyl methacrylate, polyethylene terephthalate, acrylic, or epoxy. In a present embodiment substrate 88 C is integral with window 82 C. In the present embodiment, substrate 88 C is etched directly onto window 82 C. Substrate 88 C has a thickness of about 0.05 millimeters to about two millimeters. Window 82 C has a thickness of about 0.1 millimeters to about five millimeters. Table III shows the various dimensions for each four-sided pyramid 94 C.
[0000]
TABLE III
Dimensions for Four-Sided pyramids 94C
Dimension
reference
Type
Dimension
Unit
Tolerance
98C
Angle
75
Degrees
+15/−15
100C
Length
0.018
millimeters
+5/−0.015
104C
Length
0.015
millimeters
+5/−0.015
(between each
pyramid)
108C
Radius
Zero
millimeters
+/−2
[0057] FIG. 8 shows another non-limiting exemplary embodiment of another specific geometric structure for textured surface 90 , although in FIG. 8 the textured surface of this specific embodiment is indicated at reference 90 D, within a specific wave guide 86 D. Textured surface 90 D is thus comprised of a plurality of bosses in the form of four-sided pyramids 94 D. While FIG. 8 shows each four-sided pyramid 94 D as aligned, in variations the four-sided pyramids 94 C can be irregularly aligned.
[0058] The thickness of textured surface 90 D is, in the present embodiment, between about 0.001 millimeters and about five millimeters, and the material for textured surface 90 D can be polycarbonate, polymethyl methacrylate, polyethylene terephthalate, acrylic, or epoxy. In a present embodiment substrate 88 D is integral with window 82 D. In the present embodiment, substrate 88 D is etched directly onto window 82 D. Substrate 88 D has a thickness of about 0.05 millimeters to about two millimeters. Window 82 D has a thickness of about 0.1 millimeters to about five millimeters. Table IV shows the various dimensions for each four-sided pyramid 94 D.
[0000]
TABLE IV
Dimensions for Four-Sided pyramids 94D
Dimension
reference
Type
Dimension
Unit
Tolerance
98D
Angle
86
Degrees
+/−10
100D
Length
0.03
millimeters
+5/−0.03
104D
Length
0.02
millimeters
+5/−0.02
(between each
pyramid)
108D
Radius
0.015
millimeters
+2/−0.015
[0059] It is to be understood that Function 1 in FIG. 4 is an idealized target profile for Y (where Y varies to Intensity I and Angle of Incidence AI) in the establishment of a configuration of textured surface 90 . The actual function that can result in relation to a particular geometric structure of textured surface 90 has a range of acceptable deviation from Function 1, such that in certain embodiments the geometric structure of textured surface 90 results in a profile that substantially conforms with Function 1, without exactly matching Function 1. FIG. 9 shows a variety of different curves to illustrate. In FIG. 9 , curve 150 is the curve that corresponds with Function 1 and as shown in FIG. 4 . Curve 154 shows the response curve associated with textured surface for four-sided pyramid 94 C when ambient light AL is incident along the plane shown in FIG. 3 . Curve 158 shows the response curve associated with textured surface for four-sided pyramid 94 C when ambient light is incident along the plane that is normal to the plane shown in FIG. 3 .
[0060] Again recall that curve 150 is the curve that corresponds with Function 1 and as shown in FIG. 4 . Ranges of design tolerances for curve 150 are also proposed herein, including curve 162 shows an exemplary upper tolerance boundary for design specifications for the geometric structure of textured surface 90 , while curve 166 shows an exemplary lower tolerance boundary for design specifications the geometric structure of textured surface 90 . Presently, an upper tolerance from Function 1 can be about positive five percent (+5%) a lower tolerance from Function 1 can be about negative five percent (−5%).
[0061] Curve 170 shows a measured response for a prior art device that does not include wave guide 86 . The prior art device is a BlackBerry Bold™ from Research in Motion Inc., of Waterloo, Ontario Canada.
[0062] Variations the foregoing are contemplated. For example, chamber 78 can be a vacuum or filled with a light transmissive medium. However, adjustments to wave guide 86 will be made to accommodate the index of refraction and other optical characteristics whatever medium is used within chamber 78 . As another example the means by which light sensor module 58 incorporates wave guide 86 is not particularly limited. For example, wave guide 86 can be produced as a separate item that is affixed to window 82 . Alternatively, textured surface 90 can be formed directly on the surface of window 82 that is nearest to chamber 78 , thereby obviating the need for substrate 88 altogether.
[0063] A still further variation is shown in FIG. 10 , which shows a light sensor module 58 E. Light sensor module 58 E includes many of the same components of light sensor module 58 , and accordingly like elements bear like references, except followed by the suffix “E”. However, in light sensor module 58 E, photodetector 66 E is reduced in size to allow for alight emitter such as a light emitting diode (LED) 200 E. Light sensor module 58 E can be incorporated into a portable electronic device where LED 200 E can be used as an indicator light. The indicator light can be used, for example, to indicate a low battery condition of the device. Other functions for the indicator light are contemplated. For example, where the portable electronic device includes wireless telephony or email messaging capability, then LED 200 E can be used to indicate the presence of a wireless network. LED 200 E can also be of the type that is configured to generate multiple colours. In module 58 E, wave guide 86 E has two functions: first to direct ambient light onto photodetector 66 E as previously discussed, and second to help scatter light emitted from LED 200 E out of window 82 E across a wider range of angles.
[0064] While certain specific embodiments have been discussed herein, combinations, subsets and variations of those embodiments are contemplated. It is the claims attached hereto that define the scope of time-limited exclusive privilege of this specification. | Electronic displays encounter visibility issues due to varying ambient light conditions. An ambient light sensor can be provided to sense ambient light and dynamically adjust display brightness to compensate for changes in ambient light. A wave guide for improving angular response in a light sensor is provided. | 6 |
[0001] The present application claims priority from PCT Patent Application No. PCT/EP2011/003081 filed on Jun. 22, 2011, the disclosures of which id incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention is directed to a connection element for securing a holder for a pipe or cable or cable bundle or for securing an actuating rod or a hinge part or a handle or hook or other fitting in a rectangular opening or undercut slot of a first thin wall or of a first aluminum profile, this connection element comprising a head with adjoining neck with rectangular, particularly square, outer cross section to be received in a clip-like manner such that it is secured with respect to rotation and possibly with respect to displacement in a rectangular opening in the thin wall such as a sheet metal angle or to be received in a clip-like manner such that it is secured with respect to rotation in the slot in the profile.
[0003] 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.
[0004] Document DE 603 01 994 T2 is considered as prior art provided for round holes, meaning that fixation between the one round hole necessitates a second hole at a distance thereto for fixing with respect to rotation. It is also disadvantageous that the known plastic rivet comprises more than one part.
[0005] It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. Patent law; e.g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. Patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention.
[0006] It is further noted that the invention does not intend to encompass within the scope of the invention any previously disclosed product, process of making the product or method of using the product, which meets the written description and enablement requirements of the USPTO (35 U.S.C. 112, first paragraph) or the EPO (Article 83 of the EPC), such that applicant(s) reserve the right to disclaim, and hereby disclose a disclaimer of, any previously described product, method of making the product, or process of using the product.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is the object of the invention to provide a plastic rivet or connection element which does not have these disadvantages.
[0008] The above-stated object is met by a base from which emerge two legs extending back to the neck, having grooved foot bottoms for support on the edge of the wall opening of the one plate or the undercut of the slot of the one profile, the head comprising a rectangular plate in which there is possibly located a slot for receiving a flat cable or for receiving a cable strip or, alternatively, comprising a hinge part, a handle, a hook or some other fitting part.
[0009] The connection element formed in this way is suitable for many types of application, for example, for a cable strip holder comprising a receptacle, as neck with rectangular outer cross section to be received in a rectangular opening in a thin wall of the plate so as to be secured against rotation and displacement, the head being formed of rectangular plate, while a slot is located at the neck for receiving a flat cable or for receiving a cable strip.
[0010] Two antler-like projections which can be connected to one another at the free end for enclosing a cable bundle can emerge from the rectangular plate from two opposing sides thereof.
[0011] It is advantageous when the neck with the rectangular cross section has a length such that it projects through the opening in a thin wall in working position and partially reaches into the opening of the other thin wall. In this way, the two sheet metals cannot rotate relative to one another or relative to the connection element and can accordingly be clamped in a secured position of the location secured in a rectangular cross section.
[0012] According to yet another embodiment form, the neck also projects along a portion of its extension through the opening of the other thin wall and accordingly prevents a rotation of the two thin walls relative to one another and relative to the connection element.
[0013] In case of the longer neck extension, corresponding foot areas can be provided.
[0014] It is advantageous when two areas with a lengthened neck and shortened foot are diametrically opposed.
[0015] Alternatively, two areas with a lengthened neck and shortened foot can be diametrically opposed. When the middle web of the connection element is split, this allows lateral slippage.
[0016] An eye with a bore hole can also be provided next to the base of the connection element, preferably between two connection elements, for guiding a fastening screw, particularly a screw with a self-cutting profile.
[0017] A connection element can be provided for fastening the handle by its ends.
[0018] The head can form a plate with a hook.
[0019] Alternatively, the head can be a plate with an undercut strip.
[0020] The head can also be a plate with a hinge part fitted thereto.
[0021] Finally, the neck can have a length which facilitates mounting in the undercut slot of an aluminum profile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A to 1E show different views showing the steps for assembling a cable strip holder according to the invention;
[0023] FIGS. 1F to 1H show enlarged views of a cable strip holder according to the invention;
[0024] FIGS. 2A , 2 B and 2 C show a front view, a side view and a perspective view of a cable holder of the connection element which is used according to FIG. 1 ;
[0025] FIGS. 3A , 3 B and 3 C show different views of a connection element with alternative supporting surface;
[0026] FIGS. 4A , 4 B and 4 C show corresponding views of a strip holder;
[0027] FIGS. 5A , 58 and 5 C show a U-shaped embodiment form of the connection element;
[0028] FIGS. 6A , 6 B and 6 C show a connection element with supporting surface with high edge;
[0029] FIG. 7A shows a perspective view of a cable holder in which the connection element according to the invention is inserted;
[0030] FIG. 7B shows a front view of a cable holder in which the connection element according to the invention is inserted;
[0031] FIG. 7C shows a side view of a cable holder in which the connection element according to the invention is inserted;
[0032] FIG. 7D shows a top view of a cable holder in which the connection element according to the invention is inserted;
[0033] FIG. 8A shows a perspective view of a connection element according to FIG. 8B connected to a cable strip;
[0034] FIG. 8B shows a front view of a connection element connected to a cable strip;
[0035] FIG. 8C shows a side view of a connection element according to FIG. 8B connected to a cable strip;
[0036] FIG. 9A shows a perspective view of a cable holder and two metal plates which serve as connection element and which are provided with openings, and the connection process;
[0037] FIG. 9B shows a front view of a cable holder and two metal plates which serve as connection element and which are provided with openings, and the connection process;
[0038] FIG. 9C shows a plan view of a cable holder and two metal plates which serve as connection element and which are provided with openings, and the connection process;
[0039] FIG. 10A shows a front view of an embodiment form with expanded working area;
[0040] FIG. 10B shows a side view of an embodiment form with expanded working area;
[0041] FIG. 10C shows a view from both sides of an embodiment form with expanded working area;
[0042] FIGS. 11A to 11C show a front view, a side view and a perspective view of another embodiment form of a connection element;
[0043] FIG. 12A shows a perspective view of the embodiment form according to FIGS. 10A to 10C in various stages of assembly;
[0044] FIG. 12B shows a perspective view of the embodiment form according to FIGS. 10A to IOC in various stages of assembly;
[0045] FIG. 12C shows a sectional view through the embodiment form according to FIGS. 10A to 10C in various stages of assembly;
[0046] FIG. 13A shows a front view of a modified embodiment form of the connection element with grooves;
[0047] FIG. 13B shows a side view of a modified embodiment form of the connection element with grooves;
[0048] FIG. 13C shows a perspective view of a modified embodiment form of the connection element with grooves;
[0049] FIGS. 14A , 14 B and 14 C show views analogous to FIGS. 13A to 13C but with kinematic reversal of the projections and notches;
[0050] FIG. 15A shows a front view of a connection element for a cable bundle, a pipe or hose or a rod;
[0051] FIG. 15B shows a side view of a connection element for a cable bundle, a pipe or hose or a rod;
[0052] FIG. 15C shows a perspective view of a connection element for a cable bundle, a pipe or hose or a rod;
[0053] FIGS. 16A and 16C show a perspective view of a connection element to be used as handle;
[0054] FIG. 16B shows a side view of a connection element to be used as handle;
[0055] FIG. 17A shows a perspective view of a clothes hook as connection element;
[0056] FIG. 17B shows a cross-sectional view of a clothes hook to be used as connection element;
[0057] FIGS. 17C and 17D show identical views of another embodiment form of the clothes hook;
[0058] FIGS. 18A and 18B show two views of web-shaped connection element;
[0059] FIGS. 19A to 19C show the construction of a hinge, wherein, according to FIG. 19A , one hinge part is mounted in a thin sheet metal sheet with a rectangular opening, wherein the other hinge part is arranged in an opening in a thin wall in a similar manner resulting in a sheet metal cabinet, illustrated in FIG. 19A , in which a hinge or the like can be folded out. The holding element can extend linearly in a wide area, which is advantageous in some applications;
[0060] FIGS. 20A to 20C show views of a hinge part similar to FIGS. 19A to 19C according to the invention;
[0061] FIGS. 21A to 21C show views similar to FIGS. 20A to 20C of a hinge of similar construction;
[0062] FIGS. 22A to 22C show an assembled hinge formed of connection elements according to the invention, wherein two sheet metal walls are connected to one another by the hinge;
[0063] FIGS. 23A to 23C show a hinge for articulating a thin wall at an aluminum profile and additional fastening with a head boring screw; and
[0064] FIGS. 20A to 24D show a further example showing how a thin wall can be arranged at an aluminum profile by means of the connection element according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0065] 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.
[0066] The present invention will now be described in detail on the basis of exemplary embodiments.
[0067] FIGS. 1A to 1E show a cable strip holder 10 comprising a connection element 12 which has a head 14 with adjoining neck 16 with rectangular outer cross section to be received in operation so as to be secured against rotation and displacement in a rectangular opening 18 in a thin wall 20 such as a sheet metal angle 24 and with a plate-shaped base 22 from which emerge two legs 26 extending back to the neck, which legs merge into feet 28 with a foot bottom 30 . The head 14 comprises a rectangular plate 34 in which there is a slot 35 for receiving a flat cable or for receiving a cable strip 36 .
[0068] The assembly of the arrangement according to FIGS. 1A to 1E is carried out, for example, such that the sheet metal angle is initially fastened to the housing by angle portion 24 . According to the invention, the connection element 12 is pushed with its legs through the opening 18 into the other angle, wherein the legs yield and can be pushed through the opening 18 with the results illustrated in FIG. 1B , The cable strip 36 is then drawn through the slot 34 as is shown in FIG. 1C . This arrangement is shown in detail in FIG. 1D and again in a sectional view in FIG. 1E .
[0069] The connection element 12 used in the arrangement shown in FIGS. 1A to 1D is illustrated in detail in FIGS. 2A , 2 B. Possible play is absorbed in that the foot bottom extends in a slanted manner with respect to the thin wall. The four-cornered shape of the projection 16 is also important. It prevents rotation of the connection element with respect to the opening according to FIG. 2A .
[0070] The rectangular neck 16 shown in FIG. 2A fits snugly into the openings 18 of the thin wall so as to reliably secure against rotation. The slanted surface 26 of the feet 28 facilitates insertion of the legs into the opening.
[0071] FIGS. 3A , 3 B and 3 C show an alternative embodiment form in which the neck 16 is omitted and, instead of this, toes 40 are arranged at the feet so as to contact the edges of the opening. In the embodiment form in FIGS. 4A , 4 B, 4 C, the foot additionally has a hook surface 42 .
[0072] In the embodiment form according to FIGS. 5A , 5 B, 5 C, the antler-like projection is omitted. Instead, the one leg is fixedly connected to the head, while the other leg 44 swings freely. Finally, referring to FIGS. 6A , 6 B, 6 C, a jagged supporting surface 48 is provided. FIGS. 7A to 7D show a body in which two opposing sides emerge from the rectangular plate 114 of the head in the manner of antlers, and projections at the free end thereof can be connected to one another to enclose a cable strip. The connection of the free ends can be carried out by means of a plug-in connection 52 , 54 .
[0073] In the embodiment form according to FIGS. 8A to 8C and 9 A to 9 C, the rectangular neck 216 slides only through plate 220 and partially into the opening 19 of the other thin wall 221 such that the openings are aligned. For example, a rotation of the connection element 212 with respect to the two thin walls 220 , 221 and the thin walls 220 , 221 relative to one another is prevented.
[0074] The aim of arranging the feet 228 as close as possible to the neck area 216 results in the arrangement shown in FIGS. 9A to 9C . However, this sacrifices the security of holding walls at the ends also, because the edge of the thin walls is visible in an unsightly manner. A further development shown in FIGS. 10A , 10 B and 10 C is advantageous for this reason. As can be seen, the neck 316 is shortened with respect to its axial length 68 in all of the areas of the larger foot extension 70 so that the foot area 66 is free to lie on the edge of the opening, while the neck 316 secures against rotation. In this respect, there are different options for distributing these areas 62 , 70 . In FIGS. 10A , 10 B, 10 C and 11 A, 11 B, 11 C, the arrangement is asymmetrical and has the advantage that the injection dies are simplified.
[0075] In the embodiment forms according to FIGS. 13A to 13C and 14 A to 14 C, the arrangement is symmetrical but more difficult to produce by injection molding because the injection mold must work with slides.
[0076] FIGS. 12A , 12 B, 12 C show how the arrangement is used to connect two sheet metal sheets and requires a longer neck (see FIGS. 14A to 14C ), while an embodiment form to be applied as cable holder requires a short neck (see FIGS. 15A to 15C ).
[0077] Further, a retaining loop for a cable bundle, a pipe, a hose or a rod which can be inserted laterally is shown in a perspective view in FIG. 15C , in a side view in FIG. 15B and in a sectional view in FIG. 15A .
[0078] With the connection element according to the invention it is possible to fasten any parts to a sheet metal wall so as to be secured against rotation such as, for example, a clothes hook which is shown in FIGS. 17A to 17D in perspective view and in a side view prior to assembly and after assembly. Another example is a handle strip 410 which can be constructed as shown in FIGS. 18A and 18B . Another use of the connection element for four-cornered or rectangular holes offers the further advantage that the legs only engage behind two opposing edges of the hole so that trim, aluminum profiles provided with slots and the like can also be fastened.
[0079] Further applications according to the invention are shown in FIGS. 19A to 19C in which the hinge parts of a hinge which have the fastening device according to the invention can be secured in a rectangular opening in a beveled sheet metal sheet (see also FIGS. 20A to 20C ), wherein two holding elements 12 , 112 for each hinge part are spaced apart such that a securing screw 70 can be provided, in which case this securing screw 70 has eyes 72 for a self-cutting screw 70 which are arranged between two connection elements 12 , 112 according to the invention.
[0080] FIGS. 21A to 21C also show a hinge.
[0081] FIGS. 22A to 22D also show a hinge in which the two hinge parts according to the invention can spread apart in axial direction parallel to the hinge axis.
[0082] The hinge in FIGS. 23A to 23C is similar to the hinge already shown in FIGS. 21A to 21C in which a securing screw 170 which works itself into the material of a profile is arranged between two connection elements 12 , 112 . The one hinge half is then anchored in an aluminum profile, while the other hinge part 82 is fastened with two openings 18 , 19 in a sheet metal wall 21 with holding elements 12 , 112 according to the invention.
[0083] Finally, FIGS. 24A to 24B show the fastening of a sheet metal sheet 20 to profiles 78 , wherein holding elements 12 according to the invention serve as fastening means.
[0084] The arrangement of the finger grip without plate according to FIGS. 16A to 16C requires two holes 18 , 19 , wherein fastening means can be provided at the ends of the grip.
COMMERCIAL APPLICABILITY
[0085] The invention is commercially applicable in switch cabinet construction.
[0086] 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 , 310 , 410 , 510 cable strip holder, clothes hook, handle strip, finger grip
12 connection element
14 head
16 neck
18 opening
19 opening
20 thin wall
21 , 221 thin wall
22 plate-shaped base
24 sheet metal angle
26 legs
28 feet
30 feet bottoms
32 edge
34 slot
36 cable strip
38 bevel
40 toe
42 hook
44 free leg
46 stair shape
50 antler-like projections
52 , 54 plug-in connection
56 retaining loop
58 area
60 foot area
62 portion
64 transverse extension
66 foot area
68 area length
70 securing screw
72 eye
74 hinge part
76 hinge part
78 aluminum profile
79 foot extension
80 hinge part
82 hinge part | A connection element including a head with adjoining neck with a rectangular outer cross section to be received in a clip-like manner such that it is secured with respect to rotation, and possibly displacement, in an opening in a. thin wall. The connection element also includes a base, from which emerge two legs extending back to the neck and having grooved foot bottoms for support on an edge of the wall opening, The head comprises a rectangular plate in which there is possibly located a slot for receiving a flat cable or for receiving a cable strip. Alternatively, the head may include a hinge part, a handle, a hook, or some other fitting part. | 8 |
REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation application of copending U.S. patent application Ser. No. 09/394,775 filed Sep. 13, 1999 and claims priority thereof.
FIELD OF THE INVENTION
[0002] The present invention relates to dental resin compositions (dental cements) containing a desensitizing agent. Methods of preparing dental adhesive compositions and methods of reducing the incidence or severity of tooth sensitization or post-application pain are also provided.
BACKGROUND OF THE INVENTION
[0003] All references cited herein are incorporated by reference in their entireties.
[0004] There is a growing need in the dental art for biocompatible materials which do not produce undesirable post-application side effects, such as tooth sensitivity. Materials used in dentistry have shown significant improvements over the years, particularly dental adhesive compositions or dental cements.
[0005] In the past, zinc phosphate and zinc-eugenol cements were used, but the undesirable properties of such products are well documented in the literature. Polycarboxylate cements eventually became the primary class of cements based in dentistry. Use of polycarboxylate cements declined with the advent of glass ionomer and resin cements. The most commonly utilized class of dental cements are resin and resin-reinforced glass ionomer cements.
[0006] Resin-reinforced glass ionomer and resin cements are used in numerous dental applications, e.g., to adhere crowns, artificial implants (grouting substance), bonded bridge luting cement, for core build up, and to lute bridge work, inlays and onlays, and other related dental fixtures to the desired base, usually a mature tooth. The advent of resin cements resolved many of the retention problems experienced with the zinc-based products, presently used by practitioners. Many of the resin cements are based on acrylic polymers such as polymethyl methacrylate. Resin cements are based on acrylic or diacrylate resins and they have been used to cement crowns, conventional bridges, and resin bonded bridges; for bonding of esthetic restorations to teeth; and for direct bonding of orthodontic brackets to acid-etched enamel. The early resin cements were primarily poly(methylmethacrylate) powder with various inorganic fillers and methyl methacrylate liquid. Setting was caused by a peroxide initiator-amine accelerator system.
[0007] The self-cured, composite cements are typically powder-liquid or two paste systems. One major component is diacrylate oligomer diluted with lower molecular weight dimethacrylate monomers. The other major component is silanated silica or glass. The initiator-accelerator system is peroxide amine.
[0008] The adhesive resin cements are self-cured powder-liquid systems formulated with methacryoxyethylphenyl phosphate or 4-methacryloxyethyl-trimelitic anhydride (4-META). Phosphate cement, a two paste system, contains BIS-GMA resin and silanated quartz filler. The phosphonate is very sensitive to oxygen, so a gel is used to coat the margins of a restoration until setting has occurred. The phosphate end of the phosphonate reacts with calcium of the tooth or with a metal oxide. The 4-META cement is formulated with methyl methacrylate monomer and acrylic resin filler and is catalyzed by tri-butyl-borane. The adhesive resin cements and composite resin cements in conjunction with dentin bonding agents are being used as cements for posts and cores and veneers (porcelain and acrylic).
[0009] Many of the problems associated with resin cements is due to the acrylic resins themselves. The acrylics, particularly polymethyl methacrylate, exhibit shrinkages when polymerizing. PMMA products are extremely versatile and are utilized in a variety of dental applications.
[0010] A particularly troublesome side effect associated with the use of resin cements is post-application sensitivity. Sensitization with resin cements is attributed to swelling of the cement that occurs over time, often causing the coronal aspects of the tooth and porcelain crown to break and detach. To avoid sensitization with resin cements, it is recommended that the dentin of the tooth be hybridized prior to application of the resin cement. Hybridization is a process wherein binding or desensitizing agents are applied to the dentin of the tooth prior to cementation. Without hybridization, the potential for tooth sensitization increases.
[0011] The addition of glass ionomers to resin cements greatly improves the properties and overcomes many of the difficulties associated with previous resin cement formulations. These resin reinforced glass ionomer (RRGI) cements are, therefore, a particularly preferred class of resin cements and are the product of choice for many dental applications. RRGI cements provide excellent adhesive properties, diminishes swelling and are anti-cariogenic. The anti-cariogenic properties of certain RRGI cements are attributed to fluoride which is inherent in its composition which becomes bioavailable over time. Glass ionomer cements are supplied as a powder that is mixed with water. The liquid typically is a 47.5% solution of 2:1 polyacrylic acid/itaconic acid copolymer (average molecular weight 10,000) in water. The itaconic acid reduces the viscosity of the liquid and inhibits gelation caused by intermolecular hydrogen bonding; D(+) tartaric acid (5%, the optically active isomer) in the liquid serves as an accelerator by facilitating the extraction of ions from the glass powder. In some products, the polyacrylic acid is formulated in the powder. The liquids may be water or a dilute solution of tartaric acid in water. The setting reaction is an acid-base reaction between the acidic prolyectric and the alumino-silicate glass. The polyacid attacks the glass to release cations and fluoride ions.
[0012] The glass ionomer cements bond chemically to enamel and dentin during the setting process. The bonding mechanism is thought to involve an ionic interaction with calcium and/or phosphate ions from the surface of enamel or dentin. Treatment of dentin with a dilute solution of ferric chloride preceded by an acidic cleanser improves bonding. The cleaning agent removes the smeared layer of dentin which the Fe 3 + ions are deposited and increase the ionic interaction between cement and dentin.
[0013] The powder of a glass ionomer cement is a calcium fluoraluminosilicate glass (SiO 2 —AL 2 O 3 —CAF—NaAlF 6 —ALPO 4 ). Known resin cement and RRGI cement formulations are described, e.g., in U.S. Pat. Nos. 4,360,605; 4,376,835, and 5,681,872.
[0014] Unfortunately, RRGI cements, like non-glass ionomer containing resin cements, have shown significant and oftentimes severe and persistent post-application sensitivity. Post-application sensitization attributed to the RRGI cements is a bothersome and oftentimes serious side-effect, and can result in removal of prostheses, root canal therapy and, in extreme cases, extraction of the affected tooth. The post-cementation sensitivity associated with RRGI cements is severe and capricious, occurring in approximately 5 to 10% of patients in which the RRGI cement is used.
[0015] To avoid this sensitization, dental clinicians prepare fast and relatively thick RRGI cement mixes. It is also known that moisturizing the teeth prior to application provides added benefit, but does not eliminate the problem.
[0016] It is known in other aspects of the dental art to incorporate a desensitizing agent into dental composition to treat hypersensitive teeth. For example, U.S. Pat. No. 5,718,885 to Gingold et al. disclose a composition for treating hypersensitive teeth containing a desensitizing agent, comprising a cationically charged colloid, e.g., CeO 2 , wherein the composition is phosphate free.
[0017] U.S. Pat. No. 4,978,391 to Jones describes a method for cushioning dental appliances in the mouth using a visible light-cured polytechnic material which can also be used for intraoral delivery of a medicament. The medicament may be a non-fluoride tooth desensitizing agent such as potassium nitrate.
[0018] U.S. Pat. Nos. 4,343,608 and 4,407,675 to Hodosh describe zinc polyacrylcate cements containing potassium nitrate that are said to be healthful and useful for treating pulpitis. In one described method for preparing the cements, a freeze dried zinc polyacrylate cement powder is added to zinc oxide powder, and a small amount of a saturated aqueous solution of potassium nitrate is added. The resultant cement is applied to the desired site, where it hardens to a cement-like consistency. Glass ionomer may be added to this cement. It is noted that in some cases, a transient period of cold sensitivity existed after application, which was reported to routinely disappear wither by itself or by application of potassium nitrate paste as described in U.S. Pat. No. 3,086,006.
[0019] The present invention which is described herein overcomes the problem presented by prior art cements and the use of such prior art cements.
OBJECTS OF THE INVENTION
[0020] It is an object of the present invention to provide dental adhesive compositions that preferably decrease the incidence and severity of sensitization compared to prior art formulations.
[0021] It is also an object of the present invention to provide methods of preparing the dental adhesive compositions of the invention.
[0022] It is further an object of the present invention to provide a method of reducing and preferably eliminating the incidence of tooth sensitization seen with prior are resin cements or RRGI cements by applying the dental adhesive composition of the present invention to the desired site.
SUMMARY OF THE INVENTION
[0023] These objects and others are achieved by the present invention, which is related in part to dental adhesive compositions of resin dental cements and a tooth desensitizing agent. Preferably, the resin dental cement contains a glass ionomer (RRGI cement), and the tooth desensitizing agent is a potassium-containing desensitizing agent such as KNO 3 .
[0024] The dental adhesive compositions of the present invention which typically include from about 1 to about 20% weight of the dental adhesive composition. However, the amount of desensitizing agent included in the composition will vary with the type of cement used and with the particular desensitizing agent. The amount of desensitizing agent will be effective to reduce the sensitization or incidence of sensitization of teeth compared to the corresponding formula without the desensitizing agent.
[0025] The present invention also provides a method of preparing the dental adhesive formulations by incorporating an amount of desensitizing agent sufficient to prevent the sensitization of teeth into a resin cement. Preferably, the desensitizing agent is added in the form of a solution, e.g., potassium nitrate solution. Incorporation of the ingredients can be effected in any manner known in the art, e.g., hand mixing, use of industrial mixing equipment, and the like.
[0026] Another embodiment of the present invention provides a method for preventing the painful sensitization of teeth by applying a dental adhesive formulation including a resin cement such as a RRGI cement and an effective amount of a desensitizing agent to the desired site of adhesion. Application of the dental adhesive compositions of the present invention reduces or prevents tooth sensitization compared to dental cement formulation lacking the desensitizing agent.
[0027] The invention is described in further detail below.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The dental adhesive compositions of the present invention include a resin cement and a sufficient amount of a desensitizing agent to reduce or prevent sensitization of the teeth following the application of resin and/or resin-reinforced glass ionomer cement to the tooth. In other preferred embodiments, the resin cement does not contain a glass ionomer. The resin found in the resin and RRGI cements preferably includes an acrylic polymer, but may include any biocompatible resin or other adhesive materials known in the art. Preferably, the resin or RRGI cement includes a polymeric resin such as polymethyl methacrylate or dimethacrylate.
[0029] It is preferred that an RRGI cement is used in the formulations of the invention, as they provide many advantages which are more fully described hereinabove. The glass ionomer used to prepare the RRGI resin may be any known to those skilled in the art, and may include various ceramic, glass-ceramic and glass ionomers or particulate substances.
[0030] The particular resin or RRGI cement used in accordance with the present invention is not critical, since it is the addition of the desensitizing agents to these resins that are the primary thrust of the present invention.
[0031] Any desensitizing agent known in the art may be used in accordance with the present invention. It is preferred that the desensitizing agent contains potassium. Suitable potassium-containing desensitizing agents include those described in U.S. Pat. No. 5,522,726 to Hodosh. A non-limiting list of preferred potassium-containing desensitizing agents includes potassium nitrate, potassium bicarbonate, potassium bromide, potassium phosphate, potassium alum, potassium sulfate, potassium chlorate, potassium fluoride, and mixtures thereof. Potassium nitrate and potassium fluoride are preferred, and potassium nitrate is particularly preferred.
[0032] Potassium nitrate is known for use as a local anesthetic in dental applications. Many different potassium nitrate compositions are known in the art, and are described, for example, in U.S. Pat. Nos. 4,407,675; 4,343,675; 4,400,373; 5,153,006; all to Hodosh.
[0033] Potassium fluoride is also a preferred desensitizing agent because fluoride is well known for its beneficial anti-caries effect. It will become physiologically available as it leaches through the dental adhesive composition into the dentinal tubules and dentin. Thus, dental adhesive formulations containing potassium fluoride are especially advantageous.
[0034] The amount of desensitizing agent included in the dental adhesive compositions of the invention will vary, but will typically be added to amounts of about 1 to about 20 wt. % of the final composition, preferably from about 1 to about 15 wt. %, and more preferably from about 1 to about 10 wt. %. It is understood, however, that the amount of desensitizing agent contained in the dental adhesive compositions of the invention will vary with the type of resin cement or RRGI cement used, with the desensitizing agent, and with other factors that will be readily apparent to those skilled in the art.
[0035] The amount of desensitizing agent incorporated in the dental adhesive product will be sufficient to decrease or prevent tooth sensitization. Of course, the amount of desensitizing agent must not detract significantly from the adhesive properties and favorable characteristics of the formulation so as to render the final product unfit or less fit for its intended purpose.
[0036] Certain formulations may require the addition of other ingredients to impart commercially desirable properties to these products, e.g., preservatives, colorants, and the like. It is preferred to include calcium, phosphate and fluoride containing compounds as these agents provide well-known beneficial effects.
[0037] The compositions of the present invention may be prepared by adding a desensitizing agent to the resin or RRGI cement. The manner of addition is not critical and may be accomplished using any technique known to the skilled artisan. Many practitioners will find it useful to prepare the dental adhesive compositions on an as-needed basis. The desensitizing agent may be incorporated as a solid, e.g., as a salt, into the powder or into the liquid component of the resin or RRGI cements.
[0038] It is preferred that if the cement is prepared as a melt, that the desensitizing agent be added in solid form. It may also be preferred to incorporate the desensitizing agent into the glass ionomer prior to the addition of the resin materials.
[0039] The dental adhesive formulations of the invention have adhesive properties suitable for use in a wide variety of dental application, and can be used in any application where a dental adhesive or dental cement is required. These cement may be used to lute crowns and bridges, as bases (interim) in permanent or semi-permanent applications to adhere dental prostheses or corrective devices to the desired site, usually an existing tooth. The skilled artisan will apply these formulations according to techniques known in the art.
[0040] The dental adhesive formulations of the present invention result in a reduced incidence and severity of sensitivity compared to formulations of the prior art. Preferably, the formulations of the present invention provide reduced incidence and severity of sensitivity compared to counterpart formulations lacking the desensitizing agent. It is preferred that the formulations of the present invention prevent sensitivity from occurring in most instances. Thus, an aspect of the present invention provides a method for preventing and reducing the incidence and severity of post-application tooth sensitivity in patients by applying the formulations of the present invention into the desired site.
[0041] Preferred embodiments of the invention are described in detail hereinbelow.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
[0042] 100 grams of a 80% polymethyl methacrylate resin cement is prepared using art-known techniques. 50 grams of resin cement is set aside for a comparative test.
[0043] A sufficient amount of potassium nitrate is added to the remaining 50 grams of the resin to yield a dental adhesive composition containing 10 wt. % potassium nitrate. This product is tested and found to have suitable adhesive properties.
[0044] Both resins may be applied using art-known techniques to a patient in need of bilateral dental cement usage. With post-cement usage, the patient should report significant sensitivity at the site where the desensitizing-free resin cement was applied, but it is expected that the patient will not report significant sensitization on the side where the cement containing the desensitizing agent was applied.
EXAMPLE 2
[0045] In the procedure of Example 1 is repeated in another patient in need of bilateral bridgework, except that a commercially available RRGI cement is used, the patient will likely report a slight sensitizing in the area where the non-desensitizing cement was used, but no sensitivity in the other side of treatment.
EXAMPLE 3
[0046] A paste-paste restorative is prepared according to Example 3 of U.S. Pat. No. 5,681,872. A portion of that product was removed and potassium nitrate was added to yield a final product containing 8 wt. % potassium nitrate.
EXAMPLE 4
[0047] An amount of a resin cement or resin-reinforced glass ionomer cement is mixed with substantially an equal amount of glass ionomer cement containing a potassium-containing desensitizing agent, such as potassium nitrate, to yield a resin cement or resin-reinforced cement with an amount of potassium nitrate. Note though that the proportion of the mixture of the resin cement or resin-reinforced glass ionomer cement and glass ionomer cement containing potassium nitrate may vary and will depend on, e.g., the concentration of potassium nitrate in the glass ionomer cement.
[0048] An amount of resin cement or resin-reinforced cement is set aside for a comparative test.
[0049] Both cements are applied using art-known techniques to a patient in need of bilateral dental cement usage. With post-cement usage, the patient reported significant sensitivity at the site where the desensitizing-free resin cement was applied, but the patient did not report significant sensitization on the side where the cement containing the desensitizing agent was applied.
[0050] Other embodiments of the invention will be readily apparent to those skilled in the art, and are contemplated to be within the scope of the present invention. | Dental cements containing desensitizing agents, preferably potassium-containing desensitizing agents, are described. The cements favorably provide decreased post-application sensitivity upon application compared to prior art formulations. Methods for preparing these cements are also described, as are methods for decreasing the incidence and the severity of post-application sensitivity using the desensitizing cements of the invention. | 0 |
BACKGROUND OF THE INVENTION
This invention has to do with the transmittal of messages and the like and is particularly concerned with the transmission and display of messages from within flower buds as they mature to full bloom.
It is an old and well established custom for persons who desire to express their feelings to others to directly or indirectly present the others with gifts of flowers, such as roses.
Flowers are also presented and/or displayed to celebrate happenings or events of importance, such as weddings and anniversaries.
As a general rule, when flowers, such as roses, are presented to one as a gift, young, fresh, yet to fully open or bloom buds are presented so that the recipient of the flowers can watch and enjoy them for several days, as they open to full bloom.
Often, a gentleman, enamored of a woman, will present her with a single rose bud as a symbol of his love for her.
It is also an old and well established custom for a person who is desirous of expressing his or her care and/or feelings for another person to present that other person with a printed or written message that appropriately expresses his or her care and/or feelings. Such messages are also presented to celebrate special events and happenings. Such messages often consist of single words such as "love," "peace," "hope," and "congratulations"; or, short phrases such as "I love you," "Be mine," "Happy Anniversary," "Happy Birthday," and various other maxims and/or fortunes.
Such messages are often generically referred to as "fortunes" and for the purpose of this disclosure, will be identified as such.
One old and well-known form of presenting a fortune is a fortune cookie. That is, a cookie made from a thin layer of dough folded and baked around a slip of paper bearing a fortune. A fortune cookie is broken open by its recipient to gain access to the message or fortune.
The present invention resides in a novel combining of the above-noted customs, that is, the presentation of a flower and the presentation of a fortune, as a unit. More particularly, the present invention consists of positioning a strip of sheet material bearing a fortune within a yet to fully open or bloom petals of a flower bud and such that the strip emerges from within the bud and becomes exposed as the bud opens to full bloom.
PRIOR ART
It has been found that the practice of engaging elongate strips of paper bearing fortunes about the stems of artificial flowers has been practiced in the past. For example, Veterans organizations have long engaged such strips of paper about the stems of those imitation poppy flowers that the organization distributes on those holidays on which American war veterans are celebrated. Similar strips of paper are often related to the stems of artificial flowers as tags or labels for identification purposes.
It is understood and believed that nobody, prior to the date of my invention, deposited strips of paper or the like bearing fortunes within the buds of flowers and which are progressively released from within the buds and displayed as the buds open to full bloom.
OBJECTS AND FEATURES OF MY INVENTION
It is an object of my invention to provide a fortune flower comprising a flower bud carrying an elongate flexible and resilient spirally wound, self-emerging fortune strip bearing a fortune (fortune strip).
It is an object and feature of the invention to provide a fortune flower of the character referred to above wherein the strip is spirally wound into a cylindrical form and placed substantially central within the corolla of the bud where it is substantially obscured from view and from within which it emerges as the petals of the corolla splay and the bud opens to full bloom.
An object and feature of my invention is to provide a fortune flower of the general character referred to above wherein the fortune strip is established of thin resilient sheet material that can be yieldingly spirally wound and releasably held in tight compact cylindrical form and that spirally expands and unwinds when released.
It is another object and feature of the present invention to provide a fortune strip for a fortune flower of the general character referred above that is such that any desired fortune can be imprinted or otherwise applied to it in the process of establishing my new fortune flower.
Another object and feature of this invention is to provide a fortune flower of the general character referred to above wherein the fortune strip (in spirally wound form) can be inserted into the corolla of the flower bud from the outer free end of the bud or can be inserted into the corolla of the bud through the calyx of the bud, adjacent the flower stem.
The foregoing and other objects and features of my invention will be apparent and will be fully understood from the following detailed description of the invention throughout which descriptive reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a fortune strip;
FIG. 2 is an isometric view of the fortune strip in spirally wound, cylindrical form;
FIG. 3 is a view of a yet to fully bloom flower bud with the spirally wound fortune strip shown in dotted lines within it;
FIG. 4 is a view showing the flower bud in a more fully bloomed condition and showing the fortune strip partially unwound and emerging therefrom;
FIG. 5 is a diagrammatic view showing one way of inserting a fortune strip into a flower bud;
FIG. 6 is a diagrammatic view showing another way of inserting a fortune strip into a flower bud;
FIG. 7 is an isometric view of a fortune strip having a moisture soluble adhesive at one end thereof that releasably holds the strip in spirally wound form preparatory to inserting it in a bud;
FIG. 8 is an isometric view of one form of tool that can be used to remove a core from a flower bud preparatory to positioning a fortune strip therein and that can be used to receive a fortune strip and to inject the strip into a flower bud; and,
FIG. 9 is a view of a tool to receive and spirally wind a fortune strip and to insert the strip into a flower bud.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 of the drawings, I have shown an elongate fortune strip S. The dimensions of the strip S can vary widely and are generally determined by the size and nature of the flower bud within which the strip is to be positioned. The strip S might, for example, be approximately 1/4" wide and 11/2" long and about 1 or 2 mils thick. The strip has a flat front surface or face on which a fortune, such as "I love you," is printed or otherwise applied.
In practice, fortune strips S with standard fortunes, such as "I love you," "Good Luck," and "Happy Anniversary" can be printed and cut from large flat sheets of material and rolled into cylindrical form to establish a supply of fortune strips; or, can be printed with any desired and/or suitable fortune at the time that a fortune flower is being established. For example, fortune strips can be made of standard label-making plastic ribbon stock by means of any one of several commercially available label-making machines such as are produced by Mitsubishi Electric America, Panasonic, and other office machine manufacturers. Typically, the ribbon stock provided to make labels through label-making machines is Mylar plastic film about 1 mil thick. Further, such ribbon stock is typically provided with an adhesive coating on its back surface, which coating is covered with a removable backing of plastic film. Accordingly, when such ribbon stock is utilized to establish my new fortune strips; after the strips have emerged from their related flowers, the recipient of the fortune flowers can remove the backing from the strips and apply or stick the strips onto any desired supporting structure for preservation.
Prior to inserting the strip S in a related flower bud, the strip is yieldingly spirally wound into that small in diameter structurally stable and stiff cylindrical form shown in FIG. 2 of the drawings.
In practice, the method and means for spirally winding the fortune strip into cylindrical form can vary widely without in any way affecting the broader aspects and spirit of my invention. For the purpose of this disclosure, I have, in FIG. 9 of the drawings, shown one form of tool T that can be utilized to receive and spirally wind a fortune strip S and that can thereafter be utilized to insert or inject the wound fortune strip into a related flower bud. The tool T includes an outside tubular case 10 with a longitudinal slot 11 in and through which the inner end of a strip S can be entered. The tool T next includes a central bifricated or slotted rotatable shaft 12 that extends longitudinally of the case 10 and cooperates therewith to define and annulus 14 to accommodate the strip, as it is wound up about the shaft. The inner end of the strip S, within the case 10, is engaged in the slot in the shaft and the shaft is rotated to wind the strip thereabout and within the case. Finally, the tool T includes an elongate tubular ejector tube 15 that is slidably engaged about the rear portion of the shaft and that is shiftable forwardly into and through the annulus 14 to engage and eject the spirally wound strip from within the case and from about the shaft. The spirally wound fortune strip can be transferred directly from within the tool T into a related flower bud. The tool is shown as it might appear if the case 10 and tube 15 were molded of a transparent plastic material.
Alternatively, strips S can be ejected from the tool T directly into elongate open-ended cylindrical fortune strip cartridge in which a plurality of strips can be stored in end-to-end relationship and from which they can be ejected, one at a time, by means of an ejector rod or plunger shiftably engaged within the cartridge. In FIG. 8 of the drawings, I have shown a tool M with an elongate cartridge tube 20 in which one or more spirally wound strips S can be engaged and carried, in end-to-end relationship.
The cartridge tube 20 of the tool M has an open front end into and from which the strips can be entered and ejected and has a finger-engaging flange 21 at its rear end. An elongate plunger 22 with a thumb-engaging pad 23 that is slidably entered in the rear end of the cartridge and manually shiftable therein to eject the strips S from within the cartridge.
It is to be noted that the tools T and M work to hold the spirally wound fortune strips S in tight wound condition until the strips are ejected therefrom.
In practice, if desired and as shown in FIG. 7 of the drawings, a patch of adhesive 30 can be applied to the outer free end portion of the strip S. The patch of adhesive serves to releasably secure the end of the strip to the next to last turn of the strip, when the strip is wound. When provided with the above-noted adhesive patch 30, the strip or strips need not be contained and held against unwinding prior to their being inserted into related flower buds. The adhesive used is a suitable water-soluble adhesive that is caused to release when subjected to the moisture within a related flower bud or that can be caused to release by sprinkling or otherwise moistening the flower bud with water after the strip is positioned within it.
The fortune flower of my invention next includes a live yet to fully open or fully bloomed flower bud B, such as a rose bud, in which the outer sepals 40 of the calyx 41 have not yet fully parted to release the outer petals 42 of the corolla 43 and wherein the inner petals 42' of the corolla remain in close leafed and/or overlapping engagement with each other, about the central longitudinal axis of the bud, along and about which the ovary, the style and stigma and the anther and filament of the bud lie.
The cylindrical, spirally wound fortune strip S is entered into the central portion of the bud B with an inner or lower end thereof at or in close proximity to or within the ovary, with its central portion within the inner petals 42' and with its upper end below the upper edge portions of the outer petals 42 of the corolla. The corolla of the bud encapsulates and holds the strip S.
With the fortune flower thus established, the bud is let to open or bloom. As the bud blooms, the sepals of the calyx separate and turn radially outwardly and downwardly and away from the outer petals of the corolla and the outer petals of the corolla turn radially outwardly to free the inner petals, which move outwardly. As the petals approach full open position, the sprially wound strip S commences to open spirally outwardly and to emerge from within the bud or flower, into full view where it invites a viewer to pull or pluck it from within the bud or flower and to read the fortune thereon.
As a general rule, the outer end portion of the strip S is the first portion of the strip to move an appreciable distance outward and that end of the strip has a tendency to telescopically move upwardly and radially outwardly above the inner petals of the corolla. As a result, the outer end portion of the strip often appears as a very attractive and somewhat hellically formed leading end portion of the strip emerging from within the heart or center of the opening bloom.
In practice, the resiliency of the material from which the strip S is made is utilized and serves to assist full opening and blooming of the bud or flower.
In a bouquet of buds, some of which have fortune strips placed in them and other of which are without fortune strips, the buds with the strips tend to open sooner and more fully than the buds without the strips. The buds without the strips often wilt before they fully open.
It has been found that the damage to the bud caused by the insertion and/or presence of the fortune strip therein causes no appreciable adverse affects. It does not noticeably mutilate the bud or flower and does not appreciably shorten the useful life of the bud or flower, for display purposes. The buds and/or flowers of a bouquet of buds, some of which have and some of which do not have fortune strips positioned therein appear to fade and wilt at about the same rate.
In practice, if the spirally wound self-merging fortune strip S is inserted into the bud B from the top of the bud, as shown in FIG. 5 of the drawings, care must be taken, when inserting the strip, not to crush, tear, or unduly spread petals.
In practice, if the spirally wound fortune strip S is inserted from below the bud, through the calyx thereof, as shown in FIG. 6 of the drawings, it is preferred that the bud be cut or formed with a coring tool, similar to the tool M shown in FIG. 8 of the drawings, to form a passage and/is a cavity in the bud through and into which the strip can be easily inserted. The coring tool cuts cleanly into the bud without crushing, tearing or otherwise mutilating the bud. The opening in the calyx established by the coring tool is below the visible portions of the bud and is obscured by the sepals of the calyx as they turn outwardly and downwardly and is therefore so unobtrusive that it is not likely to be noticed; and, if noticed, is not objectionable.
It has been found that if the bud is not initially cored to establish an opening to receive the fortune strip S, the strip cannot be easily inserted without excessive bruising and possible rupturing or splitting of the calyx and/or adversely disturbing other parts and/or portions of the bud.
In accordance with the foregoing it will be apparent that my new and uniquely formed fortune strip in combination with the live and blooming bud establishes a novel combination and relationship of parts having a unique dynamic rule of action wherein radial and axial spirally unwinding and display of the self-emerging fortune strip and the opening and blooming of the bud are mechanically related to take place substantially simultaneously.
Having described only typical preferred forms and embodiments of my invention, I do not wish to be limited to the specific details herein set forth but wish to reserve to myself any modifications and/or variations that might appear to those skilled in the art and which fall within the scope of the following claims. | In combination; a yet to fully open and bloom flower pistil or bud; and, an elongate strip of thin flexible and resilient sheet material having a surface with a fortune applied thereto; said strip is yieldingly, spirally rolled into an elongate cylindrical form and is positioned within the corolla of the bud in substantial axial alignment with the central longitudinal axis of the bud and within the central assembly of petals to be releasably contained thereby; said petals progressively release and allow the strip to unroll and emerge from within the bud as the bud opens toward full bloom. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a novel gypsum board and particularly to a backer board for wet areas, such as behind ceramic tile in bathtub and shower areas
U.S. Pat. No. 4,647,496 discloses a fibrous mat-faced gypsum support surface in the exterior structure of a building with insulating material adhered thereover and an exterior finishing material which may be an acrylic resin based composition or a Portland cement stucco. Woven glass cloth, glass fiber scrim or a glass fiber mesh may be embedded in the exterior finishing material, or between the insulating material and the exterior finishing material as a reinforcing component. The fibrous mat-faced gypsum support surface is preferably a set gypsum core faced with a fibrous mat. The mat can comprise continuous or discrete strands of fibers and be woven or nonwoven, but preferably it is fiber glass filaments oriented in random pattern, bound together with a resin binder, and preferably on both surfaces of the core.
Canadian Pat. No. 993,779 also discloses a gypsum core board with facings formed of woven or unwoven porous glass fiber cover sheets, the woven normally being found more expensive.
U.S. Pat. No. 3,312,585 discloses a gypsum board for use as a backer board for behind ceramic tile in wet areas, formed of a paper covered gypsum core, plus a water impervious film, such as of polyvinyl chloride, covering the front face of the board and at least one longitudinal edge.
SUMMARY OF THE INVENTION
The present invention provides a novel water resistant gypsum board having on at least one face a laminated composite facing of an outer nonwoven fiber matte, and an inner woven, or at least semi-woven, fiber scrim, the fibers of both layers being preferably glass fiber.
The two plies of the composite facings are laminated and bonded together prior to the formation of the gypsum board. Following the formation of the gypsum board, the fibrous laminated composite facing on the front face of the gypsum board, which is most likely to be subjected to water, is coated with a water-based latex coating, preferably an acrylic latex coating.
In the preferred embodiment, the gypsum core includes, within its composition, water repellent chemicals, such as emulsions of asphalt and wax.
It is an object of the invention to provide an improved gypsum board in respect to its ability to withstand the dampness which often exists on the face of a board to which ceramic tile is applied, in both tub and shower areas, or the like, and its ability to have ceramic tile bonded thereto with a resultant extra strong bond.
It is a further object to provide a fiber glass faced gypsum board having markedly improved strength and visual appearance as a result of the novel placement of an outer layer of randomly directed, discontinuous fibers in a porous felted fiber form, over an inner layer of continuous long fibers in a woven or semi-woven form, in a multi-layer, latex coated facing on a gypsum board.
It is a still further object of the invention to combine such facings on a gypsum core, of a water repellent composition, to form a board over which ceramic tile are applied to provide an improved wet area wall.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be more readily apparent when considered in relation to the preferred embodiments, as set forth in the specification, and shown in the drawings, in which:
FIG. 1 is an isometric view of a gypsum board, made in accordance with the present invention.
FIG. 2 is an enlarged cross-sectional isometric view of the edge portion of the gypsum board of FIG. 1, taken on line 2--2 thereof.
FIG. 3 is a face view of the top surface of the gypsum board of FIG. 1, coated with an acrylic latex, portions broken away showing the preferred semi-woven glass fiber inner layer continuous strands behind a nonwoven random, discontinuous glass fiber outer surface, formed of felted, random, discontinuous glass fibers, and overlapping the wrapped around edge of the back face felted fiber layer.
FIG. 4 is a face view of a ceramic tile wall intended for a bathtub, shower or other wet area, with portions broken away, showing the gypsum board of FIG. 3, covered with resin reinforced Portland cement mortar, covered with ceramic tile.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, there is shown a gypsum board 10, having a front face 12, two side edges 14, a back face 16 and two ends 18. The gypsum board 10 is formed of a gypsum core 20, enclosed within a front face laminated composite facing 22 and a back face laminated composite facing 24.
The front face composite facing 22 extends entirely throughout the extend of front face 12. The back face composite facing 24 extends throughout all of the back face 16 with only one layer of the composite facing 24 extending around each of the two side edges 14 and a short distance onto the front face 12 adjacent to each side edge 14. The front face composite facing 22, adjacent each side edge 14, overlaps the part of the back face composite facing 24 disposed thereat, forming a lapped joint 26 of the two composite facings 22, 24.
The gypsum core 20 preferably includes water repellent additives, such as asphalt and wax which were added during manufacture of the gypsum board, in the form of a 10% by weight asphalt-wax emulsion, and about 1/2% by weight polyvinyl alcohol.
The front face laminated composite facing 22 and the back face laminated composite facing 24 are both about 0.020 inch thick, formed essentially of two plies, preferably an inner semi-woven glass fiber scrim 28 and an outer nonwoven fiber glass matte 30. The scrim weight is about 11.3 pounds per thousand square feet and the matte weight is about 16.5 pounds per thousand square feet.
The front face laminated composite facing 22 has formed thereon a thin acrylic film 32 which is the product of an application of an acrylic latex to the front face 12 just before severing of the continuously formed web of gypsum board into separate gypsum boards 10, and thus prior to drying of the gypsum boards 10, permitting curing of the film 32 during drying of the gypsum core 20.
The acrylic latex which is applied is preferably a water dispersion of an acrylic polymer specifically designed for modifying Portland cement compositions, such as a Rohm and Haas Company additive identified by the trademark Rhoplex E-330. This particular aqueous acrylic emulsion is a white, milky liquid, of 47% solids, a 9.5 to 10.5 pH, a 50 cps maximum viscosity, a specific gravity of between 1 and 1.2, with freeze thaw stability to 5 cycles and a minimum film formation temperature of 10° to 12° C. It contains a maximum of 0.2% ammonia.
By employing an acrylic polymer, to form film 32, which is specifically one which is the same as that used in modifying Portland cement compositions, the film 32 is caused to be substantially better in respect to its ability to bond to resin enhanced mortars used for applying ceramic tile.
The acrylic latex is applied using two vinyl rolls covered with a cloth sleeve, which apply 12-14 pounds of solids per thousand square feet of gypsum board.
The acrylic latex penetrates completely through the very porous front face laminated composite facing 22 and on into the gypsum core, which still contains considerable excess water at the time the latex is applied, strengthening the core 20 in that portion of the core 20, which is most important in providing high shear values that contribute to bonding ceramic tile to the gypsum board. The acrylic latex also adds additional water resistance to the gypsum core.
The portion of the back face laminated composite facing 24 which extends around each of the two side edges 14 and a short distance onto the front face 12, preferably consists solely of the outer nonwoven fiber glass matte 30. The side edge 34 of the semi-woven glass fiber scrim 28 of the back facing 24 will be seen in FIG. 2 to be located at the side edge 14 of the gypsum board back face 16. By omitting the scrim 28 of back facing 24 from the portion which extends around edges 14 and onto front face 12, manufacturing processes, particularly the severing of the formed board into separate gypsum boards 10, is made easier and with less energy and less potential damage to the end product.
The semi-woven glass fiber scrim 28 has preferably a fiber count of 6 fibers/inch in the cross machine direction and 10 fibers/inch in the machine direction. The tensile strength in the cross machine direction is 122 pounds per inch, and in the machine direction is 107 pounds per inch.
The laminated composite facings 22, 24 are available, prebonded as a unitary two-ply composite from the Milliken Corporation.
During formation of the gypsum board 10, the lapped joint 26 is formed with a polyvinyl acetate based adhesive. A suitable adhesive for the lapped joint 26 is a product of L. D. Davis Industries Inc., sold under the trademark Product No. 259.
It is important, during formation of the gypsum board, that the gypsum core slurry be of a uniform consistency which results in a minimum but sufficient penetration of the core slurry into the composite facings, to provide thorough adhesion of the facings to the core without any substantial bleed-through of the core mix to the outer surface of the composite facings.
The above described gypsum board, produced by the method steps as described above, has outstanding resistance to deterioration by water that may penetrate through a layer of ceramic tile applied thereto using resin reinforced mortar, in addition to having superior bond between the ceramic tile and the gypsum board 10.
FIG. 4 shows a wet area wall 36, with ceramic tiles 38 bonded to a gypsum board 10, with a resin reinforced Portland cement mortar 40. The resin reinforced Portland cement mortar 40 was made incorporating a resin which is similar to the resin of the gypsum board film 32, preferably both being acrylic resins.
Having completed a detailed description of the preferred embodiments of my invention, so that others may practice the same, I contemplate that variations may be made without departing from the essence of the invention. | A backer board for use as a base to which ceramic tile is bonded for a bathtub or shower area, in which the board is made by forming a gypsum core board with fiber glass laminated composite facings, which include an inner fiber glass scrim, an outer fiber glass nonwoven matte and an acrylic film, which film is formed of an acrylic latex of a class commonly employed as an ingredient in Portland cement mortar for applying ceramic tile. | 1 |
This application is a continuation of application Ser. No. 07/403,449, filed Sep. 6, 1989 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an optical information recording medium which is suitable for recording and reproducing information at high speed and at high density by changing some property of a recording film with use of light, heat and the like.
By focusing a laser beam through a lens system, a small light spot having a diameter on the order of the wavelength of the beam can be formed. Use of such light beam makes it possible to form a light spot the energy density per unit area of which is high, even with use of a light source of low output power. It is therefore possible to change the material in a very small area thereof and, in addition, to read the change in that very small area. An optical information recording medium was produced by making use of this technology. Hereinafter, the optical information recording medium will be referred to as "optical recording medium" or simply as "medium".
The optical recording medium has a basic structure comprising a substrate with flat surface and a recording film layer formed on the substrate so as to make some change in state with application of the laser beam spot. Recording and reproduction of a signal are carried out in the following manner. Namely, the laser beam is focused to be applied or irradiated onto the recording film surface of the medium of a plate shape which is moved by rotating means or translating means such as motor. The recording film absorbs the laser beam to result in the temperature rise. As the output power of the laser beam is made greater than a certain threshold value, the state of the recording film is changed to allow information to be recorded. This threshold value is a quantity which depends on the thermal characteristics of the substrate, relative transverse speed of the medium with respect to the light spot and the like, in addition to the characteristics of the recording layer itself. Reproduction of the recording information is carried out by applying onto the recorded portion the laser beam spot of an output power sufficiently lower than the above threshold value and, then, detecting difference between the recorded portion and the non-recorded portion in some optical characteristic such as the intensity of transmitted light, the intensity of reflected light or the direction of polarization of these lights.
For this reason, it is hoped to develop a structure and a material the state of which is changed with a small power of the laser so as to show a significant optical change.
There are known, as the recording film, metal films of Bi, Te, or containing Bi or Te as main ingredient, and compound film containing Te. These recording films are applicable to ablative recording in which the laser beam is applied to melt or evaporate a port of the film so as to form a small hole. Since the optical phase of the reflected light or transmitted light is difference between from the recorded portion and from its peripheral portion, the lights are cancelled each other due to destructive interference or diffracted so as to change the quantity of the reflected or transmitted light capable of reaching a detection system. Reproduction is effected by detecting this change. On the other hand, there is known another recording medium called structural phase change or phase transition type in which optical change takes place without causing any change in shape of the medium. There have been proposed as the recording film material an amorphous chalcogenide film and an oxide film containing Te-TeO 2 as main ingredient (Japanese Patent Examined Publication No. 54-3725). There has also been known a thin film containing Te-TeO 2 -Pd as main ingredient (Japanese Patent Unexamined Publication No. 61-68296). As the laser beam is applied to these films, at least one of the refractive index and the extinction coefficient of the film is changed so as to effect recording. Amplitude of the transmitted or reflected light is changed in this recorded portion. As a result, the quantity of the transmitted or reflected light capable of reaching the detection system is changed so that reproduction of signal is effected by detecting this change.
Light is wave and, accordingly, is characterized by amplitude and phase. As described above, reproduction of signal is detected in accordance with the change in the quantity of the transmitted or reflected light, this change being attributable to a change in the amplitude of the transmitted or reflected light in a very small area of the film itself (amplitude change or modulation recording) and to a change in the optical phase of the transmitted or reflected light (optical phase change or modulation recording). Incidentally, reflection coefficient means hereinafter a ratio of the light energy (that is, a square of amplitude) of the reflected light to that of the incident light.
In the ablative one of the optical recording mediums described above, the quantity of the reflected light is changed greatly and the optical phase modulation recording is carried out so that recording can be executed at high recording density. However, it is difficult to form regular holes and the noise level is high at the time of reproduction. Further, it is impossible to provide a contact Protective structure so that it is necessary to provide a complicated hollow structure called air-sandwiched structure, resulting in difficulty in manufacture and high cost. In addition, since deformation of recording layer is carried out upon recording, it is impossible to erase and rewrite.
To the contrary, the structural phase change type recording medium is not accompanied with deformation so that it can have a simple structure and can be manufactured easily and at low cost. However, there has conventionally been a problem that since amplitude modulation recording has been carried out the recording density is low as compared with ablative recording. Further, there is another problem that it is difficult to have compatibility with the write once type recording medium and the read only type replica disc (such as audio disc and video disc) which are optical phase change type recording media making use of concave/convex pits. In addition, there arises a further problem that when the of the geometrical deformation type recording region with the concave/convex pits and the structural phase change type recording region are made to coexist together in advance on one recording layer, reproducing signals from the both regions are differed from each other in the form having the recording in formation therein.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a structural phase change type optical recording medium which is capable of recording information at high density as compared with a conventional structural phase change type optical recording medium.
Another object of the present invention is to provide an optical recording medium which can be easily made compatible with optical discs of write once type and read only type making use of concave/convex pits.
Still another object of the present invention is to provide an erasable optical medium which can be compatible with optical discs of write once type and read only type making use of concave/convex pits.
A further object of the present invention is to provide an optical recording medium which enables recording to be effected on a tracking groove at high density and is capable of recording and reproducing the recorded information while effecting tracking by making use of the tracking groove, and a recording and reproducing method therefor.
In order to achieve the above object, there is provided according to the present invention an optical information recording medium in which a thin film recording layer material having optical constant(s) to be changed with application of a light beam is formed on a base material so that the optical phase of reflected or transmitted light is changed between before and after the change of the optical constant, and a change in the overall amount of the reflected or transmitted light due to this optical phase change is detected. Further, it is preferable that the optical information recording medium has a structure which causes no change or a small change in the amplitude of the reflected or transmitted light between before and after that change.
With the structure above, it is possible to effect recording which is optically equivalent to the optical phase modulation recording making use of concave/convex pits. Therefore, it is possible to perform the structural phase change recording at high recording density and it is easy to have compatibility with the write once type optical recording medium and the read only type replica disc (such as audio disc and video disc) making use of the concave/convex pits. Furthermore, reproducing light from the state in which the information signal has been recorded beforehand with use of concave and convex is equivalent to reproducing light from the state in which the structural phase change recording has been effected, so that reproduction of the information signal can be Performed with use of the same optical reproducing system and signal processing circuit. In addition, since the structural phase change recording is not accompanied with deformation, it is possible to reverse the recorded state to the original state, that is, to erase and rewrite, by suitably selecting the material, thereby realizing the rewritable type optical phase modulation recording.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mention and further objects of the invention as well as above-mentioned and further features and advantages of the invention will be made clearer from description of preferred embodiments referring to attached drawings in which:
FIG. 1 is a schematic sectional view showing a structure according to an embodiment of the present invention;
FIGS. 2 and 3 are schematic sectional views showing other embodiments of the present invention;
FIG. 4 is a schematic sectional view showing the conventional structure according to the prior art;
FIG. 5 is a graph showing the dependence of the reflection coefficient on the thickness of the recording film in the conventional structure;
FIGS. 6A and 6B are graphs showing the dependence on the recording film thickness, of the change in the reflection coefficient and of the optical phase change of reflected light in the conventional structure, respectively;
FIGS. 7 is a graph showing the dependence on the thickness of the transparent layers, of the change in the reflection coefficient and of the optical phase change of reflected light in an embodiment of the present invention;
FIGS. 8A and 8B are graphs showing the dependence on the recording film thickness, of the change in the reflection coefficient and of the optical phase change of reflected light in another embodiment of the present invention, respectively;
FIGS. 9A, 9B, 10A, 10B, 11A and 11B are graphs showing the dependence on the recording film thickness, of the change in the reflection coefficient and of the optical phase change of reflected light in still other embodiments of the present invention; and
FIG. 12 and FIGS., 13, 14 and 15 are respectively schematic sectional view and oblique views showing the form of the embodiments according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining embodiments of the invention, an example of the structure of the conventional structural Phase change type optical recording medium is explained for comparison referring to FIG. 4. A recording film or layer 3 is formed on a substrate or base material 1 and a protective layer 6 is further formed on the recording film 3. The protective layer 6 may be dispensed with and, in that case, it is supposed to be an air layer in place of the protective layer 6. Laser beam is applied through the base material 1 so as to be focused on the recording film 3, thus effecting recording and reproduction.
A structural phase change type recording material is used as the recording film. As the laser beam is applied to the structural phase change type recording material to generate heat and raise the temperature, the phase of the material is changed to thereby change the complex refractive index. In the general case, the refractive index and the extinction coefficient are changed in a positive correlation. For example, a change from amorphous state to crystalline state generally results in increase in the refractive index and the extinction coefficient. The reflection coefficient of such recording layer 3 depends upon the film thickness t 2 of the recording film layer 3. This will be explained in connection with FIGS. 5 and 6. In a case that the light beam is made incident from the side of the base material 1, the reflection coefficient R of the recording film 3 is obtained as a result of multiple interference of the reflected light from a light-incident surface of the recording film and the reflected light from a surface thereof on the opposite side to the light-incident surface. As the film thickness t 2 is changed, the reflection coefficient R is increased and decreased as a result of interference with a period determined in accordance with the wavelength and the refractive index. However, with the increase of the film thickness, the quantity of the reflected light from the surface on the opposite side to the light incident surface is reduced owing to absorption, thus reducing the effect of interference. In consequence, a curve of the reflection coefficient shown in FIG. 5 is obtained in which the magnitude of increase and decrease attributable to the interference is gradually reduced with the increase of the film thickness. As the absolute value of the complex refractive index becomes large the refractive index (real part) is increased, so that the Period or change in the film thickness giving an extreme value of reflection coefficient due to the constructive/destructive interference becomes small and, at the same time, the film thickness giving the same level of light intensity is reduced in accordance with the increase in the extinction coefficient (imaginary part). As result, a reflection coefficient difference ΔR obtained at the time of the structural phase change is also changed in accordance with the film thickness as shown in FIG. 6A. It is general that the reflection coefficient difference ΔR becomes a local maximum with a film thickness which causes the reflection coefficient to become a local minimum in the phase having a smaller complex refractive index.
On the other hand, with the above structure, the optical phase change of the reflected light is small between before and after the structural phase change. The conventional structural phase change type recording medium has been used with a film thickness which causes the reflection coefficient change to become a local maximum. Accordingly, reproduction of the recorded information is carried out by detecting the difference in the reflection coefficient mentioned above. In case of recording and reproduction in a very small area of micron order, the size of the recorded portion and the size of the light beam for use in reproduction are of the same order. For example, when the laser beam having a wavelength of about 800 nm is focused by a lens system having N.A ((numerical aperture) of about 0.5, the beam can be focused to have a radius of about 0.9 μm FWHM (full width half maximum). When such beam is used to effect recording with high power, the structural phase change takes place in a range of about 0.5 to 1 μm or so to thereby provide the recorded state. Thinking about a case of reproducing this recorded state with use of the same beam, the intensity of light of the reading beam is distributed in the form of Gaussian distribution or similar one and expands outwardly of the range of the recorded state where the structural phase change has taken place, so that the overall intensity or amount of the reflected light is in proportion to the value which is the average of the reflection coefficient of the recorded state and the reflection coefficient of the non-recorded state located therearound respectively weighed by their own areas and the light intensity distribution. In consequence, when the area of the recorded state range has not enough size to cover the size of the reading beam, it is impossible to obtain satisfactory reproducing signal. Thus, the required size of the area of the recorded state limits the recording density.
On the other hand, in the case of the ablative type, the recorded state corresponds a concave/convex form so that the intensity or amount of the reflected light is changed due to interference of the reflected light from the recorded portion and its peripheral portion Therefore, when the optical phase difference between the reflected lights from the hole portion and its peripheral portion is (1±2n)π (n: integer, π: circular constant), the change in the overall intensity or amount of the reflected light becomes the greatest, so that it is desirable that the optical phase difference is approximated to, particularly, substantially equal to this value. Further, in regard to the intensity distribution of the reading beam, when the intensity of the beam incident to the hole portion is equal to that incident to the peripheral portion, interference shows the greatest effect and, accordingly, the change in the overall reflected light intensity is made great. Namely, in a case that the area of the recorded state is smaller than the size of the reading beam, it is possible to have a large reproducing signal. It is understood from the description above that the optical phase modulation recording assures the recording and reproduction at higher density than the reflection coefficient change recording.
Accordingly, the structure by which the optical phase change due to the structural phase change recording is detected assures a high recording density equally to that of the concave/convex recording. In addition, it is desirable that there is caused on or little change in the reflection coefficient.
In order to form the above-described optical phase change type optical recording medium by making use of the structural phase change type recording film material, it is preferred to provide at least on one surface of the recording layer a transparent layer the refractive index of which is different from the adjacent substrate or protective layer at the wavelength of the laser beam used. When the refractive index of the material being in contact with the recording film is changed, the reflected light is changed at respective interfaces. The reflected light from the recording film is obtained as a result of multiple interference of the reflected light from the light incident surface of the recording film and the reflected light from the surface on the opposite side to the light incident surface. In a case where the thickness of the recording film is sufficiently small and the intensity of the light arriving at the surface on the opposite side to the light incident surface is sufficiently high, there is a condition that in the non-recorded state the optical constant(s) of which is small, the intensity of the light to be reflected after arriving at the surface on the opposite side to the light incident surface is larger than that of the light reflected from the light incident surface, while in the recorded state the optical constant(s) of which is large, the intensity of the light reflected from the light incident surface is larger than that of the light to be reflected after arriving at the surface on the opposite side to the light incident surface. Optical lengths for the both are different from each other so that there is an optical phase difference between them. When this optical Phase difference is large, it becomes possible to make the optical phase of the whole reflected light change greatly when the optical constant(s) is changed due to recording, as a result of destructive interference. Further, if the difference in amplitude between the both is substantially equal before and after the recording (although it goes without saying that the relation is reversed in terms of the magnitude), the reflection coefficient can be scarcely changed.
Further, it is possible to obtain a more efficient optical phase change type optical recording medium by forming, on a substrate, a first transparent layer the refractive index of which is different from that of the substrate, a recording layer, a second transparent layer and a reflective layer in the mentioned order and by selecting properly the thicknesses of the first transparent layer, the recording layer, the second transparent layer and the reflective layer. This is because the light transmitted through the recording layer is reflected by the reflective layer so as to efficiently conduct destructive interference with other reflected light.
On the other hand, in the optical recording medium such as optical disc, it is general to employ a tracking method making use of a groove formed in the substrate (e.g., see "OPTICAL DISC TECHNOLOGY" complied under the supervision of Mr. Morio Onoe, published by Radio Gijitsusha Co., Ltd., Chapter 1, 1.2.5, pages on and after 79). In this case as well, the groove serves to change the optical phase of the reflected light so as to give information required for tracking to the detection system. Therefore, in case of performing the optical phase change (modulation) recording/reproduction simultaneously with tracking by following the tracking groove, the optical phase change due to groove and the optical phase change due to recorded information are superimposed. Accordingly, it is necessary to make consideration on how to execute the optical phase modulation recording and reproduction without damaging the tracking function.
More specifically, as shown in FIG. 13, it is usually designed that the tracking groove 8 is made to be convex toward the incident side of the laser beam 7 and has a depth capable of providing an optical phase difference of -π/2, so that when the optical phase difference due to the structural phase change recording is ±π, the both are superimposed to provide a total optical phase difference of +π/2 or -3/2×π, thereby reversing the polarity of the tracking signal (for details, see the above-mentioned book). In such case, in order to obtain satisfactory reproducing signal without affecting the tracking, it is necessary to prevent the reverse of the total optical phase difference by setting the optical phase change due to the structural phase change recording to +π/2. In this case, since the total optical phase difference in the recorded portion is 0 (zero), the polarity of the optical phase difference which is the average of the recorded portion and the non-recorded portion is still minus, thereby preventing the reverse. In addition, the fact that the optical phase difference is 0 means such a state that is equivalent to the state in which the groove disappears, thus making it possible to obtain the reproducing light equivalent to the reproducing light from a portion in which a signal indicative of address or the like has been formed beforehand and in which the groove is not formed.
Furthermore, a tracking groove may be alternatively made to be concave as seen from the laser beam incident side contrary to the groove shown in FIG. 13. In this case, since the optical phase difference due to the groove is π/2, the optical phase change due to the structural phase change recording may be selected to be -π/2.
There is also known a tracking groove 9 of what is called "on land type" as shown in FIG. 14. In this case, tracking signal due to the groove 9 does not affect the reproduced signal of the recorded information (see the above-mentioned book) so that it is possible to set the optical phase difference due to the structural phase change recording at the maximum of ±π. Reference numeral denotes the laser beam.
By making use of the technique above, it is possible to obtain an optical disc in which a surface on which a recording layer 3 is formed is divided into two sections 10, 11 so as to make one 10 of the sections serve as a signal recording surface in the form of concave/convex pattern formed beforehand and the other section 11 as a write once or rewritable recording surface of optical phase change type making use of the structural phase change as shown in FIG. 15, for example. Reproduction from the both recording surfaces can be carried out with use of the same optical system and signal processing system. Accordingly, it is possible to obtain an optical disc having a plurality of functions and a method for reproducing it with use of a simple and inexpensive system.
Now, description will be given below in conjunction with concrete embodiments. As for the structure of the recording medium, there is formed, on a substrate or base material 1, a transparent layer 2 of dielectric or the like, a recording film 3, another transparent layer 4 of dielectric or the like and a reflective layer 5 in the mentioned order as shown in FIG. 1. A contact transparent protective layer 6 is further formed on the reflective layer 5. The protective layer 6 may not be provided, although not shown in a drawing. In this case, when it is supposed to provide an air layer (having a refractive index of 1.0) in place of the protective layer, they are considered to be optically equivalent and hence can achieve the same effects It is necessary that the transparent layer 2 is made of a material the refractive index of which is different from that of the substrate 1.
By suitably selecting the thickness t 2 of the recording film 3, the thicknesses t 1 and t 3 of the transparent layers 2 and 4, and the thickness t 4 of the reflective layer 5, it is possible to obtain an optical recording medium which shows a great change in optical phase. It is also possible to obtain an optical recording medium which shows a great change in optical phase and a small change in reflection coefficient.
The substrate 1 is a flat plate with a smooth surface which is transparent with respect to a given wavelength of the laser beam used for recording and reproduction. For example, plates of glass, resin and the like material can be used. Further, the substrate may be provided on its surface with a groove for tracking.
As for the protective layer 6, any material can be used so far as it has a function of protecting the thin layer formed on the base material including the substrate 1 mechanically or chemically. For example, a coating formed by applying and drying the resin dissolved in a solvent or a plate of glass or resin bonded to the base material with adhesives can be used.
The recording film 3 is formed by a material phase-changeable between amorphous and crystalline phase like a chalcogenide such as GeSbTe base or system, SbTe base, InTe base, GeTeSn base, SbSe base, TeSeSb base, SnTeSe base, InSe base, TeGeSnO base, TeGeSnAu base and TeGeSnSb base. Oxide materials such as Te-TeO 2 base, Te-Teo 2 -Au base, Te-TeO 2 -Pd base and the like can also be used. Furthermore, a metallic compound such as AgZn base, InSb base and the like phase-changeable between one and another crystalline states thereof can be used.
As for the transparent layer 2, material which is transparent and the refractive index of which is different from that of the substrate 1 at the wavelength of the laser beam used for recording and reproduction can be used. For example, oxides such as SiO 2 , SiO, TiO 2 , MgO and GeO 2 , nitrides such as Si 3 N 4 , BN and AlN, and sulfides such as ZnS, ZnSe, ZnTe and PbS can be used.
As for the reflective layer, a thin film is used that has a sufficient reflection coefficient at the wavelength of the laser beam used for recording and reproduction. For example, a metal such as Au, Al and Cu or a dielectric multilayer film having a large reflection coefficient at the predetermined wavelength can be used.
In order to have the above materials deposited in the form of a thin film or layer, there are known a vacuum evaporation method using a multi-source, a sputtering method using a compound mosaic target and other like methods.
COMPARATIVE EXAMPLE
A ternary compound of germanium, antimony and tellurium having the composition of Ge 2 Sb 2 Te 5 , which is a structural phase change material, was used as the recording film. The recording film or layer was formed by an electron beam evaporation method which used three evaporation sources of Ge, Sb and Te so as to independently control the evaporation rate from each evaporation source. The recording film was formed in an amorphous state. On measuring the optical constants of the film in the amorphous state formed by depositing the material of the composition of Ge 2 Sb 2 Te 5 alone onto the glass plate by evaporation, the complex refractive index n +ki 4.8+1.3i at the wavelength of 830 nm. After subjection of this film to annealing at 300° C. for five minutes so as to change into crystalline state, the value was changed to 5.8+3.6i.
The Ge 2 Sb 2 Te 5 film was deposited by evaporation in the same manner as above onto a polycarbonate resin plate (abbreviated as PC and having a refractive index of 1.58) and is further coated with resin of the same refractive index so as to provide the conventional structure as shown in FIG. 4. FIGS. 6A and 6B show the calculated values of the dependency, on the film thickness t 2 , of the change ΔR of the reflection coefficient R and of the optical phase change of the reflected light in this structure, in case of the light having the wavelength of 830 nm, between before and after annealing, that is, between in amorphous state and in crystalline state.
The reflection coefficient and the optical phase of the reflected light were calculated from the complex refractive index and the film thickness of each layer in accordance with the matrix method (for example, see "WAVE OPTICS" written by Mr. Hiroshi Kubota, published by Iwanami Shoten Co., Ltd., 1971, Chapter 3). In this case, on the assumption that the substrate 1 and the protective layer 6 have infinite (thicknesses neglecting effects of the interface between the substrate and air and the interface between the contact protective layer and air), the reflection coefficient R was derived as the ratio of the intensity of the light reflected into the substrate 1 to the intensity of the light incident from the substrate 1 and the optical phase was derived taking the optical phase at the interface between the substrate 1 and the transparent layer 2 as the reference phase. The optical phase is equivalent with a period of 2π, this fact being taken into account in the drawings.
The difference ΔR in the reflection coefficient between the amorphous state and the crystalline state becomes maxima local at the film thicknesses of 15 nm and 85 nm and takes the value of 14% and 24%, respectively, while there is caused very little optical phase change of not larger than π/6.
EXAMPLE 1
In an embodiment of the present invention, as shown in FIG. 1, zinc sulfide (ZnS having a refractive index of 2.10) was deposited by electron beam evaporation method onto the substrate 1 of polycarbonate resin plate (PC having the refractive index of 1.58) so as to serve as the transparent layer 2, onto which the recording film 3 of Ge 2 Sb 2 Te 5 shown in the Comparative Example was formed in the same manner as in the Comparative Example and, further, ZnS was deposited by evaporation in the same manner as the transparent layer 2 for serving as the transparent layer 4. On the transparent layer 4, gold (Au having a refractive index of 0.20+5.04i) was deposited by electron beam evaporation method so as to serve as the reflective layer 5 which was further coated with acrylic resin having the same refractive index as the substrate 1 so as to form the protective layer 6.
In the structure above, in a case where the thickness t 2 of the recording film layer 3 is 10 nm and the thickness t 4 of the reflective layer 5 is 20 nm, the i calculated values of the dependence on the thickness t 1 and t 3 of the transparent layer 2 and 4 of the difference or change R in the reflection coefficient R and of the optical phase difference or change φ between before and after annealing, that is, between the amorphous state and the crystalline state, are shown in FIG. 7. In FIG. 5, T1 and T3 are expressed after being converted into the optical thickness through calculation of n 2 ×t 1 and n 4 ×t 3 respectively (n 2 and n 4 representing the refractive index of the respective transparent layers t 2 and t 4 ). From FIG. 7, it is understood that although both of the reflection coefficient difference ΔR and the optical phase difference φ are changed in accordance with the thicknesses t 1 and t 3 , particular dependence on the thicknesses t 1 and t 3 are different from each other, and there can be obtained such film thicknesses t 1 and t 3 that assure ΔR=0 and give a large optical phase difference.
For example, when the thickness t 1 of the transparent layer 2 is 142 nm (which corresponds to 23/64×λ) and the thickness t 3 of the transparent layer 4 is 37 nm (which corresponds to 6/64×λ), a reflection coefficient difference becomes about 0% and an optical phase difference becomes about -0.9 π. When the thickness t 1 of the transparent layer 2 is 37 nm (which corresponds to 6/64×λ) and the thickness t 3 of the transparent layer 4 is 37 nm (which corresponds to 6/64×λ), a reflection coefficient difference becomes about 0% and an optical phase difference becomes about -0.46 π.
Further, in the case where the thickness t 1 of the transparent layer 2 is 142 nm (which corresponds to 23/64×λ) and the thickness t 3 of the transparent layer 4 is 37 nm (which corresponds to 6/64×λ), the calculated dependence; on the thickness t 3 of the recording film 3, of the reflection coefficient change ΔR and of the optical phase change of the reflected light between before and after the structural phase change, that is, between the amorphous state and the crystalline state, are shown in FIGS. 8A and 8B. It is shown that in the condition shown in FIG. 7, that is, when the thickness t 2 of the recording film layer 2 is 10 nm, no change takes place in the reflection coefficient and the optical phase change of the reflected light is about -0.9 π (=1.1 π) which almost approximate to π. It can be also seen that when thickness t 2 becomes large sufficiently such as to be 50 nm or more, very little optical phase change of not larger than π/6 takes place. This is because the optical phase of the reflected light is changed greatly only in the limited area in which the thickness of the recording film is small and the transmittance of the recording film itself is sufficiently large.
As a result, it can be seen that it is possible to obtain a structure the reflection coefficient of which is scarcely changed and in which the optical phase of the reflected light alone is changed by suitably selecting the thickness of each layer. On the basis of the above calculation, the following experiment was carried out.
On a PC resin disc of 1.2 mm thickness and 200 mm diameter used as the substrate, a film of ZnS was deposited by evaporation to a thickness of 142 nm in accordance with the above-described method while rotating the PC disc in vacuum, and a recording layer of Ge 2 Sb 2 Te 5 was further deposited in amorphous state to a thickness of 10 nm in the same way. Further, another ZnS film of 235 nm thickness was deposited by evaporation and then Au was deposited by evaporation to a thickness of 20 nm. Another multilayer film of the same structure was also formed on a glass substrate of 18×18 mm area and 0.2 mm thickness. In addition, the multilayer film formed on the resin disc was covered with another PC resin disc of the same kind with UV curing adhesives so as to form a contact protective layer, thus forming an optical recording medium.
The sample formed on the glass substrate was heated at 300° C. for five minutes in an atmosphere of argon so as to wholly crystallize Ge 2 Sb 2 Te 5 of the recording layer. The coefficients of reflection from the substrate side measured before and after crystallization were both about 11%, which means that no change was observed.
A semiconductor laser beam having the wavelength of 830 nm was focused by a lens system of the numerical aperture of 0.5 on the recording film at a linear velocity of 10 m/sec while rotating this medium. A light beam modulated at a single modulation frequency of 5 MHz at a percentage modulation of 50% was irradiated onto the surface of the recording film to have a power of 8 mW thereon so as to partially crystallize the recording film for effecting recording, and then the reflected light of the light beam irradiated continuously with an output power of 1 mW was detected by a photodetector for effecting reproduction. As a result, amplitude of "reproducing signal" was observed.
In the sample on the glass substrate mentioned above, crystallization caused no change in the reflection coefficient. It is therefore understood that the "reproducing signal" was produced due to difference in the optical phases of the reflected lights between from the recorded portion and from the non-recorded portion.
Furthermore, it was confirmed that when recording and reproduction were effected by changing the frequency of the signal to be recorded, the frequency characteristic was improved at a frequency zone higher than that available in the conventional structure having the recording film of 85 nm thickness as shown in FIG. 4.
In addition, the laser beam was continuously applied or irradiated likewise onto the surface of the recording film in which signals had been recorded at the linear velocity of 10 m/sec to have thereon a power of 16 mW larger than that at the time of recording. Then it was confirmed that the recording film was melted to be changed into amorphous state to thereby erase the signals recorded before.
EXAMPLE 2
As shown in FIG. 12, a PC resin disc of 1.2 mm thickness and 200 mm diameter provided with a tracking groove of 0.6 μm width and 65 nm depth in advance was used as the substrate 1. ZnS film 2 was deposited by evaporation on this resin disc 1 to a thickness of 37 nm while rotating it and a recording film 3 of Ge 2 Sb 2 Te 5 in amorphous state was further formed thereon likewise to a thickness of 10 nm. In addition, another ZnS film 4 was deposited by evaporation to a thickness of 37 nm and Au layer 5 was deposited to a thickness of 20 nm. Another multilayer film of the same structure was also formed on a glass substrate of 18×18 mm area and 0.2 mm thickness. In addition, the multilayer film formed on the resin disc was covered with another PC resin disc of the same kind with UV curing adhesives so as to form a contact protective layer 6, thus forming an optical recording medium.
The sample formed on the glass substrate was heated at 300° C. for five minutes in an atmosphere of argon so as to be wholly crystallized. The coefficients of reflection from the substrate side measured before and after crystallization were both about 8%, which means that there was caused no change.
The medium formed on the resin disc was rotated and a semiconductor laser beam having the wavelength of 830 nm was focused by a lens system of the numerical aperture of 0.5 onto the recording film while effecting the tracking control along the tracking groove. A light beam modulated at a single modulation frequency of 5 MHz at a percentage modulation of 50% was irradiated onto the surface of the recording film to have a power of 7.5 mW thereon so as to partially crystallize the recording film, thus effecting recording. Tracking control was stable even after recording. Further, the reflected light of the light beam applied or irradiated continuously with an output power of 1 mW was detected by a photodetector for effecting reproduction, as a result of which amplitude of "reproducing signal" was observed.
In the sample on the glass substrate mentioned above, crystallization caused no change in the reflection coefficient. It is therefore understood that the reproducing signal was produced due to difference in the optical phase of the reflected light between from the recorded portion and from the non-recorded portion. It is also confirmed that the optical phase difference was in the range which had no adverse effect on the tracking control.
Furthermore, it was confirmed that when recording and reproduction were effected by changing the frequency of the signal to be recorded, the frequency characteristic was improved such that the available frequency extended to a higher-frequency zone as compared with the conventional structure having the recording film of 85 nm thickness as shown in FIG. 4.
In addition, it was confirmed that when the laser beam was continuously applied or irradiated likewise onto the surface of the recording film in which signals had been recorded at the linear velocity of 10 m/sec to have thereon a power of 16 mW larger than that at the time of recording, the recording film was melted to be changed into amorphous state to thereby erase the signals recorded before.
EXAMPLE 3
A ternary compound having the composition of Te 49 O 28 Pd 23 which is a structural phase change material is used as the recording film. An electron beam evaporation method making use of three evaporation sources of Te, TeO 2 and Pd is adopted as an evaporation method. On measuring the optical constants of the film in amorphous state formed by depositing the material of the composition Te 49 O 28 Pd 23 alone onto the glass plate by evaporation, the complex refractive index n+ki was 3.1+1.2i at the wavelength of 830 nm. After subjection of this film to annealing at 300° C. for five minutes so as to change into crystalline state, that value is changed to 3.9+1.6i.
In the conventional structure shown in FIG. 4, the difference ΔR in the reflection coefficient between the amorphous state and the crystalline state becomes local maxima at the film thicknesses of 35 nm and 135 nm and takes the value of not smaller than 10%, while there is caused very little optical phase change of not larger than π/8.
As shown in FIG. 2, ZnS (having a refractive index of 2.40) was deposited by electron beam evaporation method onto a polycarbonate resin plate 1 (PC having the refractive index of 1.58) to a thickness of 97 nm so as to serve as the transparent optical layer 2, onto which the recording film 3 of Te 49 O 28 Pd 23 was formed in the same manner as described above and, further, a coating 6 of resin of the material having the same refractive index as the substrate was applied thereon. With the structure above as shown in FIG. 2, the calculated dependence on the film thickness t 2 , of the change ΔR in the reflection coefficient R and of the optical phase change of the reflected light between before and after annealing, that is, between in amorphous state and in crystalline state, are shown in FIGS. 9A and 9B.
It is shown that when the thickness of the recording film 3 is 20 nm, there is caused very little change in the reflection coefficient and an optical phase change of the reflected light of about -π/2 can be obtained. On the basis of these results of calculation, the following experiment was carried out.
PC resin disc of 1.2 mm thickness and 200 mm diameter used as the substrate was deposited thereon by evaporation with a film of ZnS to a thickness of 97 nm in accordance with the above-described method while being rotated in a vacuum, onto which a recording film of Te 49 O 28 Pd 23 was deposited by evaporation to a thickness of 20 nm likewise. Further, another PC resin disc of the same kind was bonded with UV curing adhesives so as to form a contact protective layer. A semiconductor laser beam having the wavelength of 830 nm was focused by a lens system of the numerical aperture of 0.5 onto the recording film at a linear velocity of 5 m/sec while rotating this disc. A light beam modulated at a single modulation frequency at a percentage modulation of 50% was applied onto the surface of the recording film to have thereon a power of 8 mW for effecting recording, and the reflected light of the light beam applied continuously with an output power of 1 mW was detected by a photodetector for effecting reproduction. As a result, the existence of reproducing signal was confirmed. It was also confirmed that the frequency characteristic was improved such that the available frequency extended to a higher-frequency zone as compared with the conventional structure having the recording film of 135 nm thickness as shown in FIG. 4.
EXAMPLE 4
As shown in FIG. 3, ZnS (having a refractive index of 2.40) was deposited by electron beam evaporation method onto a polycarbonate resin plate 1 (PC having a refractive index of 1.58) to a thickness of 76 nm so as to serve as a transparent optical layer 2, onto which the recording film 3 of Te 49 O 28 Pd 23 shown in the embodiment 3 was formed in the same manner as shown in the embodiment 3 and, further, a layer 4 of ZnS was deposited by evaporation to a thickness of 130 nm likewise, and finally, a coating 6 of resin of the material having the same refractive index as the substrate 1 was applied thereon. In the structure above, the calculated dependence on the film thickness t 2 of the change ΔR in the reflection coefficient R and of the optical phase change of the reflected light between before and after annealing, that is, between in amorphous state and in crystalline state, are shown in FIGS. 10A and 10B.
It is shown that when the thickness of the recording film is 30 nm, there is caused very little change ΔR in the reflection coefficient and an optical phase change of the reflected light of about -π/2 can be obtained.
EXAMPLE 5
As shown in FIG. 3, ZnS (having a refractive index of 2.40) was deposited by electron beam evaporation method onto a polycarbonate resin plate 1 (PC having a refractive index of 1.58) to a thickness of 120 nm so as to serve as the transparent optical layer 2, onto which the recording film 3 of Te 49 O 28 Pd 23 shown in the embodiment 3 was formed in the same manner as shown in the embodiment 3 and, further, a layer 4 of ZnS was deposited by evaporation to a thickness of 54 nm likewise, and finally, a coating 6 of resin of the material having the same refractive index as the substrate 1 was applied thereon. In the structure above, the calculated the dependence on the film thickness t 2 , of the change ΔR in the reflection coefficient R and of the optical phase change of the reflected light between before and after annealing, that is, between in amorphous state and in crystalline state, are shown in FIGS. 11A and 11B.
It is shown that when the thickness t 2 of the recording film is 120 nm, there is caused very little change in the reflection coefficient and an optical phase change of the reflected light of about π/2 can be obtained. | An optical information recording medium includes a thin film material formed on a substrate; the optical constant of this thin film material is changed upon application of an incident light beam, such that the optical phase of reflected or transmitted light is shifted thereby reproducing a signal by detecting the change in either the reflected or transmitted light due to this optical phase change. It is also possible perform signal reproduction equivalent to conventional concave-convex pit methodology, but without being accompanied by resulting media deformation, thereby improving the recording density. It is easy to interchange with optical recording media of the write-once and read-only types, and, furthermore, it is possible to erase and rewrite at will. | 6 |
This invention relates to a device and method for testing magnetic inspection particle materials and more particularly to a device having at least one predetermined magnetic stripe situated thereon to receive a magnetic inspection particle suspension in order to provide a method for determining the effectiveness of the particle suspension or system for use in testing.
BACKGROUND OF THE INVENTION
It is well known in the art that magnetic inspection particle systems are useful and important in industrial applications. The basic application of this system is for non-destructive testing of an item. This importance is clearly set forth in U.S. Pat. No. 4,812,249 relating to a test system by Isabelle Y. Duminy-Kovarik, incorporated herein by reference.
A major problem with the magnetic inspection particle system is a testing of the materials and particles themselves for their effectiveness. This test for effectiveness is critical. As parts are inserted into the suspension, and tested, the testing suspension of particles will lose some of its effectiveness. It is very critical to have the suspension be effective and be able to easily determine the effectiveness of that suspension by a simple test, in order to have each part tested efficiently.
A suspension for the purposes herein is deemed to include wet method materials borne in conditioned water or kerosene-type liquid, and dry-method materials applied directly to the test surface.
This action is critical because of the expensive nature of the suspension, and the expensive parts which are being tested. It is hypercritical that these parts be tested efficiently and effectively with an effective suspension. If such efficient or effective testing is not achieved, or if the suspension is not known to have failed or been found deficient in its effectiveness, a detective part may receive a false approval and be used in a dangerously unsuitable manner. This defective part can eventually lead to a failure of a system in which it is used.
In order to compensate for this depletion of the magnetic inspection particle fluid during a series of tests on various parts, it is known to use a piece or part with a known crack in it for testing purposes. This process or testing mechanism is difficult to reproduce from factory to factory or establishment to establishment because no two cracks are the same. Thus, a part with a predetermined crack may not be the same as a part with predetermined crack in another location. In this fashion, it is impossible to use this test to have an accurately reproducible test at various locations.
There is also a settling tube or bulb test. However, the settling tube test merely shows the number of particles in the suspension. It does not show the effectiveness of the particles or the brightness of the particles or the sensitivity of the particles. The settling bulb test merely shows the number of particles in the suspension. A repeatedly used fluid can lose brightness and sensitivity. The settling bulb test is also effected by dirt, scale and metal particles from the part itself being tested. The settling bulb test thus suffers from a number of inaccuracies, especially regarding actual particle performance.
Another test for use a magnetic inspection particle fluid is a ring test. This device is accomplished by a ketos ring or Tiede MTU#3 ring. These rings suffer from a similar problem in that the ring itself is not consistently reproducible. This factor greatly interferes with the desirability of providing the same test to the same fluid at a number of different sites.
Ketos Ring Discussion
Similar testing patterns are important to determine the similar quality of the parts. The ketos ring is made of tool steel, and is a flat disc like device having a plurality of apertures drilled at various radial distances from the circumference thereof. The degree of magnetization of the ring, combined with the differing qualities of the steel and the spacing of the apertures, can have an adverse effect on the test mechanism. The defects in the ketos ring are well discussed in a paper presented by Donald Hagemaier at the 1992 ATA NDT Forum in Cincinnati, Ohio, which paper is incorporated herein by reference.
The Ketos ring is a tool that is most commonly used as grading device for evaluating the sensitivity of MPI materials. It is described most accurately by Aerospace Standard AS5282. The Ketos ring is actually a disk made of SAE J438 steel, which is manufactured with properties as described within AS5282. The disk contains a centrally located aperture, which receives a conductive copper bar. Various currents of electricity are passed through that centrally located conductive copper bar in a controlled manner. These currents ultimately generate varying magnetic fields and gradients associated with each of several small apertures drilled at varying distances inside the circumference of the ring. The small apertures are placed in such a manner that their associated fields and gradients become weaker as they are further from the circumference.
Magnetic particles can be applied to the circumference of the ring as a current is passed through the central conductor. Particles are graded by the number of apertures that can be detected by displaying a formation of particles at the circumference above the aperture at given amperage. A more sensitive powder will show more apertures than a less sensitive powder.
AS5282 describes a procedure for evaluating the Ketos ring performance by means of a magnetic field measuring device that sense the residual fields associated with the apertures after the ring has been exposed to current of 1500 amps of direct current. While this use of residual fields may suffice for evaluating rings it does not represent the gradients used to grade particles as generated by the various currents.
The Ketos ring has been accepted as the standard tool for measuring particle performance for many years. Much of this acceptance has probably been due to the fact that, despite a variety of troublesome issues surrounding the ring, a suitable replacement had not been developed. The issuance of AS5282 in 1997 has provided a standardized means of evaluation and grading rings but many inherent (and quite possibly problematic) issues remain:
AS5282 evaluates the Ketos ring in a residual state of magnetization. The correlation between the residual state and the active magnetic state at which the ring is used has not been firmly established.
The values of the magnetic fields and gradients associated with the respective apertures in the active magnetic state are not described.
Consistency of the magnetic properties of the steel from which the rings are made.
Many rings in use in industry have probably not been certified to AS5282.
A ring is only compared to itself in the residual state. Consistency between rings is not addressed.
AS5282 calls out that 3-phase, full-wave, rectified alternating current be used for ketos ring evaluation. This type of current may not always be readily available, depending on the type of equipment used by a given inspector.
The magnetizing equipment providing the current must be in proper calibration. The equipment, and even the process of equipment calibration, can be subject to error and tolerance that can affect the performance of the Ketos ring.
The complete cleaning and processing of the ring can be a time-consuming procedure.
The cleanliness of the ring surface can affect observations.
MPI is almost always used as strictly a surface inspection technique of nondestructive testing (NDT). The Ketos ring requires the evaluation of subsurface discontinuities. Interpretation of these discontinuities, especially as they are further in from the circumference, can be very subjective and subject to inspector interpretation.
The position of the ring on its central conductor bar can affect the observations.
The direction and amount of flow of particles over the ring can affect the observations.
The ability or inability of wet-method solutions to flow evenly over the surface of the ring can affect the observations.
Tiede MTU #3 Block
This device is a permanently magnetized steel disk that has been polished and heat-treated to form a pattern of various sized cracks on its flat surfaces. However, this Tiede block has a number problems. The permanent magnetization can clearly be affected if the block is dropped or otherwise mishandled. Also, the consistency from block to block cannot be ascertained.
Fluxa Block
The fluxa block is another inaccurate standard device, which can be used to compare MPI materials. The Block has a small permanent magnet encased within a rectangular prism. The prism is comprised of two steel pieces and one brass piece, assembled such that the meeting surface of the steel pieces acts as a “discontinuity”, which can be incremented to demonstrate particle sensitivity. While this device allows a quantitative observation to be made it is subject to the same difficulties of the Tiede MTU #2 Block.
Settling Tube
The settling tube is another time-honored method for wet-method MPI bath evaluation. The use of the tube is generally required in virtually all military and industrial specifications. The value of the tube lies in its use for observing the amount of particle material in a specified volume of bath. Also, it can be used to observe either solid or liquid contaminants that may have been introduced into the bath. As far as actually evaluating the particle performance, the settling tube is not especially effective because for many reasons. Use thereof requires that it be left undisturbed for at least thirty minutes before observations can be made. Also, discoloration in the fluid above settled particles may not necessarily mean that the performance of the bath has been diminished. The significance of the test is somewhat diminished because observation of the fluid in the tube is no longer required in ASTM E-1444 and many other procedural specifications. The observations allowed by this test do not, in themselves, fully describe the performance of the particles. A useable bath, as demonstrated by more meaningful tests, may not meet the requirements of the settling tube test. Interpretation of the settling volume can be very subjective. Supplemental tests are required even if the settling tube test yields acceptable findings.
Shims
Reference Standard Notched Shims (“shims”) are in use and are especially valuable in establishing the proper magnetic fields necessary to suitably inspect a given object with MPI. The shims are thin pieces of low carbon steel that contain artificial flaws produced by a photochemical method. The manufacture and use of shims is discussed in the conventional Aerospace standard under AS 5371. Another device referred to as the Burma Castrol Strip is constructed in a different manner but serves the same purpose. While shims can be effective in determination of magnetization levels and field direction their use as a evaluation of MPI materials is limited for the following reasons.
Shims must be securely and consistently attached to the surface of the object being magnetized.
The observations can be affected by any matter on the surface of the shim, including even any dirt or oil film from the finger of the person applying the shim to the object.
The type and direction of magnetizing current affects the observations.
The geometric complexity of the part to which the shim is attached can be significant.
Indications can be subject to the methodology of application of the particle bath and can be easily washed away.
Pieces with Known Defects
The use of pieces with known defects is an accepted means of MPI system quality control. These defects can be either naturally occurring or manufactured by a process such as electronic discharge machining (EDM). Similar to the shims these pieces may be effective as a system quality control device but are not necessarily effective as a particle evaluation device:
Detection of defects is subject to proper strength and orientation of the applied magnetic field.
Observation of defects serves as a “go/no go” statement rather than a description of particle performance.
Likewise, the Tiede MTU#3 ring is formed to exhibit a pattern of cracks. It is difficult to get a reproducible pattern of cracks to form from ring to ring. Thus, the Tiede MTU#3 ring is not a consistent test of the suspension.
Two of the main problems with the Tiede MTU#3 ring and the ketos ring is that each may be improperly magnetized, and that there is no reliable method for determining the proper magnetization of either of those rings. Thus, tests of the fluid with those types of rings may be inaccurate and depend on the unpredictable quality of the individual ring.
The rings inability to consistently magnetize fails to provide for a repeatable and reproducible test system. The use of single phase versus three phase current is a major problem in achieving magnetism. Furthermore, the issue of alternating current versus direct current is a major problem with the reproducibility for both of the rings.
The ketos ring and the Tiede ring fail to provide an absolute standard, due to unpredictable magnetization. There is also a major logic problem. This logic problem of the ketos ring is based on the fact that first, the particles in a suspension are used to grade a ring, and then that ring is used to grade the suspension of particles.
SUMMARY OF THE INVENTION
Therefore, among the many objectives of this invention is to provide a device for testing a magnetic inspection particle suspension with repeated accuracy.
A further objective of this invention is to provide a card having a magnetic stripe thereon to determine effectiveness of a magnetic inspection particle fluid suspension.
A still further objective of this invention is to provide a device for efficiently determining the effectiveness of the magnetic inspection fluid suspension.
Yet a further objective of this invention is to provide a device for properly testing a magnetic inspection suspension, which provides an alternative for a ketos ring.
Also an objective of this invention is to provide a device for testing magnetic inspection suspension, which provides an alternative for a Tiede ring.
Another objective of this invention is to provide a device for testing a magnetic inspection fluid, which provides an alternative for a settling tube.
Yet another objective of this invention is to provide a device for testing magnetic inspection suspension, which shows brightness of the fluid suspension.
Still another objective of this invention is to provide a device for testing magnetic inspection suspension, which shows sensitivity of the fluid suspension.
A further objective of this invention is to provide a method using card with at least one magnetic stripe thereon to determine effectiveness of a magnetic suspension.
A still further objective of this invention is to provide a method for efficiently determining the efficiency of the magnetic suspension.
Yet a further objective of this invention is to provide a method for properly testing a magnetic inspection suspension, which provides an alternative for a ketos ring.
Also an objective of this invention is to provide a method for testing magnetic inspection suspension, which provides an alternative for a Tiede ring.
Another objective of this invention is to provide a method for testing a magnetic inspection suspension, which provides an alternative for a settling tube.
Yet another objective of this invention is to provide a method for testing magnetic inspection suspension, which shows brightness of the fluid.
Still another objective of this invention is to provide a method for testing magnetic inspection suspension, which shows sensitivity of the fluid.
A further objective of this invention is to provide a method using an absolute standard for testing a magnetic particle suspension.
A still further objective of this invention is to provide a method for logically determining the efficiency of a magnetic particle suspension.
These and other objectives of the invention (which other objectives become clear by consideration of the specification, claims and drawings as a whole) are met by providing a card with a magnetic stripe thereon, having a predetermined pattern applied to the stripe, with the pattern being suitable to determine the effectiveness of the magnetic inspection suspension.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a front perspective view of the prior art ketos ring 110 .
FIG. 2 depicts a pass test pattern 112 for ketos ring 110 .
FIG. 3 depicts a fail test pattern 114 for ketos ring 110 .
FIG. 4 depicts a front perspective view of magnetic inspection suspension device 100 of this invention.
FIG. 5 depicts a rear perspective view of magnetic inspection suspension device 100 of this invention.
FIG. 6 depicts a rear perspective view of magnetic suspension device 100 of this invention, with card 120 having more than one of stripe 126 .
FIG. 7 depicts an edge view of magnetic inspection device 100 of this invention.
FIG. 8 depicts a view of FIG. 5 with magnetic inspection fluid 106 applied thereto.
FIG. 9 depicts a graph of magnetic field of the card 120 .
FIG. 10 depicts a graph of in sinusoidal form of the encoding process, showing the magnetic field may alternatively be considered the root mean square of the peak value.
FIG. 11 depicts a graph of the magnetic fields within the material, which will no longer change or respond to increased magnetic force and which shows-Hysteresis and the B-Terminology definitions.
FIG. 12 depicts the encoding device 240 for card 100 .
Throughout the figures of the drawings, where the same part appears in more than one figure of the drawings, the same number is applied thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A device for testing a magnetic particle suspension is a card with at least one magnetizable stripe. The card with a magnetized stripe can provide a test of a magnetic inspection particle material due various magnetic strengths along the magnetizable stripe. The magnetization or encoding of the stripe is easily reproducible and duplicatable. With this stripe, a suitable magnetic inspection particle material will produce a certain pattern on the magnetic stripe. All that is required is to some way apply the magnetic inspection particle material to the card and evaluate the pattern achieved.
The stripe may additionally be coated with any clear nonmagnetizable coating to protect the stripe and permit successive uses. A typical coating is polyethylene, polypropylene or similar polymeric coatings. The card with a lower magnetic gradient has more discrimination as to the particles. That is to say, the card with the lower coercivity is more easily affected by strong magnetic fields. An identical stripe is created easily by the card magnetic encoding magnetization process, which is carried out in a standard fashion. Preferably the card is colored or non-white, as opposed to white, in order to avoid reflection of ultraviolet illumination. It is also permitted to create several tracks on one stripe on the card in order to achieve the desired pattern.
The advantage of the magnetic stripe card when compared to the ketos ring or the Tiede ring is that the card requires no magnetization or demagnetization. It has no moving parts and requires no power source. The reliable duplication or perfection of the stripe on the first card or a different card for the testing provides for a repeatable and reproducible test system. The use of single phase versus three phase current is not an issue with the card, whereas it is a major problem with the rings. Furthermore, issue of alternating current versus direct current is not an issue as it is in either of the rings.
The device is also fail-safe. If the magnetic pattern of the stripe is disturbed, it will not display an acceptable reading. Thus, is almost impossible to get an improper reading. The determination of the gradients can be calculated in a qualitative fashion. This permits more accurate testing. The magnetic properties of the stripe can be verified. The card is portable and inexpensive. Unlike the ketos ring and the Tiede ring, the magnetic stripe card establishes an absolute standard.
I. Determination of Magnetic Gradients for Type C Magnetic Stripe Card
Magnetic gradients are established on the magnetic stripe of a card when the stripe is encoded with a typical alternating current (AC) encoding coil. Simply stated, the stripe is passed under the encoding coil as an AC current flows through the coil. The coil generates a reversing magnetic field proportional to the current. As the stripe passes the coil the domains of the small magnetic elements in the stripe are aligned by the polarity of the magnetic field. The directions of the domains are reversed as effected by the reversing magnetic field. The rate of the card motion and the frequency of the current determine the distance between the domain reversals. The increasing or decreasing the current flowing through the coil can control the intensity of the magnetic field.
Magnetic particles, which in this case are actually small bits of high-permeability/low retentivity iron and/or iron oxide which may or may not be pigmented or colored, are attracted not to the magnetic field of the stripe but to the magnetic gradient. The magnetic gradient is actually the change in magnetic field over distance. In the case of the magnetic stripe the gradient is determined by comparing the magnetic field (that is, amplitude of the wave) to the distance between reversals (that is, the period). At a given point the gradient can be mathematically considered to be the slope of the line tangent to the sine wave at that point, or, the derivative of the sine at that point. An average gradient can be the maximum distance between the highest and lowest points of the wave divided by the corresponding distance between those points along the x-axis, which will be one-half of the period. At a given point, the gradient can be mathematically considered to be the slope of the line tangent to the sine wave at that point, or the derivative of the sine at that point. Because of the sinusoidal form of the encoding process, the magnetic field may alternatively be considered the root mean square of the peak value (FIG. 10 ).
Additionally, the logic problem of the ketos ring is based on the fact that the particles are used to grade a ring and the ring is used to grade particles. Thus the card is not only more easily used, the test results are much more reliable. In this fashion, great advantages are be achieved.
The magnetic striped cards can assist in the evaluation of magnetic particle inspection materials. Each card is usable in water bath or oil bath suspensions and may be used with recirculating units, aerosol cans, or portable spraying devices. Dry method materials may also be evaluated with these cards. The magnetic stripe of the type A and type B cards contain a code that attracts particles in a unique pattern of fine lines across the length of the stripe.
This code pattern contains stripes that appear wide but are actually composed of many closely spaced indications. The material is simply applied over the magnetic stripe. The magnetic encoding of the stripe within a certain desired range achieves the desired results. The clarity of the indication on the stripe illustrates the quality of the magnetic inspection particle suspension. As the card is wiped with a soft cloth, it may be reused.
The type A card is used for the high coercivity applications. Generally speaking the type A card has an oersted capacity of about 3,000 to about 4,000. More preferably the oersted capacity is about 3,300 to about 3,900. Most preferably the oersted capacity of the type A card is about 3,500 to about 3,800 oersteds.
In a similar fashion, the type B card has a lower oersted capacity. The type B card preferably has a range of about 100 to about 500 oersteds. More preferably, the type B card has a range of about 150 to about 400 oersteds. Most preferably, the type B card has a range of about 250 to about 350 oersteds.
A method of specifically calculating the value of the gradient can be developed based on the magnetic properties of the stripe material and characteristics of the encoding process. Significant magnetic properties include the coercivity and hysteresis of the stripe material. Important characteristics of the encoding process include the amount of encoding current (that is, “write” current), the frequency of the current and the rate of motion of the magnetic stripe card as it passes the encoding coil.
Coercivity describes the magnetic field required to actually effect the direction of magnetic orientation within the stripe material. A material with high coercivity requires a stronger magnetic field to orient the particles than does lower coereivity material. Coercivity also describes the minimum threshold of magnetic field required to cause an arrangement or re-arrangement of magnetic orientation. Higher coercivity materials are less prone to magnetic erasure.
Hysteresis describes the response of ferro-magnetic material to an applied magnetic force. Ferro-magnetic materials can become “saturated”. When saturation occurs the magnetic fields within the material will no longer change or respond to increased magnetic force and in FIG. 11, which shows-Hysteresis and the B-Terminology definitions.
Magnetic gradients are established on the magnetic stripe of a card when the stripe is encoded with a typical alternating current (AC) encoding coil. Simply stated, the stripe is passed under the encoding coil as an AC current flows through the coil. The coil generates a reversing magnetic field proportional to the current. As the stripe passes the coil the domains of the small magnetic elements in the stripe are aligned by the polarity of the magnetic field. The directions of the domains are reversed as effected by the reversing magnetic field. The increasing or decreasing the current flowing through the coil can control the intensity of the magnetic field, as shown with the FIG. 12 and the encoding device therein.
The rate of the card motion and the frequency of the current determine the distance between the domain reversals. The current will typically have a frequency of 60 Hertz, or 60 cycles (reversals) per second. A card moving past the encoder at a rate of one inch per second will thus be encoded with 60 flux reversals per inch (FRI). If the card is moved at 0.25 inch per second, it will be encoded at 240 FRI. The distance (that is period) of the complete cycle in the latter case will be {fraction (1/240)} of an inch (0.0042 inch).
A method of specifically calculating the value of the gradient can be developed based on the magnetic properties of the stripe material and characteristics of the encoding process. Significant magnetic properties include the coercivity and hysteresis of the stripe material. Important characteristics of the encoding process include the amount of encoding current (that is “write” current), the frequency of the current and the rate of motion of the magnetic stripe card as it passes the encoding coil.
The reversing magnetic field is, by this method, encoded into the magnetic stripe of the card. The field can be represented by a conventional sine wave, with the amplitude proportional to the magnetic field and the period being the inverse of the (flux) reversals per distance (typically, flux reversals per inch or FRI).
A. Terminology refers to FIG. 11 Hysteresis Curve;
Coercivity (H c ): magnetic field required to zero remanent flux (C).
Flux: one line of force (called a Maxwell).
Flux Reversals per inch (FRI): the frequency of the encoding cycle; also, the inverse of the cycle period.
Magnetic field Strength (H): the number of flux lines passing through a unit area perpendicular to the flux.
Magnetic Flux (0): measurement of the number of magnetization or flux lines at a point (Maxwells).
Magnetic Induction (B): the density of the magnetization or flux lines at a point (Gauss).
Oersted (Oe): the number of lines of force or flux passing through an area equal to one cm 2 .
Period: the distance of one encoding cycle; also, the inverse of the frequency (FRI). For conversion to distance one period equals 2 pi radians. Maximum Magnetic Flux (0 m ): measurement of the number of magnetization or flux lines at (A).
Maximum Magnetic Induction (B m ): the density of the magnetization or flux lines at (A).
Remanent Magnetic Flux (0 r ): measurement of the number of magnetization or flux lines at (B).
Remanent Magnetic Induction (B r ): the density of the magnetization or flux lines at (B).
Root Mean Square (RMS): a means of measuring a periodic quality by averaging the square of a quantity over a period and then taking the square root of the average. The RMS of a sinusoid is the inverse of the square root of 2, or about 0.707 times the peak value.
Saturation: The point of maximum magnetic flux and/or maximum magnetic induction (A).
Squareness: the ratio of B r , to B m ; the “ideal” ferromagnetic material has a squareness of 1. Also, the ratio of 0 r /0 m .
B. Conversion Factors
Distance
1 Inch=1,000 mils=10 −6 micro inches=25.4 millimeters
1 millimeter=100 microns=0.0394 inches.
1 micron=10 −6 meters=39.4 micro inches
1 period=6.282 Radians=1/FRI
Magnetic Field
1 Oersted=1 Maxwell/cm 2 =1000/4(pi)A/m=79.6 A/m
Magnetic Flux
1 Maxwell=1 flux line/cm 2
Magnetic Gradient
(1 A/m)/m=1 A/m 2
C. Method:
This section describes the process of calculating the magnetic gradient for a given write current and period encoded on the magnetic stripe.
1. Determine the value of Maximum Magnetic Flux Density (B m ).
This value is based on typical data provided both by 3M Corporation of Minneapolis, Minn., and Anacomp (former and current manufacturers, respectively, of magnetic stripe material) by the relationships described below (Sections F and G). These relationships are built upon measured values of remnant flux density (Remanence, 0 r ) and Squareness, a ration which can be based on measured data (Section E). Unites are in Oersteds (Oe).
2. Derive the value of the Maximum Signal Amplitude.
A sheet is provided for each Type C MSC when it has been encoded. A value of maximum amplitude for a given zone is dived by the associated percentage of maximum. Units are in millivolts (mV).
3. Set Maximum Magnetic Flux Density as being proportional of Maximum Signal Amplitude.
The Maximum signal Amplitude is directly proportional to Maximum Magnetic Flux Density B m .
4. Determine the percentage of Maximum Signal Amplitude for each zone of a specific Type C MSC.
The percentage of Maximum Amplitude for each zone of a Type C MSC is shown in the table below.
1. Zone
2a. Max
2b. Convert
4. Zone
5b. Convert
Source/
Magnetic Induction
Oe to A/m
3. Percentage
Amplitude
5a. Period/2
to Meters
6. Gradient
7. Gradient
Units
(3M/Anacomp, Oe)
Oe × 79.6 = A/m
(FIG. 4)
A/m
(0.005/2, inches)
Inches × 0.0254
A/m2
(A/m2 × 10E06
Zone 1
1416
112714
72
81154
0.0025
0.0000635
1278012472
1278
Zone 2
1416
112714
68
76645
0.0025
0.0000635
1207011780
1207
Zone 3
1416
112714
64
72137
0.0025
0.0000635
1136011087
1136
Zone 4
1416
112714
59
66501
0.0025
0.0000635
1047260220
1047
Zone 5
1416
112714
54
60865
0.0025
0.0000635
958509354
959
Zone 6
1416
112714
48
54103
0.0025
0.0000635
852008315
852
Zone 7
1416
112714
41
46213
0.0025
0.0000635
727757102
728
Zone 8
1416
112714
36
40577
0.0025
0.0000635
639006236
639
Zone 9
1416
112714
27
30433
0.0025
0.0000635
479254677
479
Zone 10
1416
112714
20
22543
0.0025
0.0000635
355003465
355
Zone 11
1416
112714
11
12398
0.0025
0.0000635
195251906
195
5. Apply the percentage from Step 4 to the Maximum Magnetic Flux Density to find the Flux Density for each zone.
Multiply the respective percentages by the Maximum Magnetic Flux Density. Units are in Oersteds.
6. Determine the period of Signal Amplitude.
A magnetic stripe card is encoded at a set value of flux reversal per inch (FRI). FRI is a variable that can be controlled and changed. The period for a given FRI is its inverse value (that is: 1/FRI). Units are in inches.
7. Divide the value from Step 5 (Flux Density by one-half (50%) of the Step 6 period to determine the Average Magnetic Gradient for each zone.
Magnetic Gradients are expressed as the Change in Magnetic Field (dH) versus the change in Distance (dx). (dH) is the peak-to-peak amplitude of the Flux Density for each zone; dx is the distance along the x-axis from peak-to-peak. At this point the units are in Oersteds/inch. A more conventional unit for gradients is Amperes per meter per meter (A/m 2 ). The conversion factors are:
1 Oersted=1000/4 microAmperes/Meter
1 Inch=0.0254 Meters.
Therefore, Oersteds/inch×3133=A/m 2 , This shall be divided by 1000 to get to units of kA/m 2 .
D. Measured Encoding Data:
Squareness is a ratio of remanent magnetic induction 220 on FIG. 11 to maximum magnetic induction 230 on FIG. 11 . These values were measured to be 31.1 EMU and 44.3 EMU, respectively. EMU's are Electromagnetic Mass Units. The use of these units are not important here; the significance for these values is that they describe the relationship between the remanent and maximum values of magnetic induction.
B r =31.3 EMU (measured)
B m =44.3 EMU (measured)
Squareness= B r /B m =31.3/44.3=0.706
E. 3M Methodology:
3M Corporation used to be involved with the manufacture of magnetic stripe materials but is no longer involved with these materials. 3M personnel did provide the following relationship to determine Retentivity (B r ) based on their typical values:
Retentivity ( B r )=(Remanence (0 r )×630×1000)/Stripe Thickness
(0r)=0.85 Maxwells (typical)
Stripe Thickness=550 u-inches (typical)
Retentivity ( B r )=(0.85×630×1000)/550=974 Oe Maximum Flux Density (B m )= B r /Squareness =974/0.706 =1380 Oe
F. Anacomp Methodology:
Anacomp Corporation is currently involved with the manufacture of MSC materials. Anacomp provided the following relationship to determine the retentivity of MSC material: B r = O r / ( Stripe Thickness ) × 0.0000129 O r -= 5.7 Maxwells ( typical for a 2.0 inch square sample ) B r = ( 5.7 ) / ( 420 × 0.0000129 ) = 1052 Oe ( B m ) = B r / Squareness = 1052 / 0.706 = 1490 Oe
G. Application of Method and Data to Type C MSC #0001 (Summary of above chart).
1. B r =974 Oe from 3M and 1052 from Anacomp. Both of these are typical values. For the purpose of this example B r =1000 Oe. The squareness for a Type C MSC is measured to be 31.4/44.3=0.706.
2. B m =B r /-/706=1416 Oe.
3. The overall amplitude average in microvolts (1425.2 mV) and overall amplitude average percentage (45.97%) at the bottom of the data field. Dividing the amplitude by the percentage, the equation becomes Maximum amplitude=1425.2/0/4597=3100 mV.
4. Assuming that 3100 mV is directly proportional to 1416 Oe, the percentages may be validly applied to either figure.
5. The percentages from each of the zones are calculated in the standard fashion.
6. Type C MSC #0001 is encoded at a rate of 200 FRI. The period is the inverse of FTI; in this case 1/200=0.005 inches per period. This value is divided by two to find the average gradient.
7. the Average Magnetic Gradient for each zone is calculated and displayed on the table below. (Column 6 Gradient=Column 4 zone Amplitude/Column 5 Period/2). (Column 7 Gradient=column 6 Gradient×3133 conversion factor).
I. Comments
A range of gradients is displayed on the table that have been generated by the encoding process described above. The change in gradients from zone-to-zone is due only to the change in current flowed through the encoding coil. These gradients can also be effected by changing the rate of flux reversals by either changing the frequency of the current of the rate of which the card is passed by the coil. With a constant frequency the period will be increased, thus decreasing the gradient, by increasing the rate of motion of the card past the coil. Conversely, if the card were moved slower past the coil the period will be decreased with resulting higher gradients. The amplitude of the magnetic induction can range from below ten (10%) percent up to 100% of the maximum magnetic induction (Point A on the Hysteresis curve). In other words, the peak-to-peak values can range from less than 10,000 A/m to over 100,000 A/m. Also, the encoding FRI (flux reversals per inch) can range from over 400 to less than 20. The corresponding period thus, respectively, becomes less than 0.0025 inch to over 0.05 inch.
Certainly with a magnetic stripe card there is caution of how well the encoded pattern withstands the course of time and possible accidental erasure. Low-coercivity materials (rated about 300 Oersteds) are not likely affected by stray magnetic fields, and high-coercivity materials (about 3,000 Oe) are even less affected. Time is in itself not a factor towards the degradation of an encoded pattern.
The cards discussed herein are intended for use around strong magnetizing equipment. Since magnetic fields drop drastically as distance from the magnetic field source increases, there will probably still be no effect on the cards. The cards are in effect a “fail-safe” type of device. That is, if the encoding were to be disturbed, the card will not display any pattern when MPI materials were applied. This lack of signal will stop a competent inspector from proceeding until further evaluation of the MPI materials is conducted. If there were any questions about a particular card, that card can be simply and thoroughly evaluated by passing it through encoding equipment that originally encoded and documented it, for example, the equipment depicted in FIG. 12 .
IV. Material Test Devices
The designed purpose of the Type C MSC is to provide an instant evaluation of the particle material or bath used in the process of magnetic particle inspection. There are several devices currently in use that can function effectively but have their unique drawbacks. The most commonly used devices are listed below, along with a brief description of their operation and performance.
Type C Magnetic Stripe Card
The encoded magnetic stripe card (MSC) is very attractive as a tool for evaluation of MPI materials. The advantages of the use of the MSC include.
The testing process is very simple, because the as-used MPI material is poured over the magnetic stripe of the card and observations are noted.
The test is instantaneous.
No equipment preparation is required.
The encoded card requires no magnetization prior to use.
Documentation of the particle performance on the card is easily accomplished.
After use, the card is easily wiped off and stored.
The card is not de-magnetized after use.
The encoding process is repeatable.
The encoding process is reproducible.
The card provides an absolute, quantitative standard.
The card is fail-safe; A card that has become accidentally erased will not display any discernible particle pattern. The material being evaluated shall not be allowed for use until found acceptable by another card or test.
The smooth surface of the card allows for an observation of the water break test for water-based MPI solutions.
Particle formations on the stripe are very representative of deductibility of surface cracks (as compared to subsurface cracks).
The card is easily stored.
The card is unbreakable and can be used and re-used for many years.
The card is completely independent of the current type and waveform of MPI magnetizing equipment.
The card is not subject to MPI magnetizing equipment calibration.
The card may be re-evaluated to verify its encoded properties at any time.
The value of the magnetic gradient encoded on the card can be controlled by the encoding amperage.
The value of the magnetic gradient encoded on the card can be controlled be the encoding frequency (FRI).
The indication of the magnetic particle inspection, which is applied to the card, may be dried and lifted off the card with a transparent tape. The tape may then be attached to another substrate for separate evaluation and/or storage of the test results.
The magnetic stripe consists of magnetic material in a binder system that is coated onto a backing material. The stripe on magnetic stripe cards is itself coated again to prevent mechanical wear on the stripe from the magnetic particle materials being evaluated.
The magnetic stripe particles dispersed in the binder system are the important memory elements in the overall stripe construction. There are literally millions of these particles in the stripe and when the stripe is encoded each particle may be considered as small magnet with a north-south polarity. The polarities are set in specific directions by the encoding process and their resulting magnetic fields will be visualized with the use of inspection particles.
These individual magnets retain their encoded magnetic strength and polarity unless acted upon by some significant outside force. The three most notable forces are heat, external magnetic fields and radiation. It is unlikely that the cards are at all affected in the course of normal inspection activity.
The heat required to destroy the magnetism in a magnetic material is known as its curie temperature. The curie temperatures of the materials used as the magnetic stripes range from 110° Centigrade (250° F.) and higher. The other materials involved in the card construction are rendered useless before the temperature is reached. Unless exposed to a fire, there is little danger of failure of the magnetic stripe due to temperature.
Coercivity, expressed in oersteds, is a measure of the magnetic field strength required to affect erasure or polarity reversal in a magnetic material. An external magnetic field 50 oersteds or less will have very little erasing effect on any stripe with a coercivity greater than 250 oersteds. The Type A high-coercivity card most preferably has a coercivity of 3600 oersteds, and the Type B most preferably has a low-coercivity level of 300 oersteds. Because the strength of a magnetic field falls off by the square of the distance from the source, the mere spacing between the stripe and the magnetic field source offers considerable protection.
Examples of some field strengths for reference purposes are as follows. For the English system, earth's magnetic field is about 0.6 Oe; the field strength on the case of an electric drill is about 10 Oe; the field about three inches away from a 1500 Oe degausser drops to about 50 Oe. For the metric system, the field strength directly on the case of an electric hand drill is about 10.0 oersteds. The field strength about 7.5 centimeters away from a 1500 oersted bulk degausser is under about 50.0 oersteds. None of these values will be likely to affect the encoded pattern. The earth's magnetic field is about 0.6 oersteds.
Based on tests that purposely expose magnetically precoded materials to microwave radiation and x-rays, the intensity levels below those that adversely affect a human being will have no adverse effects on the recorded signals. Also, cards are evaluated after extended exposure to an approved kerosene-type carrier vehicle and a conditioned water bath typically used for magnetic particle inspection. Neither fluid causes any detrimental effect on the magnetic properties of the cards.
Usually particle refers to a finely divided power of highly permeable ferromagnetic iron/oxide which can be readily attracted to a magnetic field. Fluid refers to a liquid for wet-method magnetic particle inspection used to transfer or carry the particles over the inspection surface. The fluid is typically a high-flashpoint kerosene or water containing conditioning agents.
Suspension refers to the combination of particles and the fluid. The particles are, in effect, suspended in the fluid. Suspension can be broadly defined to include dry-method particles which are applied directly to an inspection surface without the use of a fluid.
In FIG. 1, the ketos ring 110 is depicted. Ketos ring 110 includes a central aperture 200 . Around the edge is an indentation arc 202 . Indentation arc 202 has twelve cylindrical indentations 204 forming the arc 202 . Each cylindrical indentation 204 has a different spacing from ring edge 210 in order to provide the desired test
FIG. 2 shows tests of the ketos ring 110 wherein the ring 110 has passed. In the test, the ring 110 has an electrical current run therethrough, and the flow of the current through the ring provides a readout in the form of toothed symbols 212 indicated in Section A and Section B of FIG. 2 . Basically, as the cylindrical indentation 202 is closer to the edge 210 , the left end 214 of the tooth symbols 212 graph narrows and the peaks become progressively lower at right end 216 . As the cylindrical indentation 202 is further away from the edge, the right end 216 of the toothed symbols 212 graph appears, thereby forming passed tooth graph 218 .
In FIG. 3, the failed tooth graph 220 is not as distinct in any way, shape or form as passed tooth graph 218 . As such, failed tooth graph 220 indicates, as the current passes therethrough, that the ketos ring 110 has failed. The device 100 using card 120 of this invention overcomes those problems and permits a simpler testing of the material used for magnetic particle suspension testing of parts.
Referring now to FIG. 3 and FIG. 4, magnetic inspection suspension device 100 of this invention appears similar to a standard credit card. Magnetic inspection suspension device 100 includes a card 120 . Card 120 is generally made of a nonmagnetic and a nonmagnetizable material, such as a synthetic resin, polymer, copolymer or plastic.
The front side 122 of card 120 may have any suitable information applied thereto by printing or other suitable fashion. Card 120 is a thin, flat piece of material. Rear side 124 of card 120 includes stripe 126 . Stripe 126 is capable of retaining a magnetic charge to determine the effectiveness of the magnetic suspension.
In FIG. 5, it may be seen that more than one stripe 126 may be applied to the rear side 124 of card 120 . This permits the same suspension to undergo a number of different tests with one card 120 .
By considering FIG. 6 and FIG. 7, the structure of card 120 becomes clear. Card 120 is shown with stripe 126 thereon. Coating 128 can be applied to protect stripe 126 .
FIG. 8 depicts card 120 with magnetic inspection fluid 106 applied thereto for testing purposes. The magnetic pattern of stripe 126 indicates the effectiveness of the fluid 106 . The pattern of fluid 106 may be removed by a standard tape or another suitable device. The tape or other suitable device may then be stored for future reference, comparison or any other suitable purpose.
With FIG. 9, the magnetic characteristics of stripe 126 are graphically depicted. The magnetizing force (H) 140 forms the X-axis of the graph The magnetic field (B) 142 is depicted on the Y-axis. Magnetizing force (H) 140 is the force used to establish the magnetic field, which in turn is measured in oersteds or amperes/meter (SI), where 1 oersted equals 79.6 A/M.
Coercivity (H c ) 144 is the magnetic force 140 required to reduce the residual magnetic field (B R ) 146 to zero. Remanence 150 relates to magnetic induction or lines of flux, resulting from the application of the magnetic force 140 . Remanence 150 is measured in Maxwells or Webers (SI), where 1 weber=10 8 maxwells.
Flux Density (B) 152 relates to remanence 150 per unit area, measured in gauss or tesla (SI), where 1 tesla=10,000 gauss=1 weber/square meter. Retentivity 154 of the magnetic field (B R ) 146 relates to the property of a material describing the magnetic field remaining following the removal of a saturating magnetic force, measured in gauss or tesla.
Squareness (B R /B MAX ) 156 is the ratio of remanence 150 following removal of the magnetic force 140 to remanence 150 at a saturating magnetic force 140 . This ratio describes the alignment of individual elements in a magnetic material. A squareness of 1 is ideal, 0.75 to 0.85 is typical.
The following examples are intended to illustrate without unduly limiting the scope of this invention.
EXAMPLE 1
A card with a high coercivity is suitable for testing a magnetic inspection particle materials is obtained having magnetic properties as shown. The card successfully tests a number of fluids.
Type A - High Coercivity
Coercivity
3679 ± 1.0% Oersteds
Remanence
0.85 ± 0.6% Maxwells
Squareness
0.84% ± 0.7%
Stripe Thickness
550 Micro-inches (typical)
Retentivity
974 Gauss
Retentivity = (Remanence × 630 */Stripe Thickness) × 1000
*630 - Aerial Density Constant
EXAMPLE 2
A card with a low coercivity is suitable for testing a magnetic inspection particle materials is obtained having magnetic properties as shown. The card successfully tests a number of fluids.
Type B - Low Coercivity Batch # 8252
Coercivity
292 ± 1.0% Oersteds
Remanence
0.85 Maxwells
Squareness
0.85
Thickness
550 Micro-inches (typical)
Retentivity
974 Gauss
Retentivity = (Remanence × 630 */Stripe Thickness) × 1000
*630 - Aerial Density Constant.
This application—taken as a whole with the specification, claims, abstract, and drawings—provides sufficient information for a person having ordinary skill in the art to practice the invention disclosed and claimed herein. Any measures necessary to practice this invention are well within the skill of a person having ordinary skill in this art after that person has made a careful study of this disclosure.
Because of this disclosure and solely because of this disclosure, modification of this method and apparatus can become clear to a person having ordinary skill in this particular art. Such modifications are clearly covered by this disclosure. | A magnetic stripe card provides a quantitative tool for the measurement of magnetic sensitivity for fine-grained iron, iron oxide or other ferro-magnetic powders, that may be used for magnetic particle inspection and other purposes. The magnetic stripe card is encoded to establish distinct areas on the magnetic stripe. Each distinct area has a specific magnetic gradient. Ferro-magnetic powders are attracted to the gradient in proportion to the value of the gradient. A higher gradient more strongly attracts the powder. A determination of the sensitivity of the powder can be ascertained by observing the gradient with the lowest value to which the powder is attracted. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. Patent Application Ser. No. 435,972, filed Nov. 14,1989, the disclosure of which is incorporated herein by reference.
The invention relates to a door comprising a frame and a flexible panel which is movable relative to said frame between a vertical closing position and a horizontal opened position.
Such a door is known and is especially, but not exclusively, intended for closing garages. It can be of importance here that in the opened position the door provides the greates possible height clearance in order, for example, to allow passage of the highest possible vehicle.
SUMMARY OF THE INVENTION
The invention has for its object to enlarge the height clearance in the opened position and to operate the door without problem.
The door assembly according to a preferred embodiment comprises a frame and a flexible panel which is movable relative to said frame between a closed position and an opened position; said frame comprising at each of both sides of the flexible panel vertical guide means defining a door opening therebetween; horizontal guide means connected to the top end of said vertical guide means; bend guide means arranged between said vertical guide means and said horizontal guide means; said vertical guide means, horizontal guide means and bend guide means engaging side edges of said flexible panel; said horizontal guide means comprising a profiled member at a first channel facing the flexible panel and receiving a side edge thereof, said member being bounded by a second channel for receiving a draw spring for balancing the weight of the flexible panel
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be elucidated in the description following hereinafter with reference to the drawings. In the drawings:
FIG. 1 is a partly broken away perspective view of a garage with a door in closed position;
FIG. 2 a perspective view of a portion of FIG.1;
FIG. 3 is of the door assembly a section view along the line III--III in FIG. 2;
FIG. 4 is a perspective view along line IV--IV of FIG. 1;
FIG. 5 is a section view along line V--V of FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENT
A door 1 according to the invention can be fitted as a prefabricated unit in the passage opening 3 of a garage 2; the unit has a frame 80 comprising side frames 4 which are fixed in a manner not shown to the side walls 5 of garage 2. Each side frame 4 consists of a vertical U-profile 6 and a horizontal S-profile 7 mutually joined by means of a brace 8. The side frames 4 are mutually connected by a buffer beam 9 which closes off the top of the passage opening 3. A flexible door panel 10 consisting of flexible steel plate material 17 having a thickness of for example, 0.5 mm is guided in the U-profiles 6 and guide channels 81 of the profiles 7. Door panel 10 is also guided behind the buffer beam 9, specifically at the location of the bend, by means of guide wheels 11 forming part of bend guide means 40, which are each mounted for rotation on a shaft 42 connected to brace 8 of frame 4 by means of a screw 41 of the self threaded tapeing kind. The screw 41 into the metal plate profile constituting the brace 8. The round and smooth periphery of the guide wheel 11 comes into contact with the side edge of the door panel 10 and while at this position the profiles 6 and 7 are recessed. The guide wheel 11 is made of synthetic resin and is constituted by a round ring 83, a hub 84 and spokes 85.
A horizontal bottom edge 16 of the flexible plate material 17 is bent over as an angle section 18 and is clamped fixedly into an angle section 19 of a profiled coupling element 20. The lower part 86 of said coupling element 20 bounds a coupling channel 87 by means of, successively, a horizontal bottom profile part 88, a first vertical profile part 89, a rounded part 90, a horizontal top profile part 91 and a second vertical part 92, which is spaced from said horizontal bottom part 88 for providing a passage 93 for a horizontal part 94 of a profiled stiffening beam 25. A vertically extending edge 22 is connected to horizontal part 94 of stiffening beam 25 and extends in closing position of the flexible door panel 10 vertically into coupling channel 87.
Guide blocks 26 provided at the side edges 24 of the stiffening beam 25 are received in the U-profiles 6. A hollow sealing profile 21 is connected to the bottom edge 95 of the stiffening beam 25 and has a rain water drip edge 96.
Each bend guide means 40 comprises above the guide wheel 11 a guide element 97 which is pivotably attached to a side frame 4 about a pivot axis 98.
As a result of the use of the stiffening beam 25 and the hinged attachment thereof to the horizontal edge 16 of the door panel 10, door panel 10 allows easy guiding out of the opened position and easy pulling into the closing position. Especially in combination with the rotatable guide wheel 11, the door panel 10 is easy to operate without the panel having the tendency to go out of square and/or become stuck. The stiffening beam 25 has on either end a guide block 26 of plastic and is rounded off at its front side and co-acts with the U-profiles 6 and with the guide element 97 for guiding. The door panel 10 has on its edges guide strips 28 of plastic which makes movement door noiseless.
The profiles 7 are S-shaped and bound a first channel 81 constituting a guide channel for the flexible panel 10 and receiving a side edge thereof and a second channel 101 accomodating a draw spring 31 for balancing the weight of the flexible panel 10. Said draw spring 31 is connected at its one end 102 to said side frame 4 in the vicinity of the guide wheel 11 and at its other end 103 to a movably pulley 104. Said movable pulley 104 engages a flexible draw member 105 such as a cable which extends from end 106 connected to said side frame 4 at the rear side of the garage 2 over said movable pulley 104 and over a fixed or stationnary pulley 107 mounted for rotation on side frame 104 at the rear side of the garage 2 to a connected member 108 connected to said flexible panel 10. The second channel 101 receives the movable pulley 104 in an inclined position wherein it extends between two opposed corners 110 and 111 of said profile S-shaped member 7. To | Described herein is a door assembly that includes a flexible panel of flexible plate material which is guided in channels between a closed position to an opened position; the flexible panel assuming a substantially horizontal position in the open position and thereby increases the height clearance in the door opening. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a non-provisional application claiming priority based on provisional application Ser. No. 60/378,023, filed May 13, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with Government support under Subcontract No. 4000000723 funded by the Government. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to filters and filter systems which are operable at elevated temperatures and capable of extracting volatilizable particulates from a gas stream. In particular, this invention relates to ceramic fiber-paper based filters which may be regenerated in situ employing microwave energy.
2. Background of the Invention
Heretofore, it has been known in the art that ceramic fibers may be formed into a ceramic paper. It is also suggested in the prior art that this paper may be corrugated and wound into a cylindrical filter for the capture of volatilizable particulates from a gas stream, and that the filter may be regenerated employing microwaves.
However, these prior art filters and/or the systems within which they are employed suffer from problems of premature clogging of the entry ends of the tubular chambers defined by the corrugations, and from inadequate capacity to accommodate the anticipated or actual overall flow of gas streams through the filter, resulting in excessive pressure drop across the filter, at times creating undesirable or even disastrous results, and/or regeneration only during shut-down or diversion of the source of the gas stream, such diversion effectively taking the filtration system offline.
BRIEF SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, there is provided at least one filter module comprising a housing which defines an inlet and an outlet for the passage of a gas stream into and out of the housing. Within the housing there is disposed a pleated ceramic fiber-based filter medium which separates the interior of the housing into at least two filtration chambers, one of which is in fluid communication with the inlet to the housing and a second one of which is in fluid communication with the outlet of the housing. As desired, multiple further filtration chambers may be interposed in fluid flow communication between the “inlet” chamber and the “outlet” chamber. A gas stream entering the inlet chamber passes through the multiple pleats of the filter medium of each chamber wherein particulates are extracted from the gas stream and accumulate on the filter medium. The filtered air stream passes through the outlet chamber and any intervening chamber, and exits the housing through the outlet thereof. As desired, the inlet and/or the inlet to the housing may be in the form of a plenum extending along one side of the housing.
In accordance with a further aspect of the invention, there is provided an outlet plenum which extends along the outlet side of the housing (opposite the inlet side). In one embodiment, this plenum serves the dual function of a pathway for conveying away the exhaust gas stream from the filter and as a selectable pathway for the transmission of microwaves into the filter housing.
In one embodiment, the overall filter structure comprises at least one, and preferably a plurality of individual housing/pleated filter subassemblies, all aligned in a common plane or parallel planes so that their respective outlet sides are aligned such that they share a common elongated exhaust plenum. Within, and concentrically of, the interior of this exhaust plenum there is provided a rotatable, preferably tubular, member. This member includes a plurality (one for each filter subassembly or grouping of filter subassemblies) of ceramic microwave-permeable segments spaced apart from one another along the length of the wall of the tubular member. The remainder of the tube includes holes of a proper diameter to stop 2.45 GH microwaves while allowing the free passage of exhaust gas therethrough. Thus, each segment is sized and designed to cover a respective one or ones of the outlets of the aligned outlets of the multiple subassemblies to define a transparent window for the admission of microwaves (while preventing the flow of exhaust gas therepast), but stopping exhaust flow, passing along the length of the tubular member, into a respective one or ones of the filter subassemblies when the segment is in register with the outlet from a respective filter subassembly. In this embodiment, each segment also is positioned at a location which is progressively rotated about the outer circumferential wall of the tubular member. In one embodiment, no two filter subassemblies are open to microwaves at any given time. In other embodiments, only a limited number of filter subassemblies are open to microwaves at any given time Thus, through selective rotation of the tubular member about its longitudinal axis, admission of microwaves into a filter subassembly may be restricted to only a single filter subassembly or a selected group of filter subassemblies, at any given time, thereby providing for the regeneration of a single filter subassembly or selected group of filter subassemblies while the remaining filter subassemblies remain available for receiving and filtering of the inlet gas stream flowing through the inlet plenum and exhausting of the cleaned gas stream via the exhaust plenum. This selective regeneration of the filter subassemblies is conducted in situ and provides for sequential regeneration of the multiple subassemblies, thereby preventing any material interruption of the flow of the gas stream through the overall filter system, hence the ability of the overall filter system to accommodate a substantially larger volume of gas flow, and avoiding undesired pressure drop (back pressure) across any one of the multiple filter subassemblies, all without deleterious effects on the normal operation of the generator of the contaminated gas stream, e.g., a diesel engine.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a representation of one embodiment of a filter system including various features of the present invention, including multiple stacked filter subassemblies;
FIG. 2 is a representation of the gas exhaust end of the filter depicted in FIG. 1 and partly cutaway to depict various internal features of the filter;
FIG. 3 is a representation, partly cutaway, depicting a filter system including various features of the present invention, including a single filter subassembly;
FIG. 4 is representation of an elongated tubular member for rotatable disposition within the exhaust plenum of the filter depicted in FIG. 1 ;
FIG. 5 is a representation of one embodiment of a housing/pleated ceramic fiber paper filter medium module suitable for use in the filter of the present invention; and,
FIG. 6 is a exploded view representing a top comb and a bottom comb employed in the disposition of a pleated ceramic-based filter paper within a module of the present system.
DETAILED DESCRIPTION OF THE INVENTION
Referring specifically to FIG. 1 , the depicted embodiment of a filter system 10 of the present invention includes a housing 12 , which in the depicted embodiment is of a generally rectangular cross-section having its opposite short sides 14 , 16 sealed by respective end plates 18 , 20 . Each of the opposite longer sides 22 , 24 of the housing preferably is rounded and partially defines an inlet plenum 26 and an outlet plenum 28 , respectively, for the flow of a gas stream (see arrows) through the filter system.
Internally of the housing there is provided at least one, and preferably a plurality of filter modules 25 (see FIG. 5 ), each of which, in the depicted embodiment includes a pleated ceramic filter paper 27 captured between first and second comb elements 29 , 31 (typical), respectively, (see FIGS. 6 and 7 ). As seen in FIGS. 2 and 5 , the top margins (ribs) 33 of each comb projects above the planar level of the pleated paper, thereby defining multiple gas flow channels 35 (typical, see arrow C)along the length of each module. The bottom of each module is of like construction as the top of the module and includes ribs 36 which define flow channels along the bottom of the module, the channels of both the top and bottom of the module being oriented in like directions from the inlet to the outlet end of the module (see FIG. 2 ).
The inlet end 37 of each module is closed by a gas impermeable wall 39 which extends from the bottom edge 41 of the inlet end of the module to a location short of the top portion 43 of each comb rib. The exhaust end 45 of each module includes an end wall 47 which extends from a height equal to the height of the ribs and extends from the rib height to terminate short of the bottom edge 49 of the module (See FIG. 2 ) thereby leaving an open space 51 at the inlet ends of the top flow channels and closure of the outlet ends of the top flow channels. The top and bottom of each module is overlaid by top and bottom panels 53 , 55 , respectively, of the housing, such panels being overlaid and sealed to the top surfaces of the ribs of the top and bottom of the module, respectively.
Referring to FIG. 6 , one embodiment of a filter module includes a first plurality of top combs 29 whose opposite ends are secured to end walls 39 and 47 and a second plurality of bottom combs 31 which are designed such that the teeth of the bottom combs mesh between the teeth of the top combs to capture therebetween a pleated sheet of ceramic fiber-based filter paper 27 .
In FIG. 2 , there are depicted two stacked modules 25 , 25 ′, the stack being formed by the placement of the bottom 57 of the upper module 25 in overlying relationship to bottom 57 ′ of the lower module 25 ′, with the bottom ribs of the top module abutting respective ones of the ribs of the bottom ribs of the bottom module of the stack, thereby defining a plurality of planar flow channels 41 between the two overlying bottoms of the modules.
At the exhaust end of the flow channels 41 of the stacked modules of FIG. 2 , there are provided first and second obliquely converging elongated panels 61 , 63 which extend along the full dimension of the exhaust ends of the stacked modules. One side 65 of the first panel 61 is secured to the end wall 47 of the top module 25 and one side 67 of the second panel 63 is secured to the end wall 47 ′ of the bottom module 25 ′. The opposite sides 69 , 71 of the converging panels are joined to one another by a porous ceramic microwave permeable wall 73 . This wall, in turn, is mounted within a slot in a tubular wall which extends along the length of the exhaust plenum of the housing.
In the depicted embodiment of FIG. 1 , the filter system further includes an inlet 77 at a first end 32 of the inlet plenum 26 , an outlet 34 at a first end of the outlet plenum 28 , and a hollow tubular microwave barrier 79 disposed internally of, concentric with, and extending along at least substantially the length dimension of the outlet plenum 28 and with a portion 81 thereof projecting beyond a second end 83 of the outlet plenum. This tubular barrier is rotatably mounted within the outlet plenum and is provided at its outboard portion 81 with a first ring gear 85 which encircles the tubular barrier. An indexing motor 87 is mounted to the housing and includes a driven shaft which carries a second ring gear 89 thereon, the teeth of the second ring gear 89 meshing with the teeth of the first ring gear whereby activation of the motor functions to rotate the tubular barrier about its longitudinal axis within the outlet plenum, as desired.
As seen in FIG. 4 , at least one, and most commonly a plurality of cutouts 90 through the wall 92 of the tubular barrier 79 are provided to define one or more outlet ports 95 , 95 ′ for the movement through such cutout(s) of microwaves from within the internal volume of the hollow tubular barrier.
Referring specifically to FIGS. 1 and 2 , microwaves are introduced from a source 99 thereof, into the end of the hollow tubular microwave barrier 79 , and move along the length of the tubular barrier toward the exhaust port. As required, a microwave barrier 101 may be provided adjacent the exhaust port to preclude the passage of microwaves out through the exhaust port. Thus the microwaves are contained within the exhaust plenum except in the instance where a port 95 , 95 ′ through the wall of the tubular barrier is in register with the ceramic wall 71 adjacent the exhaust ends of the stacked modules. In this latter situation, microwaves move from the exhaust plenum, through the ceramic wall and into the modules.
In the operation of filter system of the present invention, a gas stream bearing volatilizable particulates is directed into the filter system via the inlet and into the inlet plenum. This gas stream is distributed by the plenum into the inlet ends of the flow channels of both the top and bottom modules, hence along the exposed surfaces of the multiplicity of pleats of the ceramic-based filter paper. (see arrows in FIG. 2 indicating gas flow). The gas passes through the filter paper with the particulates in the gas stream being captured on the exposed surfaces of the pleats. The cleaned gas thereupon flows along the exhaust flow channels defined between the overlying bottoms of the modules, through the ceramic wall, thence out through the exhaust port of the exhaust plenum.
In a preferred embodiment, as indicated by the dashed lines 103 , 103 ′ of FIG. 1 , a plurality of stacked modules are ganged together are served by a common inlet plenum and a common exhaust plenum. In this embodiment, the length of the tubular microwave barrier is sufficient to include a cutout through its wall at multiple locations along the length of the barrier, a given cutout being spaced circumferentially apart from adjacent one or ones of others of the cutouts so that only one or a selected number of the cutouts are in register with their respective modules at any given time. (see FIG. 4 ). The registration of the cutouts with their respective modules is accomplished by means of the indexing motor operating through the first and second ring gears. In this manner, as desired, one or more than one of the modules are accessed by microwaves and closed to full exhaust flow at any given time, while during this given time, others of the modules are closed off from the microwaves and open to full exhaust flow.
Within those modules which are accessed by the microwaves, the microwaves react with the ceramic-based filter paper to heat the filter paper to the volatilization temperature of the particulate matter captured on the filter paper. The gaseous products from the volatilization of the particulates are swept out the exhaust plenum, thereby regenerating the filter paper in situ. During the time in which one (or more) module is being regenerated, there is no material change in the flow of gas through the others of the ganged modules, hence there is little or no deleterious effect with respect to back pressure, flow capacity, or interruption of the device which is generating the particulate-bearing gas stream. | A filtration system ( 10 ) operable at elevated temperatures and regenerateable in situ employing microwave energy ( 99 ). In one embodiment, the system includes multiple channels ( 35 ) with means for selectively placing individual ones of the channels on-line for filtration and off-line for regeneration. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is Continuation-In-Part application of U.S. patent application Ser. No. 11/446,765, filed on Jun. 5, 2006, which relies for priority on Korean Patent Application No. 10-2005-0051118, filed in the Korean Intellectual Property Office on Jun. 14, 2005. This application also relies for priority on Korean Patent Application No. 10-2008-0036208, filed in the Korean Intellectual Property Office on Apr. 18, 2008. The contents of all of the above applications are incorporated herein in their entirety by reference.
BACKGROUND
[0002] The inventive concept relates to a method of manufacturing a semiconductor, and to a method of manufacturing a photomask used in photolithography. A plurality of circuit patterns (or photoresist patterns) are formed on a wafer by using a photolithography process. In particular, as the design rule of a semiconductor device decreases, the importance of critical dimension (CD) uniformity of semiconductor patterns increases.
[0003] The CD uniformity of semiconductor patterns is affected by optical elements such as a light source, a lens, and an aperture. Highly-integrated devices are affected by CD uniformity of photomask patterns. The CD uniformity of mask patterns must increase so as to increase the CD uniformity of circuit patterns formed on the wafer.
[0004] The CDs of mask patterns may be measured and corrected using a scanning electron microscope (SEM) method or an optical critical dimension (OCD) method. In the SEM method, the CDs of a large number of photomask patterns are directly measured using electron beams so as to adjust the global uniformity of photomasks by accounting for measurement errors of equipment and local CD errors of the photomasks. However, in a current mass production process, only local CDs of photomask patterns are measured so as to increase production efficiency. Thus, the global uniformity of photomasks cannot be accurately corrected using the SEM method.
[0005] In the OCD method, after photoresist patterns are formed on a wafer using a photolithography process, CDs of photomasks are determined by measuring the reflection index (or reflection spectrum) of the photoresist patterns, and the measured CDs are corrected. In order to correct the CDs of mask patterns in the OCD method, parameters such as CDs of photoresist patterns, CD change amount due to the exposure energy (intensity of exposure source) during the photolithography process, and a CD correction amount according to an exposure condition must be measured. In this case, in order to measure and correct the CDs of photomasks using the OCD method, the photolithography process must include an exposure process, and the correction parameters must be measured. Thus, process time increases, which lead to an increase in the cost of the manufacturing process. Thus, a method for obtaining the correct global uniformity of photomasks without performing the photolithography process is required.
[0006] In addition, when using the OCD method, the measurement equipment for measuring a reflection index can be used to measure only the resultant shape of a diffraction pattern and thus cannot be used to measure a variety of patterns that are commonly used.
SUMMARY
[0007] According to an aspect of the inventive concept, there is provided a method of manufacturing a photomask. According to the method, a photomask is provided, and the photomask is exposed to obtain an aerial image of the photomask. The photomask is evaluated using the aerial image. An optical parameter of the photomask associated with the aerial image is altered according to the result of the evaluation.
[0008] The exposing of the photomask to obtain the aerial image may be performed using the same illumination system as the illumination system used to transfer the photomask onto a wafer.
[0009] The obtaining of the aerial image may include using at least one of − primary light and + primary light together with zero-order light that reacts with the photomask.
[0010] The optical parameter may be a transmittance or a reflection index.
[0011] The evaluating of the photomask may include comparing the aerial image with a design shape of the photomask and/or comparing a measurement critical dimension (CD) of the aerial image and a design CD of the photomask.
[0012] The altering of the optical parameter may include altering a transmittance of the photomask based on the measurement CD and the design CD.
[0013] The altering of transmittance of the photomask may include forming a diffraction array comprising a plurality of spots in the photomask and/or forming auxiliary patterns beside patterns of the photomask and/or forming grooves in a surface on which patterns of the photomask are formed.
[0014] Altering the optical parameter may include altering a reflection index of the photomask based on the measurement CD and the design CD. The altering of the reflection index of the photomask may include irradiating laser on the photomask.
[0015] According to another aspect of the inventive concept, there is provided a method of manufacturing a photomask. According to the method, a photomask comprising a plurality of sections is provided. The photomask is exposed to obtain an aerial image of the photomask according to each of the plurality of sections. A measurement critical dimension (CD) of the aerial image is compared with a design CD of the photomask to evaluate the photomask. An optical parameter of the photomask associated with the aerial image is altered with respect to at least one of the plurality of sections according to the result of evaluation.
[0016] In one embodiment, exposing the photomask to obtain the aerial image comprises using the same illumination system as an illumination system used to transfer the photomask onto a wafer.
[0017] In one embodiment, obtaining the aerial image includes using zero-order light, − primary light and + primary light that reacts with the photomask.
[0018] In one embodiment, altering the optical parameter includes altering a transmittance of the photomask based on the measurement CD and the design CD.
[0019] In one embodiment, altering a transmittance of the photomask includes forming a diffraction array including a plurality of spots in the photomask.
[0020] In one embodiment, altering a transmittance of the photomask includes at least one of: (i) forming auxiliary patterns beside patterns of the photomask, and (ii) forming grooves in a surface on which patterns of the photomask are formed.
[0021] In one embodiment, altering the optical parameter comprises altering the reflection index of the photomask based on the measurement CD and the design CD.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Exemplary embodiments of the inventive concept will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings.
[0023] FIG. 1 is a flowchart illustrating a method of manufacturing a photomask according to an exemplary embodiment.
[0024] FIG. 2 is a plan view of a photomask according to an exemplary embodiment.
[0025] FIG. 3 is a schematic view of an apparatus for obtaining an aerial image of a photomask according to an exemplary embodiment.
[0026] FIGS. 4 through 6 are flowcharts illustrating a method for correcting a photomask according to another exemplary embodiment.
[0027] FIG. 7 schematically illustrates CD uniformity achieved on a wafer using a photomask in which a diffraction array is formed, according to an exemplary embodiment.
[0028] FIG. 8 schematically illustrates a laser system used in manufacturing a photomask according to an exemplary embodiment.
[0029] FIG. 9 schematically illustrates CD uniformity achieved on a wafer using a photomask in which auxiliary patterns are formed, according to another exemplary embodiment.
[0030] FIG. 10 schematically illustrates CD uniformity achieved on a wafer using a photomask in which grooves are formed, according to another exemplary embodiment.
[0031] FIG. 11 illustrates a photomask having a nonuniform CD and its aerial image intensity.
[0032] FIG. 12 illustrates a corrected photomask and its aerial image intensity according to an exemplary embodiment.
[0033] FIG. 13 is a cross-sectional view of a corrected, reflection type photomask according to an exemplary embodiment.
[0034] FIGS. 14 and 15 are images showing the CD uniformity of a photomask in which correction according to an experimental example is not performed, and the CD uniformity of a photomask in which correction according to an experimental example is performed, respectively.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0035] The inventive concept will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the invention to those skilled in the art. In the drawings, the thicknesses of layers and regions are exaggerated for clarity.
[0036] A photomask according to embodiments of the inventive concept that is used in photolithography and may also be referred to as a reticle. Patterns formed on a photomask by using photolithography may be transferred onto a substrate, for example, a wafer.
[0037] FIG. 1 is a flowchart illustrating a method of manufacturing a photomask according to an exemplary embodiment, and FIG. 2 is a plan view of a photomask according to an exemplary embodiment.
[0038] Referring to FIGS. 1 and 2 , a photomask 30 may be provided in operation S 1 . The photomask 30 may comprise mask patterns (see reference numeral 37 a of FIG. 3 ) for forming circuit patterns on a substrate 31 . The photomask 30 may comprise a plurality of sections. For example, the photomask 30 may comprise a plurality of cell array regions 32 on the substrate 31 and may further comprise a peripheral circuit region 33 surrounding the cell array regions 32 . The cell array regions 32 and the peripheral circuit region 33 may constitute a chip region 34 . Each of the sections may be each cell array region 32 or a specific region in each cell array region 32 .
[0039] When the photomask 30 is a binary mask, each of the mask patterns (see reference numeral 37 a of FIG. 3 ) may be a shielding pattern such as chromium, and when the photomask 30 is a phase shift mask, each of the mask patterns (see reference numeral 37 a of FIG. 3 ) may be a phase shift pattern. Alignment keys 35 having various shapes may be formed outside the chip region 34 , and keys 36 for measuring registration may be formed along the perimeter of the chip region 34 .
[0040] The photomask 30 may be formed by the operations of forming a mask layer on the substrate 31 and pattering the mask layer to form the mask patterns (see reference numeral 37 a of FIG. 3 ) and the keys 35 and 36 . As described above, the mask layer may be a shielding layer or a phase shift layer.
[0041] The mask patterns (see reference numeral 37 a of FIG. 3 ) may be manufactured to have a predetermined design critical dimension (CD) according to sections of the photomask 30 . However, due to various errors in the manufacturing operation, the mask patterns (see reference numeral 37 a of FIG. 3 ) may be manufactured outside the range of the design CD. Accordingly, the CD distribution of the photomask 30 may be nonuniform.
[0042] Subsequently, the photomask 30 is exposed, such that an aerial image can be obtained and the photomask 30 can be evaluated. In this exemplary embodiment, the aerial image may be an image formed on a reference surface when the photomask 30 is exposed. Thus, the aerial image may be different from an imaginary aerial image that is formed by simulating an exposure condition. This is because the imaginary aerial image may be greatly affected by a simulation conditions, and the simulation conditions do not accurately reflect the exposure conditions.
[0043] In this exemplary embodiment, the aerial image may be formed under almost the same conditions as the conditions used when the photomask 30 is transferred onto the wafer. Specifically, the same illumination system as the illumination system used in an exposure operation of transferring the photomask 30 onto the wafer may be used in an exposure operation of the photomask 30 for creating the aerial image. For example, when the aerial image is obtained, at least one of − primary light and + primary light may be used together with zero-order light that reacts with the photomask 30 , and for example, all of zero-order light, − primary light, and + primary light may be used. Thus, the aerial image according to this exemplary embodiment is suitable for use in detecting a defect or uniformity of the photomask 30 under the actual exposure conditions.
[0044] FIG. 3 is a schematic view of an apparatus for obtaining an aerial image according to an exemplary embodiment. Referring to FIG. 3 , radiation such as light irradiated by a radiation or light source 42 may be transferred onto the photomask 30 via a condenser lens 47 and an illumination system 48 . The light source 42 may generate light having different wavelengths and may generate, for example, deep ultra violet (DUV) light having a wavelength less than 193 nm, for example. The illumination system 48 may use the same scanner system as a scanner system used for wafer exposure. Thus, both on-axis illumination and off-axis illumination can be readily performed using the illumination system 48 . All of zero-order light T 0 , − primary light T −1 , and + primary light T +1 that transmit the mask patterns 37 a of the photomask 30 are transferred to a detector 45 via a projection lens 49 . The detector 45 may obtain an aerial image that is realized with zero-order light T 0 , − primary light T +1 , and + primary light T +1 . For example, the detector 45 may comprise an electronic device including a photodiode, such as a charge coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) image sensor (CIS).
[0045] The detector 45 is very similar to a wafer exposure system except that light transmitted to the photomask 30 is not transferred onto the wafer. Thus, an aerial image that is very similar to patterns to be transferred onto the wafer can be obtained using the detector 45 .
[0046] The detector 45 is used to form an aerial image using light transmitted through the photomask 30 , but may be also used to obtain an aerial image using light reflected from the photomask 30 .
[0047] Referring back to FIGS. 1 and 2 , as described above, in operation S 2 , the photomask is exposed and an aerial image of the photomask is obtained and the photomask is evaluated using the aerial image of the photomask. In operation S 3 , the optical parameter of the photomask 30 may be corrected according to the above-described evaluation result. For example, when the photomask 30 is classified into sections, the optical parameter of the photomask with respect to at least one section may be corrected. In this exemplary embodiment, the optical parameter may be associated with the aerial image. That is, the aerial image may be changed by correcting the optical parameter. For example, in this exemplary embodiment, the optical parameter may be transmittance or a reflection index.
[0048] The optical parameter may be corrected by comparing the design shape of the photomask 30 with the aerial image obtained in operation S 2 . For example, the design CD of the photomask 30 and the measurement CD of the aerial image may be compared with each other.
[0049] FIGS. 4 through 6 are flowcharts illustrating a method for correcting a photomask according to another exemplary embodiment.
[0050] Referring to FIG. 4 , the design CD of the photomask 30 may be inputted in operation S 31 . As described in connection with FIG. 2 , a design CD is a target CD when the photomask 30 is manufactured. The design CD may be obtained according to sections of the photomask 30 .
[0051] Subsequently, the CD of the aerial image detected by exposing the photomask 30 in operation S 2 of FIG. 1 is measured, and the measured value may be inputted as a measurement CD in operation S 33 . The measurement CD may be obtained according to sections of the photomask 30 .
[0052] Subsequently, it may be determined whether the absolute value of a difference between a design CD and a measurement CD is in the allowable error range in operation S 34 . If the absolute values of the design CD and the measurement CD are the same, the photomask 30 is regarded as an ideal photomask. However, the absolute value of the difference between the design CD and the measurement CD according to sections of the photomask 30 may vary according to errors and the degree of optimization of an exposure condition when the photomask 30 is manufactured. Thus, an allowable process margin in a process using the photomask 30 is set to be in the allowable range so that it can be determined whether the absolute value of the difference between the design CD and the measurement CD is in the allowable range.
[0053] If the absolute value of the difference between the design CD and the measurement CD is in the allowable range, a correction operation may be ended. However, if the absolute value of the difference between the design CD and the measurement CD is not in the allowable range, the correction operation is needed. For example, a correction map may be simulated based on the difference in operation S 35 . The operation (S 35 ) of simulating the correction map will now be described with reference to FIG. 5 .
[0054] Referring to FIG. 5 , a percentage dose (illumination intensity) drop value map that affects an aerial image is obtained in operation S 351 , and a correction map for making transmittance uniform according to sections of the photomask 30 may be generated using the percentage dose (illumination intensity) drop value map in operation S 352 . Specifically, in operation S 352 , a diffraction array spot density map may be simulated.
[0055] The operation of obtaining the percentage dose (illumination intensity) drop value map will now be described in greater detail with reference to FIG. 6 . Referring to FIG. 6 , parameters for obtaining a percentage dose (illumination intensity) drop value according to sections after dividing the photomask 30 into sections, for example, a CD deviation distribution map and a dose latitude, in operation S 3511 . Subsequently, the percentage dose (illumination intensity) drop value map may be obtained using the CD deviation and the dose latitude in operation S 3512 .
[0056] In this case, the CD deviation distribution map may be obtained using operations of dividing the photomask 30 into sections or meshes and measuring CDs of mask patterns formed in each of the sections or the meshes using the transmittance, and the CD deviation distribution map according to sections may be obtained based on a section having the smallest CD. In addition, the dose latitude (CD/% dose) is obtained by measuring a change in CD of the photomask 30 according to a change in the percentage dose (illumination intensity) by changing the percentage dose (illumination intensity) while using an exposure condition used to measure the CD deviation distribution map. Exposure doses are illustrated on the x-axis, and the CD of the photomask 30 is illustrated on the y-axis, and a straight-line slope connecting measured values illustrated on an x-y plane is obtained. Next, the percentage dose (illumination intensity) used in a current exposure process is multiplied by the straight-line slope, thereby obtaining dose latitude. In addition, the percentage dose (illumination intensity) drop value map may be obtained by multiplying the dose latitude by the CD deviation, and the percentage dose (illumination intensity) drop value is obtained according to sections, thereby obtaining the percentage dose (illumination intensity) drop value map (i.e., percentage dose).
[0057] Referring back to FIG. 4 , when the percentage dose (illumination intensity) drop value map, i.e., the correction map, is obtained, as described above, the transmittance of the photomask 30 may be adjusted based on the correction map in operation S 36 . The transmittance of the photomask 30 may be adjusted by forming a diffraction array adjusting the intensity and shape of illumination in the substrate 31 , for example. When the diffraction array is formed in the substrate 31 , a diffraction array spot density map is obtained in operation S 352 of FIG. 5 to correspond to the correction map. The diffraction array spot density map is obtained using Equation 1.
[0000] I= 1−4( d 2 /p 2 ); (1)
[0000] where I corresponds to a percentage dose (illumination intensity) drop value, d is the diameter of a spot, and p is the pitch of the spot. That is, the percentage dose (illumination intensity) drop value may be obtained according to Equation 1 as a function of the diameter of the spot and the pitch of the spot by using Equation 1.
[0058] Subsequently, the operations S 31 through S 36 may be repeatedly performed until the difference between the absolute value of the difference between the design CD and the measurement CD is in the allowable range.
[0059] FIG. 7 schematically illustrates CD uniformity achieved on a wafer by using a photomask in which a diffraction array is formed, according to an exemplary embodiment.
[0060] Referring to FIG. 7 , a first section in which a first diffraction array 60 a is formed in the photomask 30 , a second section in which a diffraction array is not formed, and a third section in which a second diffraction array 60 b is formed, are illustrated. The density of the first diffraction array 60 a may be smaller than the density of the second diffraction array 60 b . The density may be adjusted by changing the pitches of spots 60 having the same size. As a result, the intensity of light (or illumination) that passes the second section in which the diffraction array is not formed is the largest, and the intensity of light (or illumination) that passes the second diffraction array 60 b is the smallest, and the intensity of light (or illumination) that passes the first diffraction array 60 a is a middle value of the intensities.
[0061] As a result, the illumination intensity distribution of light in the photomask 30 is deformed, and light of the deformed illumination intensity distribution 43 may pass the mask pattern 37 and may be transferred onto a wafer 200 . Thus, patterns 210 having uniform CD instead of conventional patterns 205 having nonuniform CDs may be printed on the wafer 200 . In this way, diffraction arrays having different densities according to sections of the photomask 30 are formed so that the CD uniformity of the photomask 30 is improved and the shot uniformity of the wafer 200 can be improved.
[0062] The spots 60 may be obtained by irradiating energy light having a predetermined density at which a substrate medium is not molten and/or vaporized but at which a refractive index is changed, for example, femto second laser. For example, FIG. 8 schematically illustrates a laser device used in manufacturing a photomask according to exemplary embodiments.
[0063] Referring to FIG. 8 , the laser device may comprise a laser generation unit 100 , a laser processor 110 , a controller 120 , and a stage 130 . The photomask 30 is loaded on the stage 130 that is controlled by the controller 120 to be movable along the x-axis and the y-axis. Next, a laser generator or source 101 of the laser generation unit 100 generates a titanium sapphire laser beam 102 having a pulse duration time of 7×10 −12 s(7 ps) and a maximum peak output per unit area of approximately 10 13 to 10 14 W/cm 2 .
[0064] The laser beam 102 is irradiated on the photomask 30 of the stage 130 via a shutter 111 , a beam expander 112 , and a focusing lens 114 of the laser processor 110 . As a result, the spots 60 are formed in the substrate of the photomask 30 . In this case, the shape of the diffraction arrays formed in the photomask 30 is controlled by a control device 121 such as a computer, in the controller 120 . Charge-coupled device (CCD) cameras 123 and 125 may be provided for use in monitoring. In addition, the focus of the laser beam 102 is adjusted so that a multi-layer diffraction array 60 b can also be implemented.
[0065] FIG. 9 schematically illustrates CD uniformity achieved on a wafer by using a photomask in which auxiliary patterns are formed, according to another exemplary embodiment.
[0066] Referring to FIG. 9 , auxiliary patterns 38 a and 38 b may be formed according to a correction map obtained by the transmittance distribution of sections so as to adjust transmittance. In this case, the distribution of transmittance and illumination intensity may be adjusted by the widths or sizes of the auxiliary patterns 38 a and 38 b . In this way, although the auxiliary patterns 38 a and 38 b are formed according to the transmittance distribution of sections, the uniformity of the wafer according to shots can be improved.
[0067] FIG. 10 schematically illustrates CD uniformity achieved on a wafer by using a photomask in which grooves are formed, according to another exemplary embodiment.
[0068] Referring to FIG. 10 , grooves 31 a and 31 b may be formed in a surface on which patterns of the photomask 30 are formed, according to the correction map obtained by the transmittance distribution of sections so as to adjust light transmittance. In this case, transmittance distribution and illumination intensity may be adjusted by the sizes and depths of the grooves 31 a and 31 b , and the grooves 31 a and 31 b are formed in sections of the photomask 30 based on the correction map, thereby improving the shot uniformity of the wafer 200 .
[0069] FIG. 11 illustrates a photomask having a nonuniform CD and its aerial image intensity.
[0070] Referring to FIG. 11 , the photomask 30 may comprise a first region R 1 having a normal distance (or normal CD) d 1 and a second region R 2 having an abnormal distance d 2 based on the mask patterns 37 a . The abnormal distance d 2 corresponds to d 1 +2 ω, and ω is smaller than the wavelength λ of a light source and the normal distance d 1 (ω>>λ <CD). The intensity of the aerial image detected by exposing the photomask 30 may be different due to the CDs of the mask patterns 37 a , for example, the difference between the distances d 1 and d 2 . Here, when the vibration axis L 2 of an image intensity curve corresponding to the second region R 2 is inversely corrected to be the same as the vibration axis L 1 of an image intensity curve corresponding to the second region R 1 , the transmittance of the second region R 2 may be corrected.
[0071] FIG. 12 illustrates a corrected photomask and its aerial image intensity according to an exemplary embodiment.
[0072] Referring to FIG. 12 , a diffraction array 60 a or 60 b is formed in the second region R 2 of the photomask 30 , thereby adjusting the intensity of the aerial image of the second region R 2 . In a modified example of this exemplary embodiment, the auxiliary patterns 38 a and 38 b or the grooves 31 a and 31 b instead of the diffraction array 60 a or 60 b may also be formed, as illustrated in FIGS. 9 and 10 . In this way, as the intensity of the aerial image becomes uniform, the CD uniformity of the photomask 30 may be obtained.
[0073] In the above-described embodiments, the photomask 30 is corrected based on light transmittance but may be corrected based on a reflection index. In this case, in operation S 36 of FIG. 4 , the reflection index may be adjusted according to the correction map.
[0074] FIG. 13 is a cross-sectional view of a corrected, reflection type photomask according to an exemplary embodiment.
[0075] Referring to FIG. 13 , a reflection type photomask 70 comprises a reflection layer 73 comprising multiple layers formed on a substrate 71 and absorption patterns 75 a formed on the reflection layer 73 . An illumination intensity adjusting unit 79 may adjust the intensity of illumination by irradiating a laser 77 on the reflection layer 73 of the photomask 70 . When the laser 77 is irradiated on the reflection layer 73 , the reflection index of the reflection layer 73 is changed. That is, the thicknesses and material properties of layers of the illumination intensity adjusting unit 79 are changed so that the reflection index of the reflection layer 73 is changed. In this case, the amount of laser irradiation and the area of laser irradiation may be decided by the correction map.
[0076] FIGS. 14 and 15 are images showing the CD uniformity of a photomask in which correction according to an experimental example is not performed and the CD uniformity of a photomask in which correction according to an experimental example is performed, respectively.
[0077] In FIG. 14 , the average of measurement CDs on mask patterns was 32.55 nm, and 3σ(%) indicating that uniformity was 3.7%. In FIG. 15 , the average of measurement CDs on the mask patterns was 32.36 nm, and 3σ(%) indicating that uniformity was 1.15%. Thus, the photomask in which correction according to exemplary embodiments is performed shows higher uniformity than the photomask in which correction according to exemplary embodiments is not performed.
[0078] While the inventive concept has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood that various changes in form and details may be made therein without departing from the spirit and scope of the invention, as defined by the following claims. | A method of manufacturing a photomask includes: providing a photomask; exposing the photomask to obtain an aerial image of the photomask and evaluating the photomask using the aerial image; and altering an optical parameter of the photomask associated with the aerial image according to the result of evaluation. | 6 |
REFERENCE TO A RELATED APPLICATION
This application is a continuation-in-part of my pending allowed application Ser. No. 840,351 filed Mar. 17, 1986, now U.S. Pat. No. 4,674,233.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates generally to edge guards for application to the trailing edges of swinging closures such as an automobile's doors.
Reference is made to the parent application for known prior art which discloses a door edge guard which fits onto a corner of a door's trailing edge. The invention of the parent application is an improvement, particularly relating to the manner of retention on the door.
The present application discloses a further embodiment which utilizes the same generic retention principle, but with a different specific organization and arrangement of the several parts.
Reference may be had to the parent application for a detailed discussion of the improvements disclosed therein. The instant application expressly incorporates the several embodiments of the parent application and adds a new embodiment according to the best mode presently contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an automobile containing a door edge guard embodying principles of the invention.
FIG. 2 is a view taken generally in the direction of arrows 2--2 in FIG. 1, and enlarged, illustrating a view of the contour of the door edge without the door edge guard.
FIG. 3 is a view taken generally in the direction of arrows 3--3 in FIG. 1 showing the relationship of the edge guard on the door edge.
FIG. 3A is a fragmentary view in the direction of arrow 3A in FIG. 3.
FIG. 4 is an end view of the door edge guard of FIG. 3 shown by itself.
FIG. 5 is an end view of another door edge guard shown by itself.
FIG. 6 is an end view of a further door edge guard shown by itself.
FIGS. 7, 8, and 9 are end views corresponding respectively to the views of FIGS. 4, 5, and 6 but showing modified forms.
FIGS. 10, 11, and 12 are end views corresponding respectively to FIGS. 4, 5, and 6 illustrating other modified forms.
FIG. 13 is an end view illustrating a further embodiment of edge guard.
FIG. 14 is an end view illustrating still another embodiment of edge guard.
FIG. 15 is a view similar to FIG. 3 but on a reduced scale of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an automobile 20 having a door 22 whose trailing edge contains a door corner edge guard 24 embodying principles of the invention. The shape is seen from consideration of FIGS. 1, 2, and 3, and in particular FIG. 3 shows that the door trailing edge 26 is defined in part by the exterior surface 28 of the door and the end surface 30 which is generally at a right angle to surface 28. As such, the door has an outer corner 32 defined at the juncture of the exterior surface 28 and the end surface 30. The door construction is composed of metal panel members such as 34, 35. It is the outer corner 32 of the door trailing edge 26 which the edge guard 24 of the present invention is adapted to protect.
Edge guard 24 is an elongate member which is conformed in curvature to the curvature of the corresponding portion of the door trailing edge 26 which it is intended to guard. The length of the edge guard may be substantially all or a lesser fraction of the overall length of the trailing edge.
From consideration of FIGS. 1 and 2 it can be seen that the outer corner edge 32 of the door has a compound curvature. The present invention provides a door edge guard which is adapted to fit with conformity onto this type of curvature although it may be used with other types of door edges having different curvatures. It is to be appreciated where the curvature of the door edge becomes extreme, it may be desirable to make certain modifications to the basic cross section if it is desired to have the edge guard bridge these regions of extreme change in curvature although the invention is well suited to conforming to many curvatures without any alteration of its basic cross sectional shape. These additional procedures may involve notching and bending, embossing, or other similar types of procedures.
Edge guard 24 is formed from an insulated metal strip wherein the metal is identified by the reference numeral 40 and the insulation by the reference numeral 42. Where a portion of the metal is exposed, it is preferable to use a decorative and durable material such as stainless steel for example. In other embodiments hereinafter described where the metal is not exposed, lesser grades of metal may alternatively be used. When viewed endwise or in transverse cross section, the edge guard is seen to possess a generally right angle channel shape. For explanation, the edge guard may be considered to comprise an outer leg 44 which is disposed against the exterior door surface 28 and a back leg 46 which is disposed against the end surface 30. The leg 46 is shown to be essentially straight and flat. A bead 47 is formed at the distal end of leg 46 by reverse turning the insulated metal strip outwardly back against itself in the manner shown. Preferably the degree of reverse turning is such that metal-to-metal contact results.
The two legs 44, 46 merge in a curved bend section 48 which may be considered to have approximately a 90° curvature as depicted in FIG. 4. The outer leg 44 extends from this section 48 in a forward direction. It comprises an inwardly curved offset section 50 extending from section 48. From the offset section 50, the leg extends in a straighter section 52 and the distal end is provided with a bead 54 by reverse turning the margin of the insulated metal strip outwardly back against itself, preferably so that metal-to-metal contact results in a similar manner to the formation of bead 47 in leg 46. The extent of the offset section 50 in relation to the rest of leg 44 is such that the exterior of bead 54 is generally flush with the point where the curved bend section 50 merges with section 48. This is exemplified by the broken line 56.
The layer of insulating material 42 is applied to one side of the metal strip 40 from which the edge guard is formed. This may be done in accordance with procedures which are the subjects of other of applicant's inventions. As such the layer may be formed by extrusion, lamination or other procedures, by way of example.
From consideration of FIG. 3 it can be seen that the non-metallic insulating material is disposed between the edge guard metal 40 from the painted metal of door 22.
Moreover, the formation of bead 54 by reverse turning the margin of the strip results in a portion of the insulating material being disposed on the exterior of the door. This presents the appearance of a band designated by the reference numeral 58. By making this band of a desired color, various color coordination schemes may result. Alternatively the insulation could be made of a metallic color closely matching the metal 40.
The corner edge guard has no self-retention capability by itself on door 22. Accordingly separate fasteners are used to make the attachment. For this purpose holes 60 are provided in leg 46 at intervals along the length of the door guard and fasteners such as headed screws 62 are passed through holes 60 and into corresponding aligned holes 64 in the end of the door. The screws can be of the self-tapping type and so sized that they clear holes 60 while cutting threads into the holes 64 as they are being installed. Where a bead such as the bead 47 might interfere with a flush fit of the screw heads against the back leg, the bead may be notched as at 66 to yield clearance for the screw heads in the manner shown. Whether notching is appropriate will depend upon each particular usage and upon the size of the screw head and the dimensions of the door edge guard's back leg.
By making leg 46 flat, it is rendered well-suited for being pressed flat against the end surface 30 of the door edge as the screws 62 are tightened with the insulating layer being conformed in between. Because there may be metal-to-metal contact between the heads of the screws and the metal 40, and because the screws shanks thread into the metal of the door, there can be continuity between the metal of the door edge guard and the door itself via the screws. By the flat mounting, and by making the metals of similar characteristics, i.e. both steel, the development of undesired detrimental effects such as corrosion is more or less inhibited even though there is metal-to-metal continuity through the fasteners. As will be seen, further inhibition of detrimental effects can be alleviated by some of the other embodiments hereinafter disclosed. Alternatively the use of non-metallic fasteners could be employed in some applications.
The edge guard is so dimensioned in its cross section that when it is installed on the corner edge the beaded end 54 of the outer leg 44 will be urged to forcefully bear against the exterior surface. This is done by a suitable dimensioning of the hole 64 from the exterior surface 28 in relation to the location of holes 60, 64 relative to leg 44. Hence as the back leg 46 is being urged flat against the end surface 30 of the edge, the fastening action is also effective to cause the beaded distal end of the outer leg to forcefully bear against the exterior surface 28. In this way the edge guard is conformed to the trailing edge at the corners where the contour of the corner edge is straight, has simple curvature, or even has compound curvature.
The construction of the sections 48 and 50 serves to provide strength to the edge guard and it also provides a space 68 between the door and the edge guard through which any moisture which might collect in the space can drain. The strengthening is well adapted to protect the corner edge of the door from impact.
FIG. 5 shows another embodiment of edge guard 70. The shape of edge guard 70 is exactly like edge guard 24 of FIG. 4 except in two respects. First, it includes two parallel ridges 72, 74 which are formed in leg 46. The ridges are deformed outwardly away from end surface 30 so that the back leg 46 can still be disposed flat against the end surface 30 when the edge guard is installed on the trailing edge. Embodiment 70 also differs in that bead 47 is omitted. While bead 47 provides a certain amount of stiffening to the leg which is useful in certain instances, the ridges 72, 74 also impart a certain stiffening such that the bead 47 can be omitted. If there is interference between ridges 72, 74 and the head of the screws used to fasten the edge guard to the door edge, such interference may not be objectionable. However the beads could be flattened locally where the screw heads bear against the leg or there could be notching in a matter analogous to that described for the bead 47 in FIG. 3. The use of like reference numerals in FIG. 5, as well as the ensuing drawing figures is intended to represent like parts, previously described in connection with FIGS. 1-4.
FIG. 6 illustrates a still further embodiment 80 which is exactly like the embodiment 2 of FIG. 4 except that the bead 47 is omitted. Although not shown in the drawings, there could be additional embodiments wherein the use of bead 47 is combined with one or both of the ridges 72, 74.
FIGS. 7, 8, and 9 portray respective embodiments 90, 100, and 110 which are exactly like the embodiments of FIGS. 4, 5, and 6 except that the entire cross section of the metal 40 is covered with a layer of insulating material 42. Such a layer can be provided by extruding plastic material onto the metal strip 40 in the flat before it is formed to the illustrated cross section. Both the major surfaces of the strip as well as the side edge surfaces are covered with insulation. The insulating material will present the exterior color and by use of selected colors, various color coordinations with the automobile may be obtained. In these embodiments 90, 100, 110 it is to be observed that the heads of the screws will bear against insulating material rather than the outer surface of the metal channel. This further tends to inhibit rust and corrosion where there are dissimilar metals involved. Because of the use of plastic to fully encapsulate the cross section, a lower grade of metal can be used. In any of the embodiments where the edge guard is cut to length, the ends of the edge guard may have exposed metal. In the embodiment shown in FIG. 7, it may be deemed desirable to cover the cut ends and this can be done by paint, plastic, or the like applied to the ends.
The embodiment 100 of FIG. 8 is exactly like the embodiment 70 except that insulation is applied to the full extent of the cross section as shown. Likewise the embodiment 110 of FIG. 9 is exactly like embodiment 80 of FIG. 6 except that the full cross section is covered by insulating material.
FIGS. 10, 11, and 12 portray embodiments 120, 130, 140 consisting solely of metal. While these embodiments are deemed less desirable because they do not possess the insulating features characteristic of the other embodiments, they do reflect the basic metal edge guard construction and each of the embodiments 120, 130, 140 is like the embodiments 24, 70, and 80 except that insulating material is omitted.
FIG. 13 portrays an embodiment 150 similar to FIG. 5 but where insulation has been extended around the end edge surface of the metal strip where the bead 47 has been removed. This type of construction is possible using the aforementioned manufacturing technique of extruding the plastic onto the metal in the flat. Likewise the embodiment 160 of FIG. 14 is like the embodiment of FIG. 6 but including insulation extending around the distal end edge of the base leg where the bead 47 has been omitted.
In all embodiments the edge guard possesses the ability to be conformed to compound curvatures while still causing the distal end of the outer leg to forcefully bear against the exterior surface while the back leg bears flat against the end surface. The embodiments which illustrate the particular shape for the sections 48 and 50 and for the outer leg are also advantageous because of the strength characteristic which they possess. It is to be appreciated that in the drawing figures the relative proportions may not necessarily be to scale or represent exact proportions since they are intended to be illustrative to principles of the invention. While PVC (polyvinylchloride) is a suitable material for the insulation 42, other insulating material may be used.
In FIG. 15 like reference numerals designate like parts as in FIG. 3. The edge guard however is identified by the general reference numeral 170. Edge guard 170 has essentially the same transverse cross sectional shape as edge guard 24 of FIG. 3. While the same generic retention principle is used, the particular means by which this principle is implemented are slightly different. Instead of fabricating the edge guard with holes 60, of providing the door with holes 64, of using screws 62 and of providing clearance notches 66 for the heads of the screws, the door is left free of holes and the edge guard is of uniform transverse section at any location along its length.
A thin double-backed adhesive tape 172 is disposed at a central region of the inner surface of the edge guard's back leg 46 and extends along the length of the back leg either continuously as a single length or as several pieces along the length. Any of the conventional commercially available tapes may be used. The particular tape selected will take into account the particular type of paint on the door and the type of material on the inner surface of the back leg of the edge guard. The tape is comparatively thin and therefore can effectively serve to minimize the overall thickness of the door guard and fastening means which will exist between the end surface 30 of the door and the adjacent door pillar when the door is closed. This is a desirable attribute. The use of such tape eliminates extra parts such as the fasteners; also the need for putting holes into the door and notches in the edge guard, such as 66 in FIG. 3.
Yet, the same retention principle exists because the size, shape and retention strength of the double-backed tape prevents the edge guard from an appreciable outward shifting which would result in loss of the forceful engagement of the distal end of outer leg 44 against the exterior surface 28 of the door.
Assembly of door corner edge guard 170 to the door is achieved by positioning the guard in such a manner at assembly that the outer leg's distal end is caused to bear forcefully against the exterior surface of the door while the back leg which contains the double-backed tape is pressed against the end surface 30 of the door. Preferably, the door corner edge guard is sold with one surface of the double-backed tape adhered to the back leg of the guard and with the other surface covered by release paper. In this way it is assured that the tape is in the best location for the particular model involved. At time of installation, the release paper is stripped to expose the adhesive, and the guard is applied to the door in the manner described. | A corner edge guard for the trailing edge of a swinging closure wherein the trailing edge is defined by surfaces which intersect at approximately 90° to form a corner. The edge guard comprises legs which are also arranged at approximately a 90° angle with the edge guard being disposed in covering a relationship to the corner. The edge guard is constructed and arranged such that concurrently with the fastening of the edge guard to the trailing edge, the distal end of the other leg forcefully bears against the other surface of the trailing edge. Preferably insulating means is disposed between the metal of the edge guard channel and the trailing edge. Various embodiments of corner edge guards are enclosed. | 1 |
This application is a continuation-in-part of application U.S. Ser. No. 149,831 filed Jan. 29, 1988.
BACKGROUND AND OVERVIEW OF THE INVENTION
Women with breast carcinoma tend to have elevated serum levels of a molecular antigenic determinant referred to as the DF3 antigen (DF3). This provides the basis for a currently used diagnostic assay in which samples of a women's serum are reacted with antibodies that bind specifically to DF3 (anti-DF3 antibodies; D. F. Hayes et al, J. Clin. Oncol. 4, 1542-1550; D. F. Hayes et al, J. Clin. Invest. 75, 1671-1678, 1985). The current invention relates to genetically engineered molecules that carry an immunologically active portion of the DF3 antigen; i.e., one that reacts with anti-DF3 antibodies. The molecules can be used to improve the reproducibility of the diagnostic assay. They can also be used as the basis for an alternative, more sensitive assay. In a related invention, individual women can be categorized as to their genetic material that determines the structure of DF3.
It has been demonstrated that naturally occurring DF3, that occurring in human breast carcinoma cells or the plasma of patients with breast cancer, is a member of a family of related but not identical high-molecular weight tumor-associated antigens (M. Abe et al, J. Immunol. 139, 257-261, 1987). Naturally occurring DF3 has been partially characterized as a high molecular weight mucin-like glycoprotein (H. Sekine et al., J. Immunol 135, 3610-3615, 1985; M. Abe et al., J. Cell Physiol. 126, 126-132, 1986), a molecule with both a polypeptide component and a carbohydrate component. The polypeptide component is comprised of one or more chains, each consisting of amino acids linked end-to-end in a specific sequence. On the average, it accounts for about 15 percent of the DF3 molecule, there being batch-to-batch variability and, within each batch, molecule-to-molecule variability, in the ratio of polypeptide to carbohydrate. As a result DF3 antigen is a collection of closely related but not necessarily identical molecules having the common property that they react with anti-DF3 antibodies. In human MCF-7 breast carcinoma cells, the antigen consists of two distinct glycoproteins with molecular weights in the range of 330 and 450 kilodaltons (kd), respectively (H. Sekine et al., J. Immunol 135, 3610-3615, 1985; M. Abe et al., J. Cell Physiol. 126, 126-132, 1986). DF3 antigen that circulates in the plasma of patients with breast cancer also has molecular weights ranging from approximately 300 to 450 kd (D. Hayes et al J. Clin. Invest. 75, 1671-1678, 1985).
In the currently used diagnostic assay for DF3, interpretation of the results requires that controls involving known amounts of DF3 be run. DF3 isolated from extracts of carcinoma cells is used to calibrate the assay. However, because of the above noted variability in the structure of DF3 antigen from molecule to molecule and from batch to batch, it would be advantageous to have a method of preparing a more reproducible version of the antigen. Improved reproducibility would be achieved if a carbohydrate-free polypeptide, capable of reacting with anti-DF3 antibody could be prepared. Previous work with the naturally occurring version had suggested that the carbohydrate portion of DF3 was essential for reaction with the anti-DF3 antibody. Nevertheless, in the current invention, synthesis of carbohydrate-free polypeptides with an antigenic determinant capable of reacting with anti-DF3 antibody (DF3 polypeptides), was achieved. Furthermore, these DF3 polpeptides can be synthesized in bacteria, which are expected to provide a less costly means of producing it.
The ability to synthesize an antigenically active polypeptide in bacteria also provides the basis for an alternative, potentially superior, means of detecting DF3 in human sera. In bacteria, the polypeptide can be synthesized with a higher specific radioactivity than is possible in human cells. It can then be used in a competition assay, one where anti-DF3 antibodies are allowed to react with a mixture of radioactive DF3 polypeptide that was synthesized in bacteria and nonradioactive antigen from the person's serum. This type of assay has been used with the carcinoembryonic antigen (CEA; See, for example, February, 1983 package insert for Carcinoembryonic Antigen Radioimmunoassay, Roche Diagnostics, Nutley, New Jersey 07110) the nonradioactive antigen will compete with the radioactive DF3 for antibody binding sites, the diminished binding of radioactivity being an index of the amount of DF3 antigen in the person's serum. This type of assay is expected to be able to detect smaller amounts of antigen in a person's serum than the currently used assay can.
In an example of the invention, a DF3 polypeptide was synthesized in the prokaryotic organism, Escherichia coil (E. coli), a bacterium. Although there is still uncertainty as to both the number of polypeptide chains in a naturally occurring DF3 antigen molecule and the size of each chain, it is likely that the synthetic DF3 polypeptide represented less than a complete naturally occurring chain. Incomplete synthesis of an antigen polypeptide chain is a possible result of the procedure used to initially isolate DNA coding for an antigenically active site. First, messenger RNA (mRNA) was isolated from human breast carcinoma cells, which are known to synthesize the antigen. DNA copies of the mRNA were then made. (Failure to isolate intact mRNA molecules or synthesize complete DNA copies are two possible reasons why incomplete synthesis of an antigen chain is ultimately achieved.) Each DNA fragment was then attached to the DNA of a bacterial virus such that, if the fragment contained the ability to direct the synthesis of human DF3 polypeptide, that peptide would be expressed as part of a fused polypeptdie also containing the bacterial polypeptide, beta galactosidase. The resulting population of DNA molecules are distributed among a very large number of bacterial cells by a transfection process. At a subsequent step, each bacterial cell was tested for the ability to direct the synthesis of a polypeptide that would react with anti-DF3 antibody. Prior to completing the test, there was uncertainty as to whether the procedure employed would be successful in generating bacteria capable of making an antigenically active polypeptide: Not only would the polypeptide lack the carbohydrate portion it has in humans, there was an excellent chance that it would be smaller than its intact human form. As it turned out, several bacteria that produced antigenically active polypeptide were found, the one presented in detail here being typical of the group.
Regardless of the precise relationship of the E. coli-produced DF3 polypeptide to the naturally occurring one, the results presented above provide the following picture:
(1) the polypeptide component of DF3 has antigenic activity in the absence of any carbohydrate component;
(2) probably only a portion of the polypeptide (not more than 103 amino acids) is required for antigenic activity; and
(3) the antigenically active portion of the DF3 polypeptide retains its antigenic activity when part of a polypeptide that is partly comprised of polypeptide sequences naturally foreign to it. As to this latter point, consider the fact that, in E. coli, the DF3 polypeptide was joined to the 116,000 dalton bacterial polypeptide, beta galactosidase. An advantage of this latter property is that the antigenically active site can be made part of a tyrosine-rich polypeptide, and radioactive iodine can be attached to the tyrosine residues, thereby increasing the specific radioactivity of the antigenic probe for use in the competition diagnostic assay.
Electrophoretic mobility patterns of an antigen are a reflection of its structure. The electrophoretic mobility patterns for circulating DF3 antigen are heterogeneous and differ among individuals (D. Hayes et al., J. Clin. Invest. 75, 1671-1678, 1985). Subsequent studies in family members have demonstrated that the electrophoretic mobility pattern of plasma DF3 antigen is genetically determined by codominant expression of multiple alleles at a single locus (D. Hayes et al., Blood, 1988, 71:436).
The aforementioned electrophoretic and genetic studies would not, however, make it obvious how one could detect the changes in DNA strucuture. Person-to-person variation in DNA structure of specific genes has been successfully demonstrated for some other genes using the technique of restriction fragment length polymorphism (RFLP). In RFLP analysis, one analyzes the size of DNA fragments that carry a particular gene after controlled digestion (by a restriction endonuclease) of that person's DNA. The technique can be used to categorize individuals genetically and also assist in identifying the individual who is the source of a particular tissue or group of body cells. Applicant used RFLP analysis to investigate the size of DNA fragments that carry the gene for the 103-amino acid antigenically active DF3 polypeptide. He discovered that indeed such RFLP analysis reveals variations in DNA structure that correlated with the variations in size of the circulating antigens. Whether there is a correction between a particular DNA structure and a predisposition to breast cancer is unknown.
SUMMARY OF THE INVENTION
In one aspect, the invention is a polypeptide that:
(1) is free or substantially free of bound carbohydrate; and
(2) includes all or a portion of the amino acid sequence that is coded for by the human nucleotide sequence of ##STR1## a dot indicating that the nucleotide is identical to the one directly above it in the mode of representation used here; in a related aspect, the polypeptide includes all or a portion of one of the following four amino acid sequences:
1) ALA PRO GLU SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
2) ALA PRO ASP THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
3) ALA PRO GLU THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
4) ALA PRO ASP SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIG GLY VAL THR SER
where each line of a sequence is read from left to right; of course, both an end-to-end linkage of any two of the amino acid sequences or an end-to-end linkage of two copies of any one of the sequences can be used in the polypeptide.
In another aspect, the invention is an antigen that reacts with anti-DF3 antibody and whose polypeptide component wash synthesized in a non-human cell under the direction of a human nucleotide sequence.
In another aspect, the invention is a recombinant DNA molecule that codes for a polypeptide capable of reacting with an anti-DF3 antibody; in another aspect, the invention is a prokaryotic organism containing such a recombinant DNA molecule in a form in which it can be expressed to direct the synthesis of a polypeptide that reacts with an anti-DF3 antibody. [A recombinant DNA molecule, in the present application, is one which does not occur in nature until human intervention leads to its construction and which, except for a specific desired nucleotide sequence, is free or substantially free of human DNA.]
In another aspect, the invention is a DNA molecule containing the sequence of 309 nucleotides depicted above, said DNA molecule being substantially free of other mammalian DNA.
In another aspect, the invention is a process of hybridizing a DNA molecule comprising the sequence of 309 nucleotides depicted above against restriction enzyme generated fragments of human DNA that have been fractionated on the basis of size. In another aspect, the invention is a process which comprises binding an anti-DF3 antibody to a polypeptide which was synthesized in a non-human cell under the direction of a human nucleotide sequence. In a further related aspect, it is a process which comprises binding an antibody to a polypeptide that was synthesized in a nonhuman cell said polypeptide being one that contains all or part of one of the following four amino acid sequences:
1) ALA PRO GLY SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
2) ALA PRO ASP THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
3) ALA PRO GLU THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, or
4) ALA PRO ASP SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER.
In subgeneric aspects of the above inventions that involve DF3 polypeptides, the entire polypeptide sequence coded for by the human DNA component of pDF3.9 are required and, in other subgeneric aspects, those are the only naturally occurring DF3 sequences present.
In additional subgeneric aspects of the above inventions that involve anti-DF3 antibodies, the anti-DF3 antibody of the invention is that produced by hybridoma No. DF3 of the laboratory of Donald W. Kufe, Dana-Farber Cancer Institute, Boston, Mass. (Hybridoma No. DF3 ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1: Immunological identification of pDF9.3 encoded recombinant antigen. Lambda gtll and pDF9.3 recombinant phage were used to lysogenize E. coli Y1089. Protein extracts were prepared from the lysogens and 10 μl of the bacterial lysates were electrophoresed in SDS/7.5% polyacrylamide gels, electroblotted onto nitorcellulose and, after the nitrocellulose was blocked with 1% BSA in Tris-buffered saline plus Tween 20, it was incubated with anti-beta-galactosidase antibody (Lane 1) or MAb DF3 (Lane 2). MAb DF3 was also preincubated with 10 ng (Lane 3), 100 ng (Lane 4) and 500 ng (Lane 5) of purified DF3 antigen prior to probing the filters. Antibody binding was detected by an enzyme linked immunoabsorbant assay (the antibody was reacted with goat anti-mouse IgG linked to alkaline phosphates) using nitroblue tetrazolium as substrate and developed with 5-bromo-4-chloro-3-nitryl phosphate (Reagents were those of the Protoblot Lambda gt11 Immunoscreening System, Promega Biotec, Madison, Wis.). Several apparent proteolytic breakdown products are noted using the anti-beta-galactosidase antibody.
FIG. 2: Southern blot analysis of genomic DNA with the pDF9.3 probe. DNAs (20 μg) from human tumor cell lines were digested to completion with EcoRI (A), PstI (B) and HindIII (C), and electrophoresed in 0.6% agarose gels. The gels were denatured and the DNA fragments transferred to nylong filters. The filters were hybridized with the 32 P-labeled pDF9.3 cDNA insert. The filters were then washed and exposed to x-ray film.
FIG. 3: Northern blot analysis with pDF9.3 and immunoblotting with MAb DF3. A. Total cellular RNA (20 μg) from human tumor cell lines was electrophoresed in a 1% agarose/formaldehyde gel, transferred to nitrocellulose and hybridized with the 32 P-labeled pDF9.3 cDNA insert. B. Extracts of the human tumor cells were analyzed by SDS/3-15% polyacrylamide gel electrophoresis, immunoblotted with MAb DF3, and then reacted with rabbit anti-mouse Ig and 125 I-labeled protein A.
FIG. 4: Nucleotide sequence of the pDF9.3 cDNA insert.
DETAILED DESCRIPTION
Library Screening
An oligo (dT) primed cDNA library was prepared from human MCF-7 breast carcinoma cells in lambda gt11 (P. Walter et al., Proc. Natl. Acad. Sci., USA 82, 7889-7893. 1985). Immunologic screening of the lambda gt11 library was performed as previously described (R. A. Young et al., Proc. Natl. Acad. Sci., U.S.A. 80: 1194-1198, 1983) using affinity purified MAb DF3 (0.25 μg/ml) [D. Kufe et al., Hybridoma 3, 223-232, 1984, describes the isolation of the hybridoma, presently referred to as Hybridoma No. DF3 in the laboratory of Donald W. Kufe, Dana-Farber Cancer Institute, Boston, Mass. The hybridoma was injected into mice, the ascites recovered, and the Mab DF3 antibodies purified by the MAPS II kit of Biorad, Richmond, Calif.] and anti-mouse IgG conjugated with alkaline phosphates (Promega Biotech, Madison, Wis.). Positive plaques were isolated and the phage was further purified to homogeneity by repeated antibody screening. DNA was isolated from MAb DF3 positive recombinant phage, digested with EcoRI and electrophoresed in 1.2% agarose gels containing ethidium bromide to determine the size of the insert.
Analysis of Lysogens for Fusion Protein
Lysogenization of E. coli Y1089 with phage and induction of fusion protein with isopropyl-beta-D-thiogalactoside (IPTG) were performed as described previously (R. A. Young et al., Proc. Natl. Acad. Sci., U.S.A. 80: 1194-1198, 1983, R. A. Young et al., Science 222: 778-782, 1983). The lysate of IPTG induced lysogen was subjected to electrophoresis in SDS/7.5% polyacrylamide gels (U. K. Laemmli, Nature 227, 680-685, 1970) and transferred to nitrocellulose filters for immunoscreening (W. N. Burnette, Anal. Biochem. 112: 195-203).
Southern and Northern Blot Analyses
The human breast carcinoma cell lines (BT-20, T47D, MCF-7, ZR-75-1), an ovarian carcinoma cell line (OV-D) and the HL-60 promyeloctyic leukemia cell line were maintained in exponential phase (M. Abe et al., J. Immunol. 139: 257-261, 1987; E. Friedman et al., Cancer Res. 46, 5189-5194, 1986; E. Sariban et al, Nature 316, 64-66, 1985). BT-20 is ATCC No. HTB, 19, T47D is ATCC NO. HTB 133, MCF-7 is ATCC No. HTB 22, ZR-75-1 is ATCC No. ATC CRL 1500, and HL-60 is ATCC No. ATC CCL 240 at the American Type Culture Collection, Rockville, Md. High molecular weight DNA and total cellular RNA were isolated by the guanidine isothiocyanate/cesium chloride method (L. G. Davis et al., Basic Methods in Molecular Biology, Elseview, N.Y., p. 130-135, 1986). The DNA was digested with EcoRI, PstI or HindIII. The DNA fragments were separated by electrophoresis in 0.6% agarose gels and then transferred to nylong membranes. The prehybridization and hybridization conditions were as described in the Zeta Probe manual (Bio-Rad Laboratories, Richmond, Calif.). The purified RNA (20 μg) was analyzed by electrophoresis in 1% agarose-formaldehyde gels followed by transfer to nitrocellulose paper. The hybridization conditions were as described previously (E. Sariban et al., Nature, 316, 64-66, 1985). The pDF9.3 cDNA probe was labeled with [ 32 P] dCTP (Amersham, Arlington Heights, Ill.) by the random primer method (A. P. Beinburg et al., Anal. Biochem. 132, 6-13, 1984) to a specific activity of approximately 10 9 cpm/μg DNA.
Immunoblot Analysis
Cells were suspended in phosphate buffered saline (PBS) (pH 7.4), 0.2 mM phenylmethylsulfonyl fluoride and aprotinin (0.015 tryspin inhibitor units/ml). the suspensions were sonicated and protein concentration was determined by the Bio-Rad protein assay (Bio-Rad Laboratories). The protein samples (100 μg) were analyzed by electrophoresis in SDS/3-15% gradient polyacrylamide gels and transferred to nitrocellulose paper (H. Towbin et al., Proc. Natl. Acad. Sci. USA 76: 4350-4354 1979). The nitrocellulose filters were washed with 5% bovine serum albumin in PBS for 1h at room temperature (25° C.), incubated with MAb DF3 (0.25 μg/ml) for 2h, rabbit anti-mouse Ig for 1h and then 125 I-labeled protein A for 2h. The filters were washed five times, dried and exposed to x-ray film.
Nucleotide Sequence Analysis
The 309 bp pDF9.3 cDNA insert was subcloned into the EcoRI site of E. coli phage M13mp8 and M23mp9. The DNA sequence was determined by sequencing both strands via the dideoxy chain termination method (F. Sanger et al., Proc. Natl. Acad. Sci. U.S.A. 74, 5463-5467, 1987) using Klenow fragment DNA polymerase I (New England Biolabs, Beverly, Mass.) and [alpha- 35 S]dCTP (Amersham).
EXAMPLES
Isolation and characterization of cDNA clones coding for DF3 antigen
MAb DF3 was used to screen the lambda gt11 library prepared from MCF-7 cells. Screening of 800,000 plaques yielded three positive clones which were further purified by repeated antibody screenings. Physical mapping showed that each of these recombinant clones contained inserts of similar size and that they had similar restriction maps (data not shown). One clone, designated pDF9.3 was characterized further. A beta-galactosidase fusion protein was prepared by infecting E. coli Y1089 with pDF9.3 and then analyzed by immunoblotting. The lambda gt11 lysogen produced a protein corresponding in molecular weight and antigenicity to beta-galactosidase (FIG. 1, Lane 1). MAB DF3 was unreactive with beta-galactosidase and other antigens present in the bacterial lysate (data not shown). In contrast, the recombinant pDF9.3 lysogen produced a fusion protein with an estimated mass of 126 kd which reacted with both MAb DF3 (FIG. 1, Lane 2) and the anti-beta-galactosidase antibody (data not shown).
Competition assays were also performed to further confirm that the epitope expressed by pDF9.3 shares homology with that identified by MAb DF3 on the DF3 glycoprotein. Thus, MAb DF3 was preincubated with purified DF3 antigen (M. Abe et al., J. Immonol. 139: 257-261, 1987) before immunoblot analysis of the pDF9.3 fusion protein. Preincubation of MAb DF3 with increasing amounts of purified DF3 antigen progressively inhibited reactivity of the antibody with the fusion protein (FIG. 1, Lanes 3-5). This finding indicates that the epitope on the fusion protein originates from the same reading frame that codes for the DF3 epitope.
Southern Blot Analysis of Genomic DNA
Identification of the cDNA was further studied by Southern blot hybridizations using 32 P-labeled pDF9.3 prepared by subcloning the 309 bp insert into the EcoRI site of pUC8. Southern blot analysis of gemonic DNAs from the human tumor cell lines digested with EcoRI, PstI, and HindIII are shown in FIG. 2. Hybridization of the 309 bp cDNA with the EcoRI and PstI DNA digests revealed restriction fragment length polymorphisms. The EcoRI digest yielded two fragments ranging from 7 to 12 kb in size for DNAs from each of the cell lines except BT-20. [In FIG. 2b, for BT-20, a faint band migrated the same distance as the approximately 3.0 kb band from MCF-7 cells.] Similar findings were obtained with the PstI fragments which ranged in size from 3.5 to 6 kb. The single EcoRI and PstI restriction fragments obtained with BT-20 DNA indicates the presence of two alleles of identical size or only a single allele. In contrast to these results, digestion of each of the DNA preparations with HindIII revealed only a single fragment of 23 kb. This finding would correspond to the absence of a HindIII restriction site in the alleles identified by pDF9.3.
Northern and Western Blot Analysis of DF3 Expression
Total cellulor RNA was prepared from each of the human tumor cell lines and monitored by Northern analysis for transcripts which hybridized to the pDF9.3 probe. A single 4.7 kb mRNA was detectable in BT-20 cells (FIG. 3A). In contrast, cell lines derived from the other breast and ovarian carcinomas expressed two transcripts which ranged in size from approximately 4.1 to 7.1 kb (FIG. 3A). Furthermore, no hybridization was detectable with RNA from HL-60 cells (FIG. 3A).
These findings by Northern blot analysis were compared to those obtained by immunoblotting with MAb DF3 and extracts prepared from each of the cell lines. The results indicated concordance in patterns of expression at the RNA and protein levels (FIG. 3B). Thus, BT-20 cells expressed a single transcript and a single DF3 glycoprotein, while the other epithelial cell lines expressed two transcripts and two DF3 antigens. Moreover, HL-60 cells had no detectable RNA and no detectable MAb DF3 reactive species. These findings further suggested that the transcripts detected by Northern analysis code for the DF3 core protein and that the size of these transcripts determines the size of the MAb DF3 reactive glycoproteins.
Nucleotide Sequence of pDF9.3
The reactivity of the fusion protein with MAb DF3 indicated that the cDNA insert contained an open reading frame which encodes for the DF3 epitope. The nucleotide sequence of pDF9.3 was found to be highly rich (85%) in GC base pairs (FIG. 4). Moreover, the sequence was found to consist entirely of 60 bp tandem repeats. These repeats were nearly identical with the exception of some transversions (FIG. 4). Furthermore, comparison of the pDF9.3 sequences with that of all genese with known sequences failed to reveal any significant homology.
Other Systems for the Invention
Prokaryotic organisms, especially bacteria, are preferred organisms for expressing the DF3 polypeptide. Many bacterial expression systems are well documented.
Techniques for taking a DNA sequence of known nucleotide sequence, such as pDF9.3, and inserting it into a plasmid or other DNA molecule so that its expression can be achieved, and preferably regulated, are well established.
Techniques for allowing an antibody to react with an antigen are well documented.
Expression of an Amino Acid Sequence from pDF9.3
Insertion of pDF9.3 into a plasmid can result in the expression of any one of six amino acid sequences, depending on which of its two DNA strands is in the same strand as the controlling plasmid promoter and depending upon which one of the three possible reading frames for pDF9.3 is in phase with the initiation codon for the polypeptide that is fused to the pDF9.3-coded polypeptide. Northern blot analyses, done using RNA with sequences contained in one strand of pDF9.3 and then using RNA with sequences from the complementary pDF9.3 strand, and using RNA from BT-20 cells containing pDF9.3, demonstrated that the RNA strand depicted in FIG. 4 is the one which is transcribed into the RNA that is translated into the DF3 polypeptide. Furthermore, polypeptides that reacted with anti-DF3 antibody were detected in about half of E. coli cells that were infected with lambda gt11 phage containing, at its EcoRI site, pDF9.3 cDNA. As a result, based on known base sequences of lamba gt11, it was deduced that pDF9.3 DNA codes for a polypeptide that is capable of reacting with anti-DF3 antibody and that contains the following four closely related amino acid sequences:
1) ALA PRO FLU SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, and
2) ALA PRO ASP THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER, and
3) ALA PRO GLU THR ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL SER, and
4) ALA PRO ASP SER ARG PRO ALA PRO GLY SER THR ALA PRO PRO ALA HIS GLY VAL THR SER.
DISCUSSION
It has previously been demonstrated that DF3 antigen in human breast tumors and milk is comprised of mucin-like glycoproteins with molecular weights ranging from 300 to over 450 kd (H. Sekine et al., J. Immunol 135, 3610-3615, 1985; M. Abe et al., J. Cell Physiol. 126, 126-132, 1986). DF3 antigenicity was found to be sensitive to both neuraminidase and proteases (H. Sekine et al., J. Immunol 135, 3610-3615, 1985; M. Abe et al., J. Cell Physiol. 126, 126-132, 1986). These results suggested that sialyl oligosaccharides on a peptide backtone are required for DF3 antigenicity. In the present study, MAb DF3 positive plaques were isolated using a lambda gt11 cDNA library prepared from human MCF-7 breast carcinoma cells. The MFC-7 cells have been previously shown to express DF3 antigen (M. Abe et al., J. Immunol. 139: 257-261, 1987). One of the positive lambda clones (pDF9.3) was further purified and found to produce a beta-galactosidase fusion protein which specifically reacted with MAb DF3. The reactivity of MAb DF3 with plaques from this expression library and the fusion protein indicates that this antibody reacts with the core protein of DF3 antigen. However, DF3 antigenicity has also been shown to be sensitive to neuraminidase (H. Sekine et al., J. Immunol 135, 3510-3615, 1985; M. Abe et al., J. Cell Physiol. 126, 126-132, 1986). Thus, MAb DF3 binding to the protein may be enhanced by the presence of glycosidic linkages.
Although patients with breast cancer and certain other carcinomas have higher levels of circulating DF3 antigen, the electrophoretic mobilities of the MAb DF3 reactive species are similar to those in normal subjects (D. Hayes et al., J. Clin. Invest. 75, 1671-1678, 1985;H. Sekine et al., J. Clin. Oncol. 3: 1355-1363, 1985). Indeed, more recent results have indicated that the variation in electrophoretic mobility of circulating DF3 antigen among family members is related to a genetically determined polymorphism (D. Hayes et al.; Blood, 1988, 71:436). The present findings support this genetic polymorphism. Thus, considerable fragment size variation was observed after hybridization of the pDF9.3 probe to EcoRI and PstI restriction digests of DNA from different cell lines. The EcoRI restriction fragments varied from 7 to 12 kb in size and the different cells had only one or two bands. Furthermore, the PstI fragments varied from 3.5 to 6 kb and each DNA preparation similarly yielded one or two bands. In contrast, hybridization of pDF9.3 probe to HindIII DNA digests revealed only one 23 kb band and indicated that this restriction enzyme has digestion sites outside the region identified by this probe.
The variation is allele size identified with pDF9.3 correlated with the presence of different sized transcripts. Thus, cells with two restriction fragments in the EcoRI or PstI DNA digests had two different sized mRNAs. In contrast, BT-20 cells had only one detectable restriction fragment in these DNA digests and expressed only one transcript. This relationship also extended to the variation in electrophoretic mobilities of DF3 antigen. BT-20 cells expressed a single MAb DF3 reactive species, while the other epithelial tumor cells expressed two DF3 antigens. Moreoever, HL-60 cells had no detectable transcripts and no detectable DF3 antigen. Taken together, these findings support out previous findings that the heterogeneity of DF3 antigen production is controlled by multiple alleles at a single locus expressed in an autosomal codominant fashion (D. Hayes et al.; Blood, 1987, in press).
The nucleotide sequence analysis of pDF9.3 provides a possible explanation for the variability in restriction fragment size and the polymorphic patterns of DF3 expression. In this regard, we have identificed a 309 bp cDNA clone which consists of multiple tandem repeats. These repeats are GC rich and encompass 60 bp. Variation in the size of the DF3 alleles could thus be due to differences in the number of these repeats and occur as a result of unequal crossing-over events. The presence of closely related repeates may also explain the finding that MAb DF3 binds to two or more epitopes in the same DF3 molecules (D. Hayes et al., J. Clin. Invest. 75, 1671-1678, 1985). The total number of these repeats in the full length cDNA, however, requires further investigation.
Similar variable tandem repeats have been reported for other genes including those coding for carcinoembryonic antigen (W. Zimmerman et al., Proc. Natl. Acad. Sci. U.S.A. 84, 2960-2964, 1987), insulin (Q. I. Bell et al., Nature 295: 31-35, 1982), alpha- and beta-globulin (D. R. Higgs et al., Nucleic Acid Res. 9, 4213-4224, 1981; R. A. Spritz, Nucleic Acid Res. 9, 5037-5047, 1981), Epstein Barr virus (S. H. Speck et al., Proc. Natl. Acad. Sci. U.S.A. 83 9298-9310, 1986), c-Ha-ras (D. J. Capon et al., Nature 302, 33-37, 1983), and a hypervariable minisatellite family (A. J. Jeffries et al., Nature 314: 67-73, 1985). Furthermore, the human complement receptor (CR1) gene consists of homologous repeats approximately 1.6 kb in size (V. M. Holers et al., Proc. Natl. Acad. Sci. U.S.A. 84, 2459-2463, 1987). Allelic variants of CR1 differ by 1.6 kb and also correlate with variations in size of both the CR1 transcripts and products (V. M. Holers et al., Proc. Natl. Acad. Sci. U.S.A. 84, 2459-2463, 1987). The lengths of most internal repeats, however, range between 120 and 300 bp (W. L. Li in Evolution of Genes and Proteins, Eds. M. Nei et al.; Sinaur, Sunderland, Mass. p. 14-37, 1983). Moreover, homology of the internal repeats for many vertebrate proteins ranges between only 20 and 50% (W. L. Li in Evolution of Genes and Proteins. Eds. M. Nei et al., Sinaur, Sunderland, Mass., p. 14-37, 1983). In contrast, the internal repeats identified in the present study exhibit a particularly high degree of homology. This finding could suggest that the DF3 gene solved more recently by duplication of a primordial gene or by exon shuffling. | A carbohydrate-free polypeptide coded for by a human DNA sequence of 309 nucleotides is immunologically reactive with monoclonal antibody against the human DF3 breast carcinoma-associated antigen. The nucleotide sequence is also useful as a probe to reveal restriction fragment length polymorphisms in human DNA. | 2 |
PRIORITY STATEMENT
This is a continuation of U.S. patent application Ser. No. 12/700,672, entitled “Interview Programming For an HVAC Controller”, filed Feb. 4, 2010, which is a continuation of U.S. patent application Ser. No. 12/424,931, entitled “HVAC Controller With Guided Schedule Programming”, filed Apr. 16, 2009, which is a continuation of U.S. patent application Ser. No. 11/421,833, entitled “Natural Language Installer Setup For Controller”, filed Jun. 2, 2006, now U.S. Pat. No. 7,634,504, which is a continuation-in-part of U.S. patent application Ser. No. 10/726,245, entitled “Controller Interface With Interview Programming”, filed on Dec. 2, 2003, now U.S. Pat. No. 7,181,317.
FIELD
The present invention relates generally to the field of programmable controllers for homes and/or buildings and their related grounds. More specifically, the present invention relates to simplified interfaces for such controllers having interview programming capabilities.
BACKGROUND
Controllers are used on a wide variety of devices and systems for controlling various functions in homes and/or buildings and their related grounds. Some controllers have schedule programming that modifies device parameter set points as a function of date and/or time. Some such device or system controllers that utilize schedule programming for controlling various functions in homes and/or buildings and their related grounds include, for example, HVAC controllers, water heater controllers, water softener controllers, security system controllers, lawn sprinkler controllers, and lighting system controllers.
HVAC controllers, for example, are employed to monitor and, if necessary, control various environmental conditions within a home, office, or other enclosed space. Such devices are useful, for example, in regulating any number of environmental conditions with a particular space including for example, temperature, humidity, venting, air quality, etc. The controller may include a microprocessor that interacts with other components in the system. For example, in many modern thermostats for use in the home, a controller unit equipped with temperature and humidity sensing capabilities may be provided to interact with a heater, blower, flue vent, air compressor, humidifier and/or other components, to control the temperature and humidity levels at various locations within the home. A sensor located within the controller unit and/or one or more remote sensors may be employed to sense when the temperature or humidity reaches a certain threshold level, causing the controller unit to send a signal to activate or deactivate one or more components in the system.
The controller may be equipped with an interface that allows the user to monitor and adjust the environmental conditions at one or more locations within the building. With more modern designs, the interface typically includes a liquid crystal display (LCD) panel inset within a housing that contains the microprocessor as well as other components of the controller. In some designs, the interface may permit the user to program the controller to activate on a certain schedule determined by the user. For example, the interface may include a separate menu routine that permits the user to change the temperature at one or more times during a particular day. Once the settings for that day have been programmed, the user can then repeat the process to change the settings for the other remaining days.
With more modern designs, the programmable controller may include a feature that allows the user to set a separate schedule for weekday and weekend use, or to copy the settings for a particular day and then apply them towards other selected days of the week. While these designs allow the user to copy settings from one day to another, a number of steps are often required to establish a program, adding to the complexity of the interface. In some cases, the interface may not permit the user to select multiple days outside of the normal weekday/weekend scheme. In other cases, the interface is simply too complex to be conveniently used to program a temperature scheme and is simply by-passed or not programmed by the user. Accordingly, there is an ongoing need in the art to decrease the time and complexity associated with programming a multi-day schedule in a programmable controller.
During the installation process, the steps required to program the controller to operate with other system components can also add to the time and complexity associated with configuring the controller. Typically, programming of the controller is accomplished by entering in numeric codes via a fixed segment user interface, by manually setting jumper switches on a circuit board, or by adjusting screws or potentiometers on a circuit board. In some cases, the codes or settings used to program the controller are obtained from a manual or table which must be consulted by the installer during the installation process. For example, to configure an HVAC system having a multistage heat pump, the controller may require the installer to enter a numeric or alphanumeric code (e.g. 91199) from a manual or table in order to program the controller to properly operate the various stages of the heat pump. Such process of referring to a manual or table of codes is not often intuitive to the user, and requires the user to store the manual in a safe place for subsequent use. Accordingly, there is also an ongoing need in the art to decrease the time and complexity associated with programming the controller during the installation process.
SUMMARY
Generally, the present invention pertains to simplified interfaces for controllers having interview programming capabilities.
In one illustrative embodiment, a method of programming a schedule of a controller having a user interface is described. The illustrative method includes the steps of providing one or more interview questions to a user via the user interface; accepting one or more user responses to the one or more interview questions from the user via the user interface; and creating and/or modifying or building a schedule based on the user responses.
In another illustrative embodiment, a method of programming configuration information within a controller is further described. An illustrative method can include the steps of providing one or more interview questions to a user via a user interface, prompting the user to selected between at least two answers simultaneously displayed on the user interface, accepting one or more user responses to the interview questions via the user interface, and modifying the operational parameters of the controller and/or one or more components controlled by the controlled based at least in part on the user responses. The interview questions can include at least one question relating to the installation or setup of the controller as well as any components controlled by the controller.
An illustrative controller having interview programming capabilities can include an interview question generator adapted to generate a number of interview questions relating to the installation or setup of the controller and/or any components controlled by the controller, a user interface including a display screen adapted to display interview questions to a user along with at least two answers for each interview question, and a memory unit for storing operational parameters within the controller based at least in part on the user responses to the interview questions.
The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures, Detailed Description and Examples which follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
FIG. 1 is a flow diagram of an illustrative HVAC interview program;
FIG. 2 is a block diagram of the illustrative HVAC interview program shown in FIG. 1 ;
FIG. 3 is a flow diagram of another illustrative HVAC interview program;
FIG. 4A is a block diagram of the illustrative HVAC interview program shown in FIG. 3 ;
FIG. 4B is an illustrative partial block diagram of the block diagram shown in FIG. 4A ;
FIG. 5 is a flow diagram of another illustrative HVAC interview program;
FIG. 6 is a block diagram of the illustrative HVAC interview program shown in FIG. 5 ;
FIGS. 7A-C are flow diagrams of another illustrative HVAC interview program;
FIGS. 8A-T are schematic drawings of an illustrative HVAC interface showing an embodiment of the flow diagram of the illustrative HVAC interview program shown in FIG. 7 ;
FIG. 9 is a block diagram of an illustrative HVAC system including a programmable controller having interview capabilities for configuring one or more HVAC components;
FIG. 10 is a block diagram showing the controller and user interface of FIG. 9 ;
FIG. 11 is a flow diagram showing several illustrative interview questions and answers that can be provided by the interview question generator of FIG. 10 ;
FIG. 12 is a flow diagram of an illustrative method of programming configuration information within a controller; and
FIGS. 13A-13J are schematic drawings of an illustrative user interface showing an illustrative implementation of the flow diagram depicted in FIG. 12 .
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION
The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
Generally, the present invention pertains to simplified interfaces for controllers having interview programming capabilities. These controllers can be used in a variety of systems such as, for example, HVAC systems, water heater systems, water softener systems, sprinkler systems, security systems, lighting systems, and the like. The Figures depict HVAC controllers. While the present invention is not so limited, an appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.
FIG. 1 is a flow diagram of an illustrative HVAC interview program 100 . The flow diagram starts at a normal thermostat operation block 110 . Normal thermostat operation block 110 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 120 , 130 provides one or more interview questions to a user via the user interface. The user interface can accept one or more responses to the one or more interview questions from the user via the user interface. The schedule is then built or modified, in some cases by adding or modifying one or more schedule parameters 140 , 150 , based on the user responses provided via the user interface. Once the schedule parameters 140 , 150 are modified, the controller can return to the normal operation block 110 , and follow the new schedule.
In some embodiments, the interview scheduling blocks 120 and 130 can provide interview questions that elicit an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. Alternatively, or in addition, the interview scheduling blocks 120 , and 130 can provide include interview questions that allow a user to select one (or more) answers from a predetermined list of answers.
In some embodiments, these interview questions can solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points such as, for example, the interview question may ask “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 120 preferably includes questions that are natural language questions, which may be phrases that have one, two, three, four, five, six, or seven or more words, although this is not required in all embodiments.
Alternatively, or in addition, interview scheduling block 130 can provide interview questions that require a numerical user response. For example, these interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 120 described above. Interview block 130 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. Like interview schedule block 120 above, interview scheduling block 130 can include questions that are natural language questions, which may be phrases that have one, two, three, four, five, six, or seven or more words, although this is not required in all embodiments.
The interview scheduling blocks 120 and 130 can provide one or more interview questions about, for example, which weekdays will have the same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in summer?, and/or what a comfortable sleeping temperature is in winter?
Alternatively, or in addition, the interview scheduling blocks 120 and 130 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
Alternatively, or in addition, once an initial schedule has been built, the interview scheduling blocks 120 , and 130 can display a previous answer that was accepted by the user interface based on the prior built schedule. This illustrative feature can provide the user with a convenient option to select and alter only the schedule parameters 140 , 150 that the user desires to modify. This feature can be utilized in all illustrative embodiments described herein, however it is not required.
FIG. 2 is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 1 . Controller 200 includes a control module 210 that can be a microprocessor or the like. The control module 210 communicates with a user interface 220 , and can include an interview question generator 225 , a response acceptor 240 and a programmable schedule 250 . The control module 210 can also generate a control signal 260 to a device (not shown), such as an HVAC system or device.
In an illustrative embodiment, the interview question generator 225 provides interview questions, such as those described above, to the user interface 220 . The user interface 220 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, and/or an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 225 by any suitable mechanism, such as by pressing a schedule button on a touchscreen of the user interface 220 . Alternatively, or in addition, the controller 210 may activate the interview question generator 225 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to questions posed by the interview question generator 225 , the user can enter one or more user responses into the user interface 220 . The response acceptor 240 accepts the user responses and provides the response to the programmable schedule 250 . In some embodiments, the programmable schedule 250 has a number of time and temperature set points that can be entered or modified by the response acceptor 240 . Once the schedule is built and/or modified, a control signal 260 is generated by the control module 210 based on the programmable schedule 250 .
FIG. 3 is a flow diagram of another illustrative HVAC interview program 300 . The flow diagram starts at a normal thermostat operation block 310 . Normal thermostat operation block 310 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 325 provides one or more interview questions to a user via a user interface. The user interface then accepts one or more responses to the one or more interview questions from the user via the user interface. A user response translator 360 translates the one or more user responses to form a translated response. One or more schedule parameters 370 are then modified based on the translated responses from the response translator 360 . Once the schedule parameters 370 are modified, the controller can return to the normal operation block 310 .
In some embodiments, the interview scheduling block 325 includes interview questions that require an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. In addition, the interview questions can solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points. For example, the interview question may ask “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 325 can include questions that are natural language questions such as, for example, phrases that can have one, two, three, four, five, six, or seven or more words.
In an illustrative embodiment, interview scheduling block 325 may also provide interview questions that require a numerical user response. These interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 325 described above. The interview block 325 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. The interview scheduling block 325 can include questions that are natural language questions such as, for example, phrases that can have one, two, three, four, five, six, or seven or more words.
In the illustrative embodiment, the interview scheduling block 325 can also provide one or more interview questions related to, for example, which weekdays will have the same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in the summer?, or what a comfortable sleeping temperature is in the winter?
The response translator 360 can translate the user responses to create appropriate schedule parameters 370 that help define the schedule of the controller. That is, the response translator 360 applies the user responses to one or more interview questions to establish the controller schedule. For example, the response translator 360 can take an affirmative user response to the interview question, “Do you want the same schedule for Saturday and Sunday?” and correlate with the interview question, “What temperature do you like when the heat is on?” to establish the schedule parameters for the heating temperature during at least selected periods on Saturday and Sunday.
Alternatively, or in addition, the interview scheduling block 325 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
FIG. 4A is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 3 . Controller 400 includes a control module 410 that can be a microprocessor or the like. The control module 410 communicates with a user interface 420 , and may include an interview question generator 425 , a response acceptor 440 , a response translator 460 , and a programmable schedule 470 . The control module 410 can also generate a control signal 465 to a device (not shown), such as an HVAC system or device.
In the illustrative embodiment, the interview question generator 435 provides interview questions, such as those described above, to the user interface 420 . The user interface 420 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, and/or an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 435 by any suitable mechanism, such as by pressing a mechanical schedule button on the controller, touching an appropriate region of a touchscreen, voice activation, etc. Alternatively, or in addition, the controller 410 may activate the interview question generator 425 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to questions posed by the interview question generator 425 , the user can enter one or more user responses into the user interface 420 . The response acceptor 440 accepts the user responses and provides the response to the response translator 460 . The response translator 460 provides a translated response to a programmable schedule 470 . In some embodiments, the programmable schedule 470 has a number of time and temperature set points that can be entered or modified by the response translator 470 . Once the schedule is built and/or modified a control signal 465 is generated by the control module 410 based on the programmable schedule 470 .
FIG. 4B is an illustrative partial block diagram of the block diagram shown in FIG. 4A showing one embodiment of the interaction of the interview question generator 425 , response acceptor 440 , response translator 460 and programmable schedule 470 . The illustrative programmable schedule 470 has a plurality of cells such as, for example, a Saturday wake cell 471 , a Sunday wake cell 472 , a Saturday sleep cell 473 , and a Sunday sleep cell 474 . In this embodiment, each cell 471 , 472 , 473 , 474 may include a number of schedule parameters such as, for example, a start time, a heat temperature and a cool temperature.
Interview questions 425 are posed to the user. As shown in the illustrative example: an interview question 425 of “Same schedule for Saturday and Sunday?” elicits an user response 440 of “YES”; an interview question 425 of “For the weekend, is someone home all day?” elicits an user response 440 of “YES”; an interview question 425 of “What time does the first person wake up?” elicits an user response 440 of “7:00 a.m.”; an interview question 425 of “What time does the last person go to sleep?” elicits an user response 440 of “10:00 p.m.”; an interview question 425 of “What temperature is comfortable when the heat is on?” elicits an user response 440 of “72° F.”; an interview question 425 of “What temperature is comfortable when the air conditioning is on?” elicits an user response 440 of “68° F.”; an interview question 425 of “What is a comfortable sleeping temperature in summer?” elicits an user response 440 of “67° F.”; and an interview question 425 of “What is a comfortable sleeping temperature in winter?” elicits an user response 440 of “65° F.”.
In the illustrative embodiment, the response translator 460 accepts the user responses provided in block 440 . The response translator 460 then builds and/or modifies the programmable schedule 470 . In the illustrative embodiment, each cell 471 , 472 , 473 , 474 includes a start time, a heat temperature and a cool temperature. The Saturday wake cell 471 and the Sunday wake cell 472 has a start time of 7:00 a.m., a heat temperature of 72° F., and a cool temperature of 68° F., all of the times and temperatures are provided by the response translator. The Saturday sleep cell 473 and the Sunday sleep cell 474 has a start time of 10:00 p.m., a heat temperature of 65° F., and a cool temperature of 67° F., all of the times and temperatures are provided by the response translator.
In this illustrative embodiment, the response translator 460 takes a plurality of user responses 440 to the interview questions 425 and builds and/or modifies a plurality of schedule parameters. The Saturday and Sunday Leave and Return cells 475 , 476 , 477 , and 478 are ignored and/or zeroed out by the response translator 460 since they are not required based on the user responses 425 for this example.
FIG. 5 is a flow diagram of another illustrative HVAC interview program 500 . The flow diagram starts at a normal thermostat operation block 510 . Normal thermostat operation block 510 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 525 provides one or more interview questions to a user via a user interface. The user interface then accepts one or more responses to the one or more interview questions from the user via the user interface. A sufficient information block 560 determines if enough information has been solicited from the user response to the interview questions sufficient to build or modify the schedule at block 570 . If not, the interview scheduling block 525 provides another interview question to the user via the user interface. If the sufficient information block 560 determines that enough information has been solicited, then the schedule is built or modified by the modify schedule block 570 . Once the schedule is built or modified by the modify schedule block 570 , the controller can return to the normal operation block 510 .
The sufficient information block 560 can, for example, help ensure that a sufficient number of schedule parameters are defined, such as, for example, a start time, a heating temperature and a cooling temperature for a particular time period such as, for example, a specific day or group of days wake period, leave period, return period and/or sleep period, as shown in FIG. 4B .
In some embodiments, the interview scheduling block 525 provides a number of predetermined interview questions in a predetermined sequential order. The number of questions or queries may be adapted to collect information from the user responses to generate at least a portion of the schedule parameters.
Like above, the interview scheduling block 525 can include interview questions that require an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. For example, interview scheduling block 525 can provide interview questions solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points such as, for example, “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 525 can include questions that are natural language questions which can be phrases that have one, two, three, four, five, six, or seven or more words in length.
Alternatively or in addition, interview scheduling block 525 can provide interview questions that require a numerical user response. For example, these interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 525 described above. The interview block 525 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. Again, the interview scheduling block 525 can include questions that are natural language questions that can be phrases which can be one, two, three, four, five, six, seven or more words, although this is not required in all embodiments.
The interview scheduling block 525 may also provide one or more interview questions about, which weekdays will have a same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in the summer?, or what a comfortable sleeping temperature is in the winter?
Alternatively, or in addition, the interview scheduling block 525 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
FIG. 6 is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 5 . Controller 600 includes a control module 610 that can be a microprocessor or the like. The control module 610 communicates with a user interface 620 , and may include an interview question generator 625 , a response acceptor 640 and a programmable schedule 650 . The control module 610 can also generate a control signal 660 to a device (not shown), such as an HVAC system or device.
In the illustrative embodiment, the interview question generator 625 provides interview questions, such as those described above, to the user interface 620 . The user interface 620 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 625 by any suitable mechanism, such as by pressing a schedule button on a touchscreen of the user interface 620 . Alternatively, or in addition, the controller 610 may activate the interview question generator 625 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to the questions posed by the interview question generator 625 , the user can enter one or more user responses into the user interface 620 . The response acceptor 640 accepts the user responses and provides the responses to the programmable schedule 650 if it determines that sufficient information has been provided by the user responses to establish a program schedule. If not, the response acceptor 640 instructs the interview question generator 625 to provide another interview question to the user via the user interface 620 . Once the response acceptor 640 determines that sufficient information has been provided by the user to establish a program schedule 650 the program schedule 650 is built and/or modified. In some embodiments, the programmable schedule 650 has a number of time and temperature set points that can be entered or modified by the response acceptor 640 . Once the programmable schedule 650 is built and/or modified, a control signal 660 is generated by the control module 610 based on the programmable schedule 650 .
FIGS. 7A-C are flow diagrams of another illustrative HVAC interview program 700 . The flow diagram starts at a normal thermostat operation block 710 , but this is not required in all embodiments. In the illustrative embodiment, the interview program 700 can be initiated by pressing a program initiation button or key such as, for example, an “EZ Schedule” button.
The program can begin by asking whether the user wants the same schedule to be used for every day of the week, as shown at block 720 . If the user responds with a “YES” response, then the program can move to ask context questions for that group of days, as shown at block 725 , which may set the schedule for the week assuming the same schedule for every 24 hour period or day. If the user responds with a “NO” response, the program may ask the user if the same schedule applies to both weekend days, Saturday and Sunday, as shown at block 730 . If the user responds with a “YES” response, then the program can ask if the user wants two schedules, one for weekdays and one for weekends, as shown at block 735 . A “YES response to block 735 can move the program to asking context questions for a weekend group of days and a weekdays group of days, as shown at block 725 , to set the schedule for the week assuming a first schedule for weekend days and a second schedule for weekdays. A “NO” response to block 730 can cause the program to ask whether the user wants three schedules including a weekday schedule, a Saturday schedule, and a Sunday schedule, as shown at block 740 . A “YES” response to block 740 moves the program to asking context questions for a week day group of days schedule, a Saturday schedule and a Sunday schedule, as shown at block 725 , to set the schedule for the week assuming a first schedule for weekdays, and a second schedule for Saturday and a third schedule for Sundays. A “NO” response to either block 740 or block 735 moves the program to asking the user to group each day of the seven days of the week into similar schedule groupings until all days are assigned to one group, as shown at block 750 . The program can ask if all days are assigned at block 755 , with a “NO” response returning the user to block 750 to assign a non-assigned day or days until all days have been assigned. Once all days have been assigned to a group, the program moves to asking context questions for each group of days schedule, as shown at block 725 , to set the schedule for the each grouping of days assuming a first schedule for a first group, a second schedule for a second group, a third schedule for a third group and so on until all groupings of days are scheduled.
The program 700 can ask a variety of context sensitive question to determine the desired schedule for each grouping of days identified by the program 700 above. For example, and as shown in FIG. 7B , the program 700 can inquire whether someone is home all day, as shown at block 760 . If the user enters a “YES” response to block 760 , the program can ask when the first person gets and request that the user to enter a wake time, as shown at block 770 . Then the program 700 can ask when the last person goes to sleep and request that the user to enter a sleep time, as shown at block 780 . If the user enters a “NO” response to block 760 , the program can ask when the first person gets up, and request that the user to enter a wake time, as shown at block 761 . Then the program can ask what time the first person leaves home and request that the user enter a leave time, as shown at block 762 . The program can also ask when the last person gets home for the day, and request the user to enter a return time, as shown at block 763 . The program can also ask when the last person goes to sleep, and request that the user enter a sleep time, as shown at block 764 . Once all the above information has been entered by the user for each grouping of days, the program may move to an end block 781 .
The program 700 can then request information from the user regarding comfortable awake, sleeping and away temperatures. For example, and referring to FIG. 7C , the program can request that the user enter a comfortable temperature when the heat is on, as shown at block 790 . The temperature information received in block 790 can be automatically inserted into a program schedule for each grouping of days to set the wake heat and return heat set points. The program can also request that the user enter a comfortable temperature when the air conditioning is on, as shown at block 791 . This information can be automatically inserted into a program schedule for each grouping of days to set the wake cool and return cool set points. This illustrative program can also request that the user enter a comfortable summer sleeping temperature, as shown at block 792 . This information can be automatically inserted into a program schedule for each grouping of days to set the sleep cool set point. The program can also request that the user enter a comfortable winter sleeping temperature, as shown at block 793 . This information can be automatically inserted into a program schedule for each grouping of days to set the sleep heat set point. The program can also request that the user to enter an energy savings offset at block 794 . This information can be automatically inserted into a program schedule for each grouping of days to set the leave cool and leave heat set points.
In some embodiments, the program 700 can allow the user to request a schedule review at block 795 , which can allow the user to review the built or modified schedule, as shown at block 796 . If the user does not wish to review the schedule or when the user is done reviewing the schedule, the program returns to normal thermostat operation block 710 under the newly built or modified schedule.
FIGS. 8A-T are schematic drawings of an illustrative HVAC interface 800 showing an illustrative embodiment of the flow diagram of the HVAC interview program shown in FIGS. 7A-7C . The schematic screen shots are taken in sequential order based on the user selections shown in each screen shot. At FIG. 8A , a user 810 selects an “EZ Schedule” 801 button located on the interface 800 to begin the interview scheduling program.
At FIG. 8B , the program asks the user 810 , via the interface 800 , if the user 810 wants the same schedule to apply to every day of the week. The user 810 is shown selecting a “NO” response 802 .
At FIG. 8C , the program asks the user 810 , via the interface 800 , if the user 810 wants Saturday and Sunday to follow the same schedule. The user 810 is shown selecting a “YES” response 803 .
At FIG. 8D , the program asks the user 810 , via the interface 800 , to verify the there will be two schedules, one for weekends and a second for weekdays. The user 810 is shown selecting a “YES” response 804 .
At FIG. 8E , the program asks the user 810 , via the interface 800 , whether someone will be home all day on weekdays. The user 810 is shown selecting a “NO” response 805 .
At FIG. 8F , the program asks the user 810 , via the interface 800 , to enter what time the first person wakes up on weekdays. The user 810 is shown pressing an “ENTER” button 806 after selecting a wake time.
At FIG. 8G , the program asks the user 810 , via the interface 800 , to enter what time the last person leaves the house on weekdays. The user 810 is shown pressing an “ENTER” button 807 after selecting a leave time.
At FIG. 8H , the program asks the user 810 , via the interface 800 , to enter what time the first person arrives home on weekdays. The user 810 is shown pressing an “ENTER” button 808 after selecting a return time.
At FIG. 8I , the program asks the user 810 , via the interface 800 , to enter what time the last person goes to sleep on weekdays. The user 810 is shown pressing an “ENTER” button 809 after selecting a sleep time.
At FIG. 8J , the program asks the user 810 , via the interface 800 , whether someone will be home all day on weekends. The user 810 is shown selecting a “YES” response 811 .
At FIG. 8K , the program asks the user 810 , via the interface 800 , to enter what time the first person wakes up on weekends. The user 810 is shown pressing an “ENTER” button 812 after selecting a wake time.
At FIG. 8L , the program asks the user 810 , via the interface 800 , to enter what time the last person goes to sleep on weekends. The user 810 is shown pressing an “ENTER” button 813 after selecting a sleep time.
At FIG. 8M , the program asks the user 810 , via the interface 800 , a comfort question such as, what temperature do you like when the heat is on? The user 810 is shown pressing an “ENTER” button 814 after selecting a desired temperature.
At FIG. 8N , the program asks the user 810 , via the interface 800 , a comfort question such as, what temperature do you like when the air conditioning is on? The user 810 is shown pressing an “ENTER” button 815 after selecting a desired temperature.
At FIG. 8O , the program asks the user 810 , via the interface 800 , a comfort question such as, what is a comfortable sleeping temperature in the summer? The user 810 is shown pressing an “ENTER” button 816 after selecting a desired temperature.
At FIG. 8P , the program asks the user 810 , via the interface 800 , another comfort question such as, what is a comfortable sleeping temperature in the winter? The user 810 is shown pressing an “ENTER” button 817 after selecting a desired temperature.
At FIG. 8Q , the program asks the user 810 , via the interface 800 , another comfort question such as, what energy saving offset is desired? The user 810 is shown pressing an “ENTER” button 818 after selecting a desired energy saving offset.
At FIG. 8R , the program informs the user 810 , via the interface 800 , that the schedule has been completed, and may allow the user to view a portion of the schedule or selected day groupings. The user 810 is shown pressing a “VIEW WEEKDAYS” button 819 .
At FIG. 8S , the program informs the user 810 , via the interface 800 , specifics of the selected schedule. The user 810 is shown pressing a “DONE” button 821 .
At FIG. 8T , the program displays, via the interface 800 , specifics of the currently running schedule.
Referring now to FIG. 9 , a block diagram of an illustrative HVAC system including a programmable controller having interview capabilities for configuring one or more HVAC components will now be described. The HVAC system 900 can include a programmable controller 902 in communication with a number of system components that can be activated to regulate various environmental conditions such as temperature, humidity, and air quality levels occurring within the space to be controlled. As shown in FIG. 9 , for example, the controller 902 can be connected to a heating unit 904 and cooling unit 906 that can be activated to regulate temperature. The heating unit 904 can include a boiler, furnace, heat pump, electric heater, and/or other suitable heating device. In some embodiments, the heating unit 904 can include a multistage device such as a multistage heat pump, the various stages of which can be controlled by the controller 902 . The cooling unit 906 can include an air-conditioner, heat pump, chiller, and/or other suitable cooling device which can likewise be either single staged or multistaged depending on the application.
A ventilation unit 908 such as a fan or blower equipped with one or more dampers can be employed to regulate the volume of air delivered to various locations within the controlled space. A filtration unit 910 , UV lamp unit 912 , humidifier unit 914 , and dehumidifier unit 916 can also be provided in some embodiments to regulate the air quality and moisture levels within the controlled space. One or more local and/or remote sensors 918 can be connected to the controller 902 to monitor temperature or humidity levels inside, and in some cases, outside of the space to be controlled. In some embodiments, the controller 902 can be connected to one or more other controllers 920 such as another HVAC controller for providing multi-zoned climate control. The system components can be directly connected to a corresponding I/O port or I/O pins on the controller 902 , and/or can be connected to the controller 902 via a network or the like.
The controller 902 can include a user interface 922 to permit an installer or service technician to input commands for programming the controller 902 to operate with the various system components and any other connected controllers 922 . The user interface 922 can include, for example, a touch screen, liquid crystal display (LCD) or dot matrix display, an aural interface including a speaker and microphone, a computer, or any other suitable device for sending and receiving signals to and from the controller 902 . Depending on the configuration, the user interface 922 can also include buttons, knobs, slides, a keypad, or other suitable selector means for inputting commands into the controller 902 .
FIG. 10 is a block diagram showing the controller 902 and user interface 922 of FIG. 9 in greater detail. As can be further seen in FIG. 10 , the controller 902 can include a control module 924 such as a microprocessor/CPU, a storage memory 926 , a clock 928 , and an I/O interface 930 that connects the controller 902 to the various system components in FIG. 9 . An internal sensor 932 located within the controller housing can be used to measure the temperature, humidity levels, and/or other environmental conditions occurring within the controlled space.
During installation, the control module 924 communicates with the user interface 922 to provide the installer with interview questions relating to the configuration of one or more of the system components. In the illustrative embodiment of FIG. 10 , the controller 902 includes an interview question generator 934 that prompts the installer to provide feedback to the controller 902 regarding the types of system components to be controlled, the dates and times such components are to be operated, the power or temperature levels in which such components are to be operated, the bandwidth or offsets at which such components are to be operated, the type of space to be controlled, as well as other operating parameters. Activation of the interview question generator 934 can occur, for example, by pressing an installation button on a touchscreen or keypad of the user interface 922 . Alternatively, or in addition, the controller 902 may activate the interview question generator 934 on its own when a new system component is connected to the I/O interface 930 or when additional setup information is needed or desired by the controller 902 .
Input commands received via the user interface 922 can be fed to a response acceptor 936 , which accepts the user responses to the interview questions generated by the interview question generator 934 . The response acceptor 936 can be configured to translate the user responses into operation parameters 938 that can be stored within the memory unit 926 along with other information such as prior usage, scheduling parameters, user preferences, etc. The operation parameters 938 can then be used by the controller 902 to generate control signals 940 to operate the various system components in a particular manner.
FIG. 11 is a flow chart showing several illustrative interview questions and answers that can be provided by the interview question generator of FIG. 10 . As shown in FIG. 11 , once the installation mode has been initiated, the user interface can be configured to prompt the installer to enter a desired language in which to display the interview question and answer queries, as indicated generally by block 1000 . For example, the user interface may prompt the installer to select between “English”, “Espanol”, or “Francais” as language choices. The selection of a particular language at block 1000 causes the user interface to subsequently display the interview questions and answers in that selected language.
Once the desired language is chosen, the user interface can be configured to provide interview questions pertaining to the various system components to be installed. At block 1002 , for example, the user interface can prompt the installer to select the type of equipment to be controlled by the controller. In certain embodiments, for example, the user interface can prompt the installer to select between a conventional heating/cooling unit, a heat pump, or heat only. Once the type of equipment has been selected, the user interface may then prompt the installer to enter the number of stages of heat and cool to be controlled by the controller, as indicated generally by blocks 1004 and 1006 . In some embodiments, the answers provided to the interview question at block 1004 may affect whether the user interface displays a follow-up query at block 1006 . For example, if the response to the interview question regarding the number of heat stages at block 1004 is “2”, the interview question generator may assume that there are 2 cooling stages, and thus skip the query at block 1006 .
For each stage of heat and cool, the user interface can be configured to prompt the installer to select the number of cycles per hour to be provided by the equipment, as indicated generally by block 1008 and 1010 , respectively. At block 1008 , for example, the user interface may prompt the installer to select the cycles per hour to be provided by each stage of heating selected at block 1004 . If, for example, the installer indicates at block 1004 that the equipment has 3 stages of heating, the user interface can be configured to repeat query block 1008 three separate times for each individual stage to be configured. A similar process can then be performed at block 1010 for each stage of cooling to be controlled by the controller. If at block 1004 the installer indicates that there are “0” stages of heat, the user interface can be configured to skip the query at block 1008 . In addition, if at block 1006 the installer indicates that there are “0” stages of cool, or if at block 1002 the installer indicates that the equipment is “Heat Only”, the user interface can be configured to skip the query at block 1010 .
In some embodiments, the user interface can be further configured to provide the installer with interview questions and answers that can be used to set other operational parameters within the controller. As indicated generally at block 1012 , for example, the user interface can be configured to prompt the installer to select the minimum amount of on time that the equipment operates. The user interface can further prompt the installer to select a lower and/or upper temperature limit at which the system operates, as indicated generally at blocks 1014 and 1016 , respectively. If desired, the temperature offset and proportional bandwidth of the system can be further set via query blocks 1018 and 1020 , respectively.
Although several exemplary interview questions and answers are illustrated in FIG. 11 , it should be understood that the type, number, and ordering of the interview questions and answers provided to the installer may be varied based on the type of equipment to be configured, the user's previous answers to interview questions, the number of stages to be controlled, as well as other factors. In some embodiments, the interview questions and answers can be grouped together to permit the installer to configure a particular system component or components without having to answer interview questions for the remaining system components. If, for example, the installer desires to only configure a newly installed heat pump, the user interface can be configured to provide the installer with interview questions and answers relating to the cooling unit, skipping those queries related to other components not affected by the installation.
FIG. 12 is a flow diagram of an illustrative method 1100 of programming configuration information within a controller. The method 1100 can begin generally at block 1102 in which an installation mode of the controller is activated to permit an installer to configure the controller to operate with one or more system components. Initiation of the installation mode can occur, for example, by the installer selecting an installation mode button on a touchscreen or keypad of the user interface, or automatically when the controller is activated for the first time or when one or more system components are connected to the controller.
Once the installation mode has been initiated, the controller can then be configured to provide one or more interview questions to the installer via the user interface, as indicated generally by block 1104 . The interview questions provided can be configured to solicit information from the installer regarding the type and configuration of the various system components to be controlled by the controller. In certain embodiments, for example, the interview questions can include a sequence of interview questions relating to the type of equipment to be controlled, the number of heat stages the equipment has, the number of cooling stages the equipment has, the number of cycles per hour each stage of heating requires, and the number of cycles per hour each stage of cooling requires.
In some embodiments, other interview questions pertaining to the type or configuration of the controller and/or any system components controlled by the controller can be further presented to the installer via the user interface. Examples of other interview questions can include, but are not limited to, the minimum operating time desired to operate the system, whether a pump exercise is to be enabled for any installed heat pumps, the upper temperature limit at which to operate the system, the lower temperature limit at which to operate the system, the temperature offset at which the controller operates, the proportional bandwidth of the equipment, the type and operating times of the ventilation fan employed, the type and rating of the UV lamp employed, and the type and rating of the humidifier or dehumidifier employed. Other interview questions relating to the user's preferences such as the date and time format, daylight savings options, schedule programming options, temperature display options, etc. can also be provided, if desired. It should be understood that the types of interview questions and their ordering will vary depending on the type of equipment to be controlled.
The interview questions may be provided to the installer in the form of natural language questions, which may be phrases having one or more words that prompt the installer to select between one or more answers from a predetermined list of answers. For example, the interview questions can include a question such as “What type of equipment is the thermostat controlling?” In some embodiments, one or more of the interview questions may elicit an affirmative “YES” or “NO” user response. Alternatively, or in addition, one or more of the interview questions can solicit information requiring a numeric or alphanumeric user response.
With certain interview questions, and in some embodiments, the controller can be configured to prompt the installer to select between at least two answers or responses displayed on the display screen of the user interface, as indicated generally by block 1106 . For example, in response to the interview question “What type of equipment is the thermostat controlling?”, the user interface can be configured to display the answers “Conventional”, “Heat Pump”, and “Heat Only”, prompting the installer to select the appropriate type of equipment to be installed and/or configured. The user interface can then be configured to accept the user responses to each of the questions and then modify the operational parameters of the controller based on the user responses, as indicated generally by blocks 1108 and 1110 , respectively.
In some embodiments, the user interface can be configured to display each of the answers simultaneously on the display screen of the user interface. In such configuration, the selection of a user response at block 1108 can be accomplished by the installer selecting an answer to the interview question from a list of multiple answers graphically displayed on the screen. In those embodiments in which the user interface includes a touchscreen, for example, the selection of a response can be accomplished directly by pressing the desired answer from a choice of answers provided on the screen, causing the controller to store that parameter and cycle to the next interview question in the queue. Alternatively, in those embodiments in which the user interface includes an LCD or dot matrix screen, the selection of the desired answer from the choice of answers can be accomplished via a button, knob, slide, keypad, or other suitable selector means on the user interface.
The user interface can vary the presentation of the interview questions based at least in part on the installer's previous responses to other interview questions. If, for example, the installer selects on the user interface that the type equipment being installed is “Heat Only”, the interview question generator can be configured to skip those questions pertaining to the stages and cycle times for cooling. The ordering of the interview questions can also be varied based on the particular piece of equipment being configured. If, for example, the installation mode at block 1102 is initiated in response to a new piece of equipment connected to the controller, the interview question generator can be configured to present to the installer only those questions pertaining to the new equipment.
The interview question generator can also be configured to suggest a default answer based on any previous responses, based on any previous controller settings, and/or based on settings which are commonly selected for that particular piece of equipment. For example, with respect to the selection of the number of stages for heating, the user interface can be configured to default to a common answer or response of “2” while providing the installer with the ability to select among other numbers of heating stages (e.g., “0”, “1”, “3”, “4”, “5”, “6”, etc.), if desired. The suggestion of a default answer can be accomplished, for example, by highlighting or flashing the answer on the display screen, by moving a selection indicator adjacent to the answer on the display screen, or by other suitable means.
FIGS. 13A-13J are schematic drawings of an illustrative HVAC touchscreen interface 1200 showing an illustrative implementation of the flow diagram depicted in FIG. 12 . In a first view depicted in FIG. 13A , the interface 1200 can be configured to display a main installation menu screen 1202 on the display panel 1204 , providing the installer with the choice of configuring one or more HVAC system components. The main installation menu screen 1202 can include, for example, a “FULL SET-UP” icon button 1206 , a “COMPONENT BASED SET-UP” icon button 1208 , and a “MANUAL SET-UP” icon button 1210 .
The “FULL SET-UP” icon button 1206 can be selected on the display panel 1204 to permit the installer to fully configure the controller to work with the system components for the first time, or when the installer otherwise desires to cycle through each of the interview questions in sequence. The “COMPONENT BASED SET-UP” icon button 1208 , in turn, can be selected to permit the installer to configure only certain system components or to configure the system in a different order than that normally provided by the interface 1200 . The “MANUAL SET-UP” icon button 1210 can be selected to permit the installer to configure the controller manually using numeric or alphanumeric codes, if desired.
FIG. 13B is a schematic drawing showing the selection of the “FULL SET-UP” icon button 1206 on the main installation menu screen 1202 of FIG. 13A . As shown in FIG. 13B , the selection of icon button 1206 causes the interface 1200 to display a language setup screen 1212 that prompts the installer to select a desired language format for the remainder of the installation configuration. The interface 1200 can be configured to display, for example, an “ENGLISH” icon button 1214 , an “ESPANOL” icon button 1216 , and a “FRANCAIS” icon button 1218 . Other language choices can also be displayed on the language setup screen 1212 , if desired. A “BACK” icon button 1220 and “ENTER” icon button 1222 can be provided on the display panel 1204 to permit the installer to move back to the prior screen or to enter the current setting selected and move forward to the next question in the queue. A “QUIT” icon button 1224 can be provided on the display panel 1204 to permit the installer to quit the installation configuration mode, save any changes made, and then return the controller to normal operation.
FIG. 13C is a schematic view showing the interface 1200 after the selection of the “ENGLISH” icon button 1214 on the language setup screen 1212 of FIG. 13B . As shown in FIG. 13C , once the installer has selected a desired language, the interface 1200 can be configured to display an equipment type screen 1226 allowing the installer to select the type of equipment to be configured. In some embodiments, for example, the equipment type screen 1226 may prompt the installer to select among a “CONVENTIONAL” icon button 1228 , a “HEAT PUMP” icon button 1230 , or a “HEAT ONLY” icon button 1232 each simultaneously displayed on the display panel 1204 .
Once the installer has selected the desired equipment to be installed via the equipment type screen 1226 , and as further shown in FIG. 13D , the interface 1200 can be configured to display a screen 1236 prompting the installer to select the number of heat stages to be configured, if any. Several numeric icon buttons 1238 can be provided on the screen 1236 to permit the installer to select the desired number of heat stages to be controlled. If, for example, the equipment to be configured has 2 stages of heating, the installer may select a “2” icon button 1238 a on the screen 1236 . Conversely, if the equipment to be configured has no heating stages, the installer may select a “0” icon button 238 b on the display screen 1236 , causing the interface 1200 to thereafter skip those interview questions pertaining to heating stages and cycles.
Once the number of heat stages has been configured via screen 1236 , and as further shown in FIG. 13E , the interface 1200 can be configured to display another screen 1240 prompting the installer to select the number of cooling stages to be configured, if any. Several numeric icon buttons 1242 can be provided simultaneously on the screen 1240 to permit the installer to select the desired number of cooling stages. If, for example, the equipment to be configured has 2 stages of cooling, the installer may select a “2” icon button 1242 a on the screen 1240 . Depending on the response to the previous interview question on screen 1236 of FIG. 13D , the interface 1200 can be configured to default to a particular answer (e.g. “2”) by blinking or flashing the answer on the screen 1240 . In some cases, the interface 1240 may assume that the number of cooling stages is the same as the number of heating stages and skip screen 1240 altogether.
FIG. 13F is a schematic view showing the interface 1200 subsequent to the steps of configuring the heating and cooling stages in FIGS. 13D-13E . As shown in FIG. 13F , the interface 1200 can be configured to provide a screen 1244 initially prompting the installer to select a desired number of cycles per hour for the first stage of heating. Several numeric icon buttons 1246 can be provided simultaneously on the screen 1244 to permit the user to select the cycle rate at which the system operates for the particular stage number 1248 displayed on the screen 1244 . For the first stage of heating for a two-stage system, for example, the installer may select the “6” icon button 1246 a to operate the first heating stage for six cycles per each hour. Once a response is received for the first heating cycle, the interface 1200 may then prompt the installer to select the number of cycles for the second heating stage, as further shown in FIG. 13 G. The process can be repeated one or more times depending on the number of heating stages to be configured.
FIG. 13H is a schematic view showing the presentation of another screen 1250 on the interface 1200 for selecting the cycle rate for each cooling stage to be configured within the controller. Similar to the screen 1244 depicted in FIGS. 13F-13G , the screen 1250 may prompt the installer to initially select a desired number of cycles per hour for the first stage of cooling, and then repeat the interview process for each additional stage to be programmed, if any. Several numeric icon buttons 1252 can be provided simultaneously on the screen 1250 to permit the installer to select the cycle rate at which the system operates for the particular stage number 1254 displayed on the screen 1250 . Once the installer has completed configuring each stage of heating and cooling, the interface 1200 can be configured jump to additional interview questions for any other components to be configured, or, alternatively, can exit the routine and return to normal operation using the newly programmed settings.
Once programming is complete, and as further shown in FIG. 13I , the interface 1200 can be configured to display a screen 1256 indicating that the configuration was successful along with a “VIEW SETTINGS” icon button 1258 allowing the installer to view the controller settings. A “BACK” icon button 1260 can be selected if the installer desires to go back and modify or change any settings. A “DONE” icon button 1262 , in turn, can be selected by the installer to return the controller to normal operation.
Referring back to FIG. 13A , if the installer desires to configure only selective components of the system, or prefers to enter configuration information in an order different than that generated by the interview question generator, the installer may select the “COMPONENT BASED SET-UP” icon button 1208 on the main installation menu screen 1202 . When selected, the interface 1200 can be configured to display a component selection screen 1264 , allowing the installer to select from among several different categories of equipment for configuration, as shown in FIG. 13J . The component selection screen 1264 can include, for example, a “HEATING” icon button 1266 , a “COOLING” icon button 1268 , a “VENTILATION” icon button 1270 , a “FILTRATION” icon button 1272 , a “UV LAMP” icon button 1274 , a “HUMIDIFICATION” icon button 1276 , and a “DEHUMIDIFICATION” icon button 1278 . The icon buttons can correspond, for example, to the system components described above with respect to FIG. 9 , although other combinations of system components are contemplated. An “OTHER” icon button 1280 provided on the screen 1264 can be selected by the installer to configure other system components such as any sensors or other connected controllers, if desired.
The selection of the icon buttons on the component selection screen 1264 causes the interface 1200 to display one or more interview questions and answers on the display panel 1204 based on the type of equipment to be configured. If, for example, the installer desires to configure only the heating and cooling system components, the installer may select both the “HEATING” icon button 1266 and “COOLING” icon button 1268 on the screen 1264 , causing the user interface 1200 to present only those interview questions that pertain to heating and cooling control. The process of providing the installer interview questions and answers in multiple-choice format can then be performed in a manner similar to that described above with respect to FIGS. 13C-13H . If desired, the process can be performed for any other system component or components to be configured.
The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention can be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification. | Controllers and methods are disclosed for aiding a user in programming a schedule of a programmable controller. In an illustrative embodiment, a guided programming routine can be activated by a user, which then guides a user through two or more screens that are designed to collect sufficient information from the user to generate and/or update at least some of the schedule parameters of the controller. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 10/417,045, filed on Apr. 15, 2003, now U.S. Pat. No. 7,060,106 which application is incorporated herein by reference.
FEDERAL SPONSORSHIP
Not Applicable.
BACKGROUND
A variety of machines in which clothes may be hung and processed in a single unit have been proposed. There are a series of patents that require the use of solvents for dry cleaning garments, for example U.S. Pat. No. 2,845,786, issued to E. L. Chrisman on Aug. 5, 1958; U.S. Pat. No. 3,166,923 issued to Zacks on Jan. 26, 1965; and U.S. Pat. No. 2,741,113, issued to Norkus on Apr. 10, 1056. The use of solvents, especially in the home, can create health and safety issues.
There are additional patents that claim a machine in which the clothes are “finished” only. These patents are directed toward de-wrinkling and smoothing the clothes, typically by using steam. However, these machines do not clean the clothes, these machines are used after the clothes are already clean. Some examples of these devices are seen in U.S. Pat. No. 3,707,855 issued to Buckley on Jan. 2, 1973; U.S. Pat. No. 4,391,602 issued to Stichnoth et al. on Jul. 5, 1983; U.S. Pat. No. 3,739,496 issued to Buckly et al. on Jun. 19, 1973; U.S. Pat. No. 3,732,628 issued to Bleven et al. on May 15, 1973; and U.S. Pat. No. 4,761,305 issued to Ochiai on Aug. 2, 1988. U.S. Pat. No. 6,189,346 issued to Chen et al. on Feb. 20, 2001 discloses a clothes treating apparatus that uses a “conditioning mist” as an alternative to dry-cleaning clothes. This patent does not provide for washing clothes with water or rinsing the clothes.
In addition, some patents claim machines that only dry clothes, and do not wash or finish the clothes: for example U.S. Pat. No. 3,257,739 issued to Wentz on Jun. 28, 1966; and U.S. Pat. No. 3,102,796 issued to Erickson on Sep. 3, 1963.
U.S. Pat. No. 3,114,919 issued to Kenreich on Dec. 24, 1963 discloses a machine that can wash and dry using conventional laundry soap, however, this apparatus can only wash one shirt, or the like, and one pair of pants, or the like, at a time. In addition, this patent discloses an apparatus that has fixed outlets for dispensing wash and rinse water. This patent, like U.S. Pat. No. 3,664,159 issued to Mazza on May 23, 1972, utilizes a shaking of the garments to remove dirt and debris from the garments. However, shaking the garments can cause the garments to fall during the washing cycle, and can impart wrinkles to the garments. In addition, these patents teach that the wash water is applied from the top and bottom of the clothing, and not along the length of the clothing.
Finally, U.S. Pat. No. 3,672,188 issued to Geschka et al. on Jun. 27, 1972 discloses an apparatus that uses conventional laundry soap water, and hot air to wash and dry clothes. However, in this patent the soap and water are applied to the garments from top and bottom nozzles. Likewise, in U.S. Pat. No. 3,868,835 issued to Todd-Reeve on Mar. 4, 1975, the water and soap are applied from nozzles located near the top and bottom of the apparatus. In neither of these apparatuses is the soap and water applied over the entire length of the garments.
SUMMARY OF THE INVENTION
The invention is generally designed to wash and dry garments or other items in a single machine. The invention is for use in residences or in hotel rooms, hospitals, laundromates, and other commercial applications. In a conventional clothes washing machine it is best to transfer the clothes soon after they are washed to the dryer in order to prevent wrinkling. In addition, it is even more important to rapidly remove dried clothes from the dryer shortly after completion of the drying process to further prevent wrinkling. When using the invention, there is no need to rapidly move clothes from the washing machine to the dryer, or to rapidly remove clothes from the dryer. The clothes are washed and dried on hangers in a single machine. Once the cycle is complete, the clothes may remain in the invention indefinitely, until ready to be worn, suspended from the hangers.
The device is used by placing garments on conventional hangers, and hanging the garments on bar within the machine cabinet. The inventor prefers to use plastic hangers, however any hanger that will support the garments without imparting stains to the wet garments may be used. A manifold supplies wash water, rinse water and finally hot air to the clothes. The manifold contains a series of arms, with one arm between each garment. The arms contain nozzles directed downward and toward the garments. The manifold, arms, and nozzles contain a dual internal system of pipes. One set of internal pipes allows wash water and rinse water to be directed toward the clothes. The other set of internal pipes allows hot air to be directed toward the clothes.
During operation, the wash water containing soap travels up the first set of internal pipes in the manifold, through the arms, out the nozzles, and onto the clothes. The entire manifold traverses up and down the length of the hanging clothes, spraying the clothes with soapy water.
After the wash cycle is complete, rinse water travels through the same first set of internal pipes in the manifold, and arms, and out the same nozzle. The manifold again traverses up and down the length of the hanging clothes, spraying the clothes with rinse water.
In the drying cycle hot or cool air travels through the second set of internal pipes in the manifold, through the arms, and out a separate set of nozzles and toward the clothes. The hot air may exit the apparatus through vents, or may be re-circulated through a compressor. The compressor will remove the moisture from the hot air and direct the hot toward the garments.
The duration of the washing cycle, rinse cycle, and drying cycle is controlled through a control panel.
When the clothes washing and drying cycle is complete the clothes may remain in the machine until such time as is convenient to remove the clothes.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view, and shows the device from the front with the door open, and a cut-away section to see inside the sub-cabinet.
FIG. 2 is a plan view of the manifold.
FIG. 2 a is cross-sectional view of the manifold.
FIG. 2 b shows a partial sectional view of the area indicated in FIG. 2 .
FIG. 3 is a perspective view without a cut-away.
DESCRIPTION OF THE INVENTION
Apparatus 10 comprises a cabinet 12 with front wall 12 a , rear wall 12 b , two side walls 12 c and 12 d , and a top and bottom wall 12 e and 12 f . In the preferred embodiment said walls of cabinet 12 are insulated. Apparatus 10 , like conventional washers and dryers, is connected to a water supply by hose 16 , to an electrical supply by conductors 18 , and to a drain by hose 20 .
Bottom wall 12 f contains drain 14 . Drain 14 is connected to drain hose 20 , and drains cabinet 12 . Cabinet 12 , which is sealed against the escape of water, is provided with a door 22 through which clothing to be processed can be inserted. In the preferred embodiment door 22 is transparent, and the garments may be viewed during the operating cycle. Alternatively, door 22 may be opaque and insulated. Door 22 is attached to cabinet 12 with one or more conventional hinges 6 . Door 22 is closed and watertight during operation of the device. Door 22 may, but does not have to, extend the entire length of the front wall 12 a of cabinet 12 .
Cabinet 12 is adjacent to sub-cabinet 24 . Sub-cabinet 24 contains the mechanism by means of which the operating cycle of apparatus 10 is automatically carried out. The operating cycle may include any variation or combination of pre-washing, washing, rinsing and drying. For means of illustration only, and not as a limitation, the device control mechanism could allow the consumer to set the device for heavy or light washing; set the water temperature; add bleach, fabric softeners, or other laundry additives; set one or more rinse cycles; set a initial delay of the start of the washing cycle to allow for the action of spot-removers; set a delay of the start of the washing cycle to accommodate the convenience of the user; set a pre-wash cycle; and set varying drying temperatures and times. The various washing and drying requirements are set via control panel 28 . The electricity for running control panel 28 , and all other parts of the device, is supplied through conductor 18 .
The device requires the use of a control panel 28 to effectuate the different washing and drying needs of the user. Said control panel 28 includes a timer, a means for setting or programming the various washing and drying cycles, a means for dispensing laundry detergent, bleach, fabric softener, or other laundry additives, and a means for regulating the washing, rinsing, and dying times.
The clothes-receiving portion of cabinet 12 has, at its upper end, a hanging bar 30 . Hanging bar 30 is suspended horizontally and parallel to walls 12 a and 12 b . Hanging bar 30 has one or more hanger spacers 32 . Clothes, towels, sheets or other items to be laundered are placed on a conventional, non-rusting, hanger. The hanger is inserted onto hanging bar 30 , and held at regularly spaced intervals by hanger spacers 32 .
Manifold 40 is comprised of a plurality of arms 42 . The arms 42 are in a single plane, and are parallel to each other, and perpendicular to hanging bar 30 . The arms extend between hanger-mounted garments 26 . The first arm in the parallel plane is 42 a , and the last arm in the parallel plane is 42 z.
Inside manifold 40 are two sets of internal pipes. One set is the liquid-carrying pipes 46 . The other set is the air-carrying pipes 47 . The liquid-carrying pipes 46 and air-carrying pipes 47 may be a separate set of internal pipes inside manifold 40 . Alternatively, as shown in FIG. 2 b , the manifold 40 , liquid-carrying pipes 46 , and air-carrying pipes 47 may be manufactured as a single unit with a divider 55 separating the air in the air-carrying pipes 47 from the water in the water-carrying pipes 46 .
Water enters sub-cabinet 24 through water supply hose 16 . Laundry detergent or other laundry additives may be added to the water, as requested by the user. For example, and for purposes of illustration and not limitation, laundry detergent may be added to the water. The water/detergent mixture then travels into manifold 40 and arms 42 through liquid-supply hose 48 , and into manifold 40 . Once inside manifold 40 , the water/detergent mixture travels through liquid-carrying pipes 46 . The water/detergent mixture exits arms 42 through liquid-exits 44 and sprays the hanger-mounted garments 26 . Liquid-exits 44 may be either nozzles or holes. The inventor currently prefers to use nozzles for liquid-exits 44 . Manifold 40 moves up and down the length of the hanger-mounted garments 26 spraying both sides of garments 26 with the water/detergent mixture. The water/detergent mixture will run off the garments 26 , down to bottom wall 12 f , through drain 14 , and out drain nose 20 . In the preferred embodiment bottom wall 12 f will be sloped in such a manner that drain 14 is at the lowest point in bottom wall 12 f , causing the water to run out drain 14 , and exit the device through drain hose 20 .
The drying cycle may be started after completion of the washing cycle. In the drying cycle warm or cool air is forced from subcabinet 24 to manifold 40 via air-supply hose 49 , and then into manifold 40 . Once inside manifold 40 , the air travels through air-carrying pipes 47 and out air-exits 45 . Air-exits 45 may be either nozzles or holes. The inventor currently prefers to use holes for air-exits 45 . Manifold 40 again moves up and down the length of hanger-mounted garments 26 blowing air on both sides of garments 26 , and thereby drying the garments 26 .
In the preferred embodiment, each arm 42 has a plurality of liquid-exits 44 and air-exits 45 . Arm 42 a has a plurality of exits 44 a and 45 a on only the side facing toward garment 26 , and arm 42 z has a plurality of exits 44 z and 45 z on only the side facing toward garment 26 . The remainder of arms 42 have a plurality of exits 44 and 45 on both sides of each arm 42 so that hanger-mounted garments 26 may be sprayed from both sides.
Liquid-exits 44 and air-exits 45 are placed on arms 42 so that the liquid or air exits arms 42 in a downward direction. The shape of the arms may be any shape that allows the liquid- and air-exits to point downward. The inventor currently prefers to have the cross-sectional shape of the arms be an isosceles triangle with the two equal sides of the triangle facing downward, and to place the liquid- and air-exits on the two downward facing sides of the triangle. The downward angle of the liquid or air may be any angle necessary to prevent garments 26 from tangling and twisting, and to help smooth garments 26 . The inventor currently prefers to use a downward angle of between 40 degrees and 60 degrees on liquid-exits 44 and air-exits 45 .
There are no specific requirements regarding placement of liquid-exits 44 and air-exits 45 relative to each other. That is, liquid-exits 44 and air-exits 45 may be placed in a horizontal line, may be placed with either on top of the other, or may be placed in any arrangement that allows liquid to exits the liquid-exits 44 , and allows air to exit air-exits 45 .
Manifold 40 has one or more unthreaded guide holes 51 . Apparatus 10 contains one or more guide post 50 . In the preferred embodiment, the number of unthreaded guide holes 51 is equal to the number to guide posts 50 . Guide post 50 is a smooth post that runs in a vertical direction parallel to rear wall 12 b . Guide post 50 is inserted through unthreaded hole 51 in manifold 40 , and manifold 40 may freely move along the length of guide post 50 .
Manifold 40 has one or more threaded screw holes 53 . Apparatus 10 contains one or more screw posts 52 . In the preferred embodiment, the number of threaded screw holes 53 is equal to the number of screw posts 52 . Screw post 52 is a threaded post runs in a vertical direction parallel to rear wall 12 b . Screw post 52 and threaded screw hole 53 are threaded so that the threaded screw post 52 will turn inside threaded screw hole 53 and, in turning, move manifold 40 either up or down.
Screw post 52 is moveably attached to motor 54 . Motor 54 will turn screw post 52 in an alternating clockwise and counter-clockwise direction, thereby moving manifold 40 up and down screw post 52 . Motor 54 may be programmed via control panel 28 so that screw post 54 turns in one direction for varying lengths of time. The length of time that screw post 54 turns in any one direction is directly correlated to the length that the manifold travels in any one direction. Thus, screw post 54 may turn for such a length of time that manifold 40 travels only part of the height of cabinet 12 , or the entire length of cabinet 12 . Control panel 28 may also provide a means for setting or programming the speed of the upward/downward motion, as well as the distance manifold 40 travels in the upward/downward plane.
Manifold 40 will continue to spray garments 26 for the length of time as set by the user. After the wash cycle is completed, the rinse cycle will begin. In the rinse cycle, water alone travels through liquid-supply hose 48 to manifold 40 and into arms 42 through liquid-supplying pipes 46 . The water exits arms 42 through liquid-exits 44 , and sprays the garments 26 with rinse water. The rinse water exits the device through drain 14 and drain hose 20 .
The drying cycle will begin at the time requested by the user after the rinse cycle is complete. The inventor currently prefers to allow a length of time for passive dripping of water from the clothes before beginning the drying cycle. However, the drying cycle may be set to begin at any time, even immediately after completion of the rinse cycle. Ambient air will be drawn into sub-cabinet 24 through air-intake hose 61 . If requested by the user, the air will be heated. The air will travel through air-supply hose 49 to manifold 40 and then into arms 42 through air-carrying pipes 48 . The air exits through air-exits 45 . Manifold 40 moves up and down the length of the garments 26 spraying air onto the garments. The heated air may exit cabinet 12 passively through vent 60 . Alternatively, the heated air may be removed from cabinet 12 and processed through condenser 62 , removing the moisture from the air. The treated air will then be returned to recirculate in cabinet 12
In the preferred embodiment the apparatus will indicate the end of the washing and drying cycle by a light or suitable alarm.
Although not required, in the preferred embodiment one or more racks 70 may be attached to bottom wall 12 f . The rack 70 extends horizontally near the bottom of the cabinet 12 . Socks or other small items may be placed on the rack 70 and treated as described above. | A device for washing and drying garments or other items in a single unit. The garments or other items are placed in the device on conventional plastic hangers leaving space in between each item. A manifold with arms extends between the items. The manifold moves up and down so that the arms move up and down the length of the items to be treated. The arms have one set of pipes that spray wash water, rinse water and other washing liquids on the items. The arms have another set of pipes that carry air to the items, drying the items. After the cycle is complete the clothes or other items may be left in the device until needed. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the design of a method and apparatus for seek control algorithm of servo system design associated with a hard disk drive. More specifically, the invention devises an extended sinusoidal waveform as current profile for a seek controller to move data heads of a hard disk drive from one position to another position fast and robustly. The controller forces the motion of recording heads to follow the seek trajectories during the process of seeks, including acceleration, velocity and position, which are derived from the design current profile.
[0003] 2. Background
[0004] Hard disk drives include a plurality of magnetic transducers that can write and read information by magnetizing and sensing the magnetic field of a spinning disk(s), respectively. The information is typically formatted into a plurality of sectors that are located within an annular track. There are a number of tracks located across each surface of the disk. A number of vertically aligned tracks are usually referred to as a cylinder.
[0005] Each transducer is integrated into a slider that is incorporated into a head gimbal assembly (HGA), which is referred to as either a head or recording head in the following. Each HGA is attached to an actuator arm. The actuator arm is actuated by a voice coil motor (VCM), which is attached to the actuator assembly, and is composed of a coil and a magnetic circuit device. The hard disk drive typically includes a driver circuit and a controller that provide current to excite the VCM in accordance with a servo algorithm. The excited VCM is the energy source to rotate the actuator arm and moves the heads (or, synonymously, transducers) across the surfaces of the disk(s).
[0006] When writing or reading information the hard disk drive performs a seek routine to move a head (transducer) from one track to its target track on a disk surface. The controller performs a servo routine to assure the transducer moves to the target position fast and accurately. It is always desirable to minimize the amount of time required to write to and to read from the disk(s). Therefore, the seek routine performed by the drive should move the heads to new positions in shortest possible time. Additionally, the settling time of the HGA should be minimized so that the heads can quickly start the read or write operation when they arrive the commend targets.
[0007] Prior art of seek control algorithms includes two major seek trajectories: bang-bang control trajectory and standard sinusoidal trajectory. Many disk drive designs utilize a bang-bang control algorithm for the servo routine to move the recording heads (transducers) because the bang-bang trajectory is theoretically the time optimal method for seek control to move a transducer from its present position to any target position in shortest time. The waveform of the bang-bang current profile is a positive square wave followed by another square wave in opposite direction. Square waveforms contain high frequency harmonics, which are likely to stimulate mechanical resonance of the mechanical system of a hard disk drive. Moreover, the current rise time and current switching time for the bang-bang profile are infinitely fast, which is physically not possible. For practical implementation, various modifications are usually necessary to trim the bang-bang trajectory for a servo algorithm to work well for a hard disk drive. With all these modifications, the bang-bang algorithm is no longer time-optimal for seeks. The mechanical vibrations excited by a bang-bang current profile due to its wide range of frequency contents are often unacceptable for the servo system because of the consideration of stability margin. Additionally, these vibrations are a major source generating acoustic noises during seeks.
[0008] A sinusoidal wave of prior art as current profile for seeks has been used to replace a bang-bang trajectory for seeks control in the hard disk drive industry. A standard sinusoidal seek trajectory is simply a sine function with seek-length dependent period. There are, at least, two noticeable reasons for the change. First, a sinusoidal wave has only one frequency component, which is less likely to excite the mechanical system of a drive. Second, the sinusoidal current profile is very smooth because of the gentle current rise and current reverse, and, additionally, the current gradually reduces to zero at the target position for smooth landing. The major shortcoming of a sinusoidal current profile is due to its rigid waveform. The current rise time of the sinusoidal seek is set by the waveform, and once the current reaches its design peak, it starts to fall off following the sinusoidal waveform. In other words, the sinusoidal wave lacks the capability to stay at the design current peak for a finite duration of time; therefore, the only method to improve the movement time of seeks is to increase the amplitude of the current profile, which is usually not possible.
[0009] The current trajectory of an extended sine wave is essentially a sinusoidal wave with the extension that it allows the trajectory to stay at its design peak value (positive for acceleration and negative for deceleration) for a fixed duration of time for faster seek time. The current profile with the extended sine wave is very flexible for tuning seek performance. The duration of either the constant acceleration peak or the constant deceleration peak of the trajectory can be easily adjusted and tuned for performance. The extended sinusoidal trajectory for current profile is very general because it includes both the bang-bang trajectory and the sinusoidal seek trajectory as its two extreme limiting cases. The extended sinusoidal current profile possesses the performance advantages of both bang-bang design and the sinusoidal seek design. A seek control using the extended sinusoidal current profile is both fast and robust.
[0010] There is an approach of prior art following the lines of concept similar to this invention to generate the acceleration trajectory for seek by employing a Fourier series representation with a finite number of terms. For implementation consideration, the number of terms is limited to very few, such as two or three. Special efforts are made to eliminate the well-known Gibbs phenomenon of classical Fourier analysis in the constant acceleration portion of the trajectory. Thus, the approach for seek is named a generalized Fourier seek method because it is not an ordinary Fourier series. The method is capable of generating an acceleration trajectory with constant maximum acceleration for certain duration of time. The duration of constant acceleration generated by the Fourier seek method is generally not easily adjustable. An optimization method to choose Fourier coefficients by minimizing the total mean-square error in the constant acceleration phase exists in prior art. Such a generalized Fourier seek method coupled with the optimization method for the determination of series coefficients involves quite some mathematical manipulations. A major shortcoming of the method is its relative inflexibility to adjust the duration of constant phase in the acceleration trajectory. The extended sinusoidal trajectory, on the other hand, works directly on the geometry of the standard sinusoidal waveform to insert a constant phase of acceleration. Therefore, the method is very general and flexible for the adjustment of the duration of constant acceleration phase in the acceleration trajectory. Additionally, the direct method of waveform modification in the invention is simpler to use for implementation.
[0011] The seek trajectories using the extended sinusoidal waveform as the current profile of seeks consist of three trajectories. The acceleration trajectory is essentially the same as the current trajectory with the only difference of a proportional constant. The acceleration trajectory is a curve with time as a parameter. The acceleration trajectory is integrated once with respect to the parameter of time to yield the velocity trajectory. The velocity trajectory is integrated once more to yield the position trajectory, which is also called the displacement trajectory. These theoretically generated trajectories based on the extended sinusoidal waveform are the design trajectories for use with the seek controllers in the invention.
[0012] The extended sinusoidal waveform is constructed by saturating the standard sinusoidal wave at a specified level smaller than unity. The resulting waveform is then normalized to have unit amplitude. The extended sinusoidal wave is capable of moving the heads faster to target positions because of its higher energy content compared to the sinusoidal seek method. The specified level for the construction of the extended sinusoidal waveform is adjustable. Depending on seek length, the recommended strategy of trajectory usage is a combination of different saturation levels of the waveform construction. Typically, no saturation model, which reduces to the standard sinusoidal model, shall be applied for short to medium range seeks, and, for relatively longer seeks, a saturation level between 0 and 1 shall be set before normalization for better seek time performance.
SUMMARY
[0013] One embodiment of the present invention is a hard disk drive, which moves a transducer (or recording head) across a disk surface so that the transducer has an extended sinusoidal current trajectory. The extended sine wave is devised to be current profiles for use in seeks control to move a recording head from one position to another position as fast as possible. The extended sinusoidal waveform as a current profile provides a design compromise to achieve near time-optimal seek performance, and, at the same time, to minimize mechanical resonance and its associated acoustic noise generated during seeks. An extended sine wave is generated from a standard sine wave by saturating the sine function to a specified value, which is less than a unity. This saturated sine function is then normalized so that it has unit amplitude. This extended sine wave as current profile for a seek servomechanism has the advantages of being more controllable than a prior art of conventional bang-bang control and faster than another prior art of sinusoidal seek algorithm. Since the maximum current of an extended sine wave can stay at its peak for a fixed duration of time, the current trajectory is devised for designing certain seek profiles to achieve fast access time in hard disk drive applications. A controller using seek trajectory on the phase plane may be used to incorporate the extended sinusoidal trajectory for best benefits. One major application of the new class of seek trajectories is to improve the seek time for long seeks because faster seek time can be achieved without the need to increase maximum current. The other application of the trajectory is in designing hard drive for extreme operating temperatures by increasing the duration of constant peak current when maximum current output is a restraint. The method using extended sine wave is both general, flexible and powerful compared to the prior art of either bang-bang control algorithm or sinusoidal seek method.
DRAWINGS
[0014] FIG. 1 . Generation of Extended Sinusoidal Waveform without Coast Mode
(a) Construction of Waveform (Restraint: 0<p<1) (b) Resulting Extended Sinusoidal Waveform after Normalization (Full Cycle of Extended Sine Wave with Coast Mode: Trajectory a-b-c-d-e-f)
[0017] FIG. 2 . A Typical Extended Sinusoidal Waveform with Coast Mode
(a) Extended Sinusoidal Wave with Coordinates of Border Points between Phases (b) Extended Sinusoidal Wave with Border Points between Phases on Trajectory (Full Cycle of Extended Sine Wave with Coast Mode: Trajectory a-b-c-d-e-f-g-h)
[0020] FIG. 3 . Comparison of Seek Trajectories for the Extended Sinusoidal Wave—-Extended Sinusoidal Wave (p=0.5) with Standard Sinusoidal Model
[0021] FIG. 4 . Comparison of Seek Trajectories for the Extended Sinusoidal Wave—-Extended Sinusoidal Wave (p=0.8) with Standard Sinusoidal Model
[0022] FIG. 5 . Conversion of Seek Trajectories of Parametric Form to the Phase Plane
[0023] FIG. 6 . Comparison of Seek Trajectories on the Phase Plane—-Extended Sinusoidal Wave (p=0.5) with Standard Sinusoidal Model
[0024] FIG. 7 . Comparison of Seek Trajectories on the Phase Plane—-Extended Sinusoidal Wave (p=0.8) with Standard Sinusoidal Model
[0025] FIG. 8 . Comparison of Parametric Seek Trajectories with Coast Mode—-Extended Sinusoidal Wave (p=0.65, C=0.2) with Standard Sinusoidal Model
[0026] FIG. 9 . Comparison of Seek Trajectory on Phase Plane with Coast Mode—-Extended Sinusoidal Wave (p=0.65, C=0.2) with Standard Sinusoidal Model
[0027] FIG. 10 . Seek Time Comparison of Different Waveforms—-Extended Sine Model (p=0.5) versus Sinusoidal and Bang-Bang-Control
[0028] FIG. 11 . Seek Time Comparison of Different Waveforms—-Extended Sine Model (p=0.8) versus Sinusoidal and Bang-Bang-Control
[0029] FIG. 12 . Controller Using Parametric Seek Trajectories (Seeks without Coast Mode)
[0030] FIG. 13 . Controller Using Seek Trajectory on Phase Plane (Seeks without Coast Mode)
[0031] FIG. 14 . Controller Using Parametric Seek Trajectories (Seeks with Coast Mode)
[0032] FIG. 15 . Controller Using Seek Trajectory on Phase Plane (Seeks with Coast Mode)
DETAILED DESCRIPTION
[0000] 1. Generation of Current Profile
[0033] An extended sinusoidal waveform is constructed by limiting the standard sine function to saturate at a specified level as illustrated in FIG. 1 ( a ). The resulting waveform is then normalized so that its peak value is exactly one as shown in FIG. 1 ( b ).
[0034] For a seek without coast mode, the current trajectory using the extended sine function can be divided into five phases as shown in FIG. 1 ( b ):
1. Phase I: Acceleration phase (Initial seek phase) 2. Phase II: Constant acceleration phase 3. Phase III: Transition phase 4. Phase IV: Constant deceleration phase 5. Phase V: Approaching phase (Near the end-of-seek phase)
[0040] Notice that the transition phase covers the duration of seek from acceleration to deceleration.
[0041] When a coast mode is present in seeks, a phase of zero acceleration is inserted in between the acceleration mode and the deceleration mode. During the coast mode, the maximum velocity remains as a constant, which is the maximum design velocity of the transducer(s) to read Gray code reliably. Due to the addition of the coast mode, there are two addition phases in the current profile. Depending on the slope of the current profile, the acceleration phase of the current profile is further divided into the initial acceleration phase where slope
ⅆ a ( x ) ⅆ x > 0
and the final acceleration phase slope
ⅆ a ( x ) ⅆ x < 0.
[0042] Similarly, the deceleration phase is decomposed into two separate phases depending on the slope of the current profile: initial deceleration phase for slope
ⅆ a ( x ) ⅆ x < 0
and final deceleration phase for slope
ⅆ a ( x ) ⅆ x > 0.
[0043] The extended sinusoidal waveform with a coast mode is illustrated with a sketch in FIG. 2 .
[0044] These seven phases of the extended sinusoidal current profile for seeks with a coast mode are
1. Phase I :
Initial acceleration phase ( 0 ≤ a ( x ) < 1 and slope ⅆ a ( x ) ⅆ x > 0 )
2. Phase II :
Constant acceleration phase ( a ( x ) = 1 > 0 and slope ⅆ a ( x ) ⅆ x = 0 )
3. Phase III :
Final acceleration phase ( 0 ≤ a ( x ) < 1 and slope ⅆ a ( x ) ⅆ x < 0 )
4. Phase IV :
Coast mode phase ( slope ⅆ a ( x ) ⅆ x > 0 )
5. Phase V :
Initial deceleration phase ( - 1 < a ( x ) ≤ 0 and slope ⅆ a ( x ) ⅆ x < 0 )
6. Phase VI :
Constant deceleration phase ( a ( x ) = - 1 < 0 and slope ⅆ a ( x ) ⅆ x = 0 )
7. Phase VII :
Final deceleration phase ( - 1 < a ( x ) ≤ 0 and slope ⅆ a ( x ) ⅆ x > 0 )
[0045] The final deceleration phase is synonymous with the approaching phase (or near the end-of-seek phase).
[0000] 2. Seek Trajectories without Coast Mode
[0046] As shown in FIG. 1 ( a ), the amplitude of an extended sine wave is denoted by p, which is a parameter falling in the range of 0<p<1. In the limiting case when p→1, the extended sine wave reduces to a standard sine wave. Another limiting case when p→0 is the classical bang-bang control curve. Let the duration of the acceleration phase be denoted by A. There is a restraint on the parameter A:
A ≤ 1 4 .
[0047] The extended sine model is powerful in the sense that the seek time can be very fast by decreasing the parameter p without the need to increase the maximum current as is required for a sinusoidal seek model.
[0048] For a given truncated value p, the duration of acceleration phase A is given by
x p = 1 2 π sin - 1 p ≡ A ( 1 )
[0049] In Eq. (1), there are two restraints on the two parameters A and p:
0 < p ≤ 1 and A ≤ 1 4 ( 2 )
[0050] In the following, the acceleration (or current trajectory) is limited by a preset value of p instead of 1. Therefore, all the trajectories given in the following have to be scaled by a factor of 1/p for normalization.
[0051] The current profile a(x) in phase I has the property of a(x)>0 with its slope
ⅆ a ( x ) ⅆ x > 0 ,
and the a(x) reaches its maximum when the slope of current decreases to 0. In phase II, the current is a positive constant, and the slope of current is zero. Depending on the sign of the acceleration slope, Phase III can be further separated into two sub-phases, phase III-A and phase III-B. In phase III-A, we have a(x)>0 and its slope
ⅆ a ( x ) ⅆ x < 0.
In phase III-B, we have a(x)<0 and its slope
ⅆ a ( x ) ⅆ x < 0 too .
The current a(x) reaches its minimum when its slope increases to zero. In phase IV, the current is a negative constant, and the slope of current is zero. In phase V, we have a(x)<0 and its slope
ⅆ a ( x ) ⅆ x > 0.
[0052] Note that the slope of the extended sine wave is not continuous at the boundary points between neighboring phases. As shown in FIG. 1 ( b ), these boundary points between neighboring phases are the points of b, c, d and e.
[0053] Before normalization for unit acceleration amplitude, the trajectories for these five phases are given in the following.
Acceleration Profile
a I ( x ) = sin ( 2 π x ) , 0 ≤ x ≤ A ( 3 ) a II ( x ) = p , A < x ≤ 1 2 - A ( 4 ) a III ( x ) = sin ( 2 π x ) , 1 2 - A < x ≤ 1 2 + A ( 5 ) a IV ( x ) = - p , 1 2 + A < x ≤ 1 - A ( 6 ) a V ( x ) = sin ( 2 π x ) , 1 - A < x ≤ 1 ( 7 )
[0054] The current trajectory for Phase I, Phase II and Phase III are coincident with separate portions of one cycle of sine function. Notice that there are no phase delays involved in these three trajectory phases.
Velocity Profile
v I ( x ) = 1 2 π ( 1 - cos 2 π x ) , 0 ≤ x ≤ A ( 8 ) v II ( x ) = v 1 + p ( x - A ) , A < x ≤ 1 2 - A ( 9 ) v III ( x ) = v 2 + 1 2 π [ cos π ( 1 - 2 A ) - cos 2 π x ] , 1 2 - A < x ≤ 1 2 + A ( 10 ) v IV ( x ) = v 3 - p ( x - 1 2 - A ) , 1 2 + A < x ≥ 1 - A ( 11 ) v V ( x ) = v 4 + 1 2 π [ cos 2 π ( 1 - A ) - cos 2 π x ] , 1 - A < x ≤ 1 ( 12 )
[0055] Initial conditions in the velocity trajectories for, Phase II through Phase V are
Position Profile
d I ( x ) = 1 2 π [ x - 1 2 π sin 2 π x ] , 0 ≤ x ≤ A ( 13 ) d II ( x ) = d 1 + ( v 1 - p A ) ( x - A ) + p 2 ( x 2 - A 2 ) , A < x ≤ 1 2 - A ( 14 ) d III ( x ) = d 2 - 1 2 [ v 2 + 1 2 π cos π ( 1 - 2 A ) ] ( 1 - 2 A ) - 1 ( 2 π ) 2 [ sin 2 π x - sin π ( 1 - 2 A ) ] + [ v 2 + 1 2 π cos π ( 1 - 2 A ) ] x , 1 2 - A < x ≤ 1 2 + A ( 15 ) d IV ( x ) = d 3 + [ v 3 + 1 2 + A ] ( x - 1 2 - A ) - p 2 [ x 2 - ( 1 2 + A ) 2 ] , 1 2 + A < x ≤ 1 - A ( 16 ) d V ( x ) = d 4 + [ v 4 + 1 2 π cos 2 π ( 1 - A ) ] ( x - 1 + A ) - 1 ( 2 π ) 2 [ sin 2 π x - sin 2 π ( x + 1 - A ) ] , 1 - A < x ≤ 1. ( 17 )
[0056] Initials positions in the position trajectories for Phase II through Phase V are
d 1 = d I ( A ) ( 18 ) d 2 = d II ( 1 2 - A ) ( 19 ) d 3 = d III ( 1 2 + A ) ( 20 ) d 4 = d IV ( 1 - A ) ( 21 )
[0057] Multiplying by 1/p, every one of these seeks trajectories given above is normalized to yield the trajectories with unit acceleration amplitude.
[0058] The comparison of seek trajectories with extended sinusoidal current waveform (p=0.8) with the corresponding trajectories of the sinusoidal seek method is shown in FIG. 3 and FIG. 4 for p=0.5 and p=0.8, respectively.
[0000] 3. Trajectory on the Phase Plane
[0059] The seek trajectories, including acceleration or current, velocity and position, have been expressed as functions of time. Since the time is a parameter in each design profile, these profiles are referred to as trajectories of the parametric form.
[0060] Depending on the design of seek controller, there are two possible methods to apply the extended sinusoidal wave to seeks in the servomechanism of hard disk drive. The first type seek controller is the conventional approach, which relies on the availability of seek trajectories at any instant of servo interrupt. Since these seek profiles are available at any time instant, they are the parametric trajectories.
[0061] The current trajectory is always given in parametric form because the major part of the current input to voice coil motor (VCM) is based on this design trajectory. However, the velocity trajectory and the position trajectory can be combined into a single trajectory on the phase plane by explicitly eliminated the time variable from these trajectories equations. The second type seek controller uses the seek trajectory on the phase plane. At any instant of servo interrupt, the head position is measured with a sensor. Alternatively, the head position is estimated using an estimator (or observer) when it is available in the servo system design. Given the head position from either the position sensor output or the estimator output, the design velocity at that particular position is extracted from the seek trajectory on the phase plane. The design velocity at that position is then compared against the actual velocity at that instant from either the estimator output or a tachometer output.
[0062] Using either one of the two seek controllers, the controller output consists of three parts:
(1) The current corrections associate with the differences between the design velocity and measured velocity, and between the design position and measured position. These error terms are scaled by appropriate gains to yield current corrections. (2) The design current, which is based on current trajectory at the instant of servo interrupt. (3) The adjustment current to account for bias caused by flex cable and other possible sources
[0066] FIG. 5 presents an illustration of the procedures to generate the seek trajectory on the phase plane. The seek trajectory on the phase plane has the velocity as the coordinate and the position as the abscissa.
[0067] The parametric seek trajectories for velocity and position in FIG. 3 are combined into a single seek trajectory on the phase plane of FIG. 6 . There are two seek trajectories on the same phase plane for the extended sinusoidal waveform with p=0.5 (continuous line) and the standard sinusoidal waveform (dashed line) for comparison.
[0068] The parametric seek trajectories for velocity and position in FIG. 4 are combined into the seek trajectory on the phase plane of FIG. 7 . There are two seek trajectories on the same phase plane for the extended sinusoidal waveform with p=0.8 (continuous line) and the standard sinusoidal waveform (dashed line) for comparison.
[0000] 4. Trajectories with Coast Mode
[0069] A coast mode is present in the extended sinusoidal waveform for relatively long seeks, which has zero acceleration. The notation A stands for the duration of the initial acceleration phase, which is equal to the duration of the final acceleration phase, initial deceleration phase or final deceleration phase. Denote the duration of coast mode by C, and the duration of either constant acceleration or deceleration by B. As shown in FIG. 2 ( a ), we have the following relationship for the normalized extended sinusoidal current profile.
4 A+ 2 B+C= 1. (22)
[0070] Define the symbols
Θ = 2 π C 1 - C ( 23 ) Ω = 2 π 1 - C ( 24 ) Λ = 1 Ω = 1 - C 2 π ( 25 )
[0071] For seeks with coast mode, there are two additional phases than the case without coast mode.
[0000] Phase I: Initial acceleration phase (0≦x≦A)
a I ( x )=sin Ω x (26)
v I ( x )=Λ(1−cos Ω x ) (27)
d I ( x )=Λ( x−Λ sin Ω x ) (28)
Phase II: Constant acceleration phase (A<x≦½(1−C)−A
a II ( x ) = p ( 29 ) v II ( x ) = v 1 + p ( x - A ) ( 30 ) d II ( x ) = d 1 + ( v 1 - pA ) ( x - A ) + p 2 ( x - A ) 2 ( 31 )
Phase III: Final acceleration phase (½(1−C)<x≦½(1−C))
a III ( x ) = sin Ω x ( 32 ) v III ( x ) = v 2 + Λ { cos Ω [ 1 2 ( 1 - C ) - A ] - cos Ω x } ( 33 ) d III ( x ) = d 2 + { v 2 + Λ cos Ω [ 1 2 ( 1 - C ) - A ] } [ x - 1 2 ( 1 - C ) + A ] - Λ 2 { sin Ω x - sin Ω [ 1 2 ( 1 - C ) - A ] } ( 34 )
Phase IV: Coast mode phase (Coast Mode) (½(1−C)<x≦½(1+C))
a IV ( x ) = 0 ( 35 ) v IV ( x ) = v 3 = V Max ( 36 ) d IV ( x ) = d 3 + v 3 [ x - 1 2 ( 1 - C ) ] ( 37 )
Phase V: Initial deceleration phase ((½((1+C)<x≦½(1+C)+A)
a v ( x )=sin(Ω x −Θ) (38)
v V ( x ) = v 4 - Λ [ - cos ( Ω ( 1 + C ) 2 - Θ ) + cos ( Ω x - Θ ) ] ( 39 ) d V ( x ) = d 4 + [ v 4 + Λ cos ( Ω ( 1 + C ) 2 - Θ ) ] [ x - 1 2 ( 1 + C ) ] - Λ 2 [ sin ( Ω x - Θ ) - sin ( Ω ( 1 + C ) 2 - Θ ) ] ( 40 )
Phase VI: Constant deceleration phase (½(1+C)+A<x≦1−A)
a VI ( x ) = - p ( 41 ) v VI ( x ) = v 5 - p [ x - 1 2 ( 1 + C ) - A ] ( 42 ) d VI ( x ) = d 5 + [ v 5 + p 2 ( 1 + C ) + Ap ] [ x - 1 2 ( 1 + C ) - A ] - p 2 [ x 2 - ( 1 + C + 2 A ) 2 4 ] ( 43 )
Phase VII: Final deceleration phase (1−A<x≦1)
a VII ( x )=sin(Ω x −Θ) (44)
v VII ( x )= v 6 +Λ{cos[Ω(1− A )−Θ)]−cos(Ω x −Θ)} (45)
d VII ( x )= d 6 +{v 6 +Λ cos[Ω(1 −A )−Θ]}( x −1 +A )−Λ 2 {sin(Ω x −Θ)−sin[Ω(1 −A )−Θ)]} (46)
[0072] In the generation of seek trajectories for Phase II through Phase VII of seeks with coast mode, we need initial conditions including initial velocity and initial position, which are the terminal velocity and terminal position at the end of previous phases.
[0073] Initial velocities of these trajectories for Phase II through Phase VII are as follows: These initial velocities are the terminal velocities at the end of previous phases.
v 1 = v I ( A ) ( 47 ) v 2 = v II [ 1 2 ( 1 - C ) - A ] ( 48 ) v 3 = v III [ 1 2 ( 1 - C ) ] ( 49 ) v 4 = v IV [ 1 2 ( 1 + C ) ] = V Max ( 50 ) v 5 = v V [ 1 2 ( 1 + C ) + A ] ( 51 ) v 6 = v VI ( 1 - A ) ( 52 )
[0074] Initial displacements of these trajectories for Phase II through Phase VII are given below. These initial displacements (or positions) are the terminal positions at the end of each trajectory of previous phases.
d 1 = d I ( A ) ( 53 ) d 2 = d II [ 1 2 ( 1 - C ) - A ] ( 54 ) d 3 = d III [ 1 2 ( 1 - C ) ] ( 55 ) d 4 = d IV [ 1 2 ( 1 + C ) ] = V Max ( 56 ) d 5 = d V [ 1 2 ( 1 + C ) + A ] ( 57 ) d 6 = d VI ( 1 - A ) ( 58 )
[0075] FIG. 8 shows the seek trajectories for the extended sinusoidal current waveform with p=0.65 and C=0.2. The top trace is the trajectory showing normalized current versus normalized time. Shown in the middle trace is the normalized velocity trajectory as a function of the normalized time. The bottom trace in FIG. 8 shows the normalized position trajectory versus the normalized time.
[0076] The velocity trajectory and the position trajectory in FIG. 8 are combined into a single seek trajectory on the phase plane by eliminated the variable of time from these two trajectories. The combined seek trajectory is shown on the phase plane in FIG. 9 with the coordinate as the velocity and the abscissa as the position.
[0000] 5. Seek Time as a Function of Seek Length
[0077] Seek time in the following refers to the movement time of a transducer from one location to another without the inclusion of settling time for the transducer to be ready for read or write operation at the new location.
[0078] The comparison given below applies to seek without coast mode only.
[0079] For any general current profile, the relationship between seek length (X SK ) and seek time (T SK ) is given by the following equation.
T SK = ψ 1 K VCM I MAX X SK = ψ J K T I MAX X SK . ( 59 )
where
K VCM =K T /J=VCM constant, K T =VCM torque constant, J=Mass moment of the inertia, I MAX =Maximum current
[0084] The constant Ψ in Eq. (59) is determined from the boundary condition, which leads to the following equation.
ψ = p d V ( 1 ) . ( 60 )
[0085] In Eq. (60) the parameter p is the limitation level of sine function as defined in Eq. (1), and d v (1), computed using the phase V position trajectory given in Eq. (17), stands for the dimensionless seek length at the end of seek.
[0086] The parameter Ψ for sinusoidal seek profiles is
Ψ=√{square root over (2π)}. (61)
[0087] For bang-bang current profile, the parameter v becomes
Ψ=2. (62)
[0088] For a rigid body motion subjected to a constant acceleration only (no deceleration), the parameter Ψ is given by
Ψ=√{square root over (2)}. (63)
[0089] The parameter Ψ for the extended sinusoidal waveform is proportional to the square root of another waveform-dependent parameter p as shown in Eq. (60). This parameter Ψ falls in between the two limits.
2<Ψ<√{square root over (2π)}. (64)
[0090] Since the waveform is so complicated, there is no closed form representation for this parameter. Numerical solutions, however, are available for the parameter Ψ, which are summarized in Table 1 below for various different p values.
TABLE 1 Relationship between A*, p and ψ, for the Extended Sine Wave p A B ψ Comment 0.1 0.0159 0.4682 2.0329 Getting closer to bang-bang trajectory 0.2 0.0320 0.4360 2.0681 0.3 0.0485 0.4030 2.1050 0.4 0.0655 0.3690 2.1444 0.5 0.0833 0.3334 2.1878 0.6 0.1024 0.2952 2.2363 0.7 0.1234 0.2532 2.2891 0.8 0.1476 0.2048 2.3467 0.9 0.1782 0.1436 2.4208 1.0 0.2500 0.0000 2.5155 Sinusoidal seek trajectory * Note : B = 1 2 - 2 A
[0091] It is easy to make movement time comparison for relatively short seeks without coast mode. FIG. 10 shows the seek time comparison for servo seek mechanism with bang-bang control, sinusoidal seek method and extended sinusoidal seek waveform with p=0.5 as current profile, respectively. It is noted that the bang-bang control algorithm has the shortest seek time, and the sinusoidal seek has the slowest seek time. The seek time for the extended sinusoidal seek model falls in between these two extremes. However, the seek time for the extended sinusoidal seek model is adjustable. As the parameter p of the extended sinusoidal waveform gets smaller, the waveform gets closer to the bang-bang current trajectory, and its corresponding seek time also gets shorter. FIG. 11 is the seek time comparison for servo systems with these three different current profiles: bang-bang control, extended sinusoidal waveform with p=0.8 and the sinusoidal seek method.
[0000] 6. Seek Controller Design
[0092] There are two different seek controllers available:
(1) Seek controller using seek trajectories of parametric form (2) Seek controller on the phase plane
[0095] When there is no coast mode involve in the seek, the controller for seek can be either one of the designs shown in FIG. 12 and FIG. 13 for parametric form and phase-plane form, respectively.
[0096] For longer seeks with coast mode, the controller for seek can be either one of the designs shown in FIG. 14 and FIG. 15 for parametric form and phase-plane form, respectively.
[0097] The control current for the parametric form seek controller ( FIG. 12 or FIG. 14 ) is, given by
u ( n )= K 1 X err ( n )+ K 2 V err ( n )+ i D ( n )− w E ( n ) (65)
[0098] For seek controller on the phase plane, the controller current ( FIG. 13 or FIG. 15 ) is computed as follows.
u ( n )= K V V err ( n )+ i D ( n )− w E ( n ) (66)
[0099] Note that the parametric trajectories are explicitly dependent on time. The seek trajectory is explicitly dependent on position; however, it is implicitly dependent on time.
[0000] 7. Summary and Usage of Trajectory
[0100] The extended sinusoidal current profile is a new class of waveform devised to improve the robustness of the conventional bang-bang control algorithm of seeks for servomechanism in hard disk drive application, and, at the same time, retaining near time-optimal seek performance. Compared to the sinusoidal seek algorithm, the extended sinusoidal current profile can much improve the seek time while maintaining descent robustness in control.
[0101] The generation of the current profile for the extended sinusoidal seek is made by limiting the sine wave not to exceed a saturation level of p (0<p<1). When the sine wave is larger than p, the current saturates at the level of p; and, on the other hand, the current is set to −p when the current falls to be less than p. The current trajectory is then normalized so that the current falls within the range of ±1.
[0102] The extended sinusoidal waveform includes the conventional bang-bang control waveform and the sinusoidal waveform as its two opposite limiting cases when the duration of constant current profile is always at its peak and, for the other extreme, the constant duration does not exist, respectively.
[0103] The new current trajectory can be very valuable under certain circumstances. First, when the servo system design is pursuing a faster seek time, the new trajectory is used by extending the duration of current at peak instead of increasing the magnitude of the peak, which, usually, is not possible. Second, under the restriction of certain VCM driver, one may not have a choice to raise maximum current for VCM to meet the criterion of design seek time. Commonly, a hard drive is designed for extreme operating conditions such as 55° C. environment with 10% supply voltage reduction. The extended sine wave allows the design engineer to reduce the maximum current and, at the same time, to increase the duration of constant acceleration. Consequently, seek time for a recording head in a long seek can still be faster. | A hard disk drive moves a transducer (or recording head) across a disk surface so that the transducer has an essentially extended sinusoidal acceleration trajectory. The transducer may be integrated into a slider that is incorporated into a head gimbal assembly (HGA). The HGA may be mounted to an actuator arm, which can move the transducer across the disk surface. The movement of the actuator arm and the transducer may be controlled by a controller. The function of a controller is to move the transducer from its present track to a target track in accordance with a seek routine and a servo control routine. During the seek routine the controller may move the transducer in accordance with an extended sinusoidal current trajectory. The extended sine wave is devised to be current profiles for use in seeks control to move a recording head from one position to another position fast and robustly. The extended sinusoidal waveform as a current profile may provide a balance design to achieve near time-optimal seek performance, and, at the same time, to minimize mechanical resonance and its associated acoustic noise generated during seeks. This extended sine wave as current profile for a seek servomechanism may have the advantages of being more controllable than conventional bang-bang control and faster than a sinusoidal seek algorithm. The extended sinusoidal waveform is very general, which represents a new class of versatile trajectories. Both the conventional bang-bang trajectory and the sinusoidal trajectory are limiting cases of the extended sinusoidal waveform. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on U.S. Provisional Patent Application Ser. No. 61/413,685 filed on Nov. 15, 2010, the content of which is relied upon and incorporated herein by reference in its entirety, and the benefit of priority under 35 U.S.C. §119(e) is hereby claimed.
GOVERNMENT SPONSORSHIP
N/A.
BACKGROUND
1. Field of the Invention
Embodiments of the invention relate generally to photobioreactors and associated photobioreaction methods and applications. More particularly, embodiments of the invention are directed to optofluidic photobioreactor apparatuses and associated methods and applications, in which light is delivered to a photosynthetically-active entity (e.g., bacteria, algae, or other photosynthetic microorganism) through the evanescent radiation field from the surface of a waveguide adjacent the microorganism. Non-limiting embodied applications of the invention pertain to the delivery of said evanescent radiation to said microorganisms to directly or indirectly produce fuels, chemicals, and/or biomass such as, but not limited to, algae, that can be further processed to produce chemicals such as, but not limited to, fuel.
2. Technical Background
The conversion of solar energy to fuel through the cultivation of photosynthetic algae and cyanobacteria relies critically on light delivery to microorganisms. Conventional direct irradiation of a bulk suspension leads to nonuniform light distribution within a strongly absorbing culture, and related inefficiencies.
Growing concern over global climate change and the rising cost of fossil fuels has led to substantial investment and research into alternative fuel sources. For this reason, bioenergy approaches have been developed to produce fuels such as ethanol, methanol, hydrogen and diesel. In order to compete with fossil fuels, however, producing biofuels require large feedstock volumes of inexpensive biomass. Although many feedstocks have been explored, including used cooking oil, food crops, and biowastes, most suffer from low net energy benefit, poor energy density, large footprint requirements and/or insufficient availability. Alternatively, microalgae, which exhibit high growth rates and oil content compared to higher plants and have and have the ability to grow in a range of diverse environments, have been used to produce biofuels. In particular, cyanobacteria use solar energy to convert carbon dioxide and water into biofuel, making possible a near carbon neutral petrochemical alternative.
Cost-effective biofuel production from cyanobacteria is directly linked to the density of cultures within a photobioreactor and its overall volume. Currently, the simplest strategy for cultivation of large volumes of microalgae is an open racetrack-style pond exposed to ambient air and sunlight. However, due to issues related to insufficient light distribution, temperature control, nutrient delivery, contamination, and water consumption, pond operations run at low cell densities. As a result, pond strategies suffer from poor areal productivity and low overall power density. Consequently, fully enclosed photobioreactors have been designed to provide precise control over the cultivation environment and maintain growth conditions. However, a central problem common to both open and closed cultivation strategies remains the efficient delivery of light to the microorganisms. As cultures increase in both volume and density, it becomes increasingly difficult for light to be distributed evenly to the individual bacteria. In current reactors, areas near the exposed surface tend to be overexposed, resulting in photoinhibition, and large interior regions are effectively in darkness. Flowing, dilute solutions must be employed to circulate bacteria through regions with productive light levels, placing a fundamental limit on culture density and overall power density of this technology.
A variety of photobioreactor strategies have been developed to provide more effective light distribution to cells by spatially diluting the light over a larger surface area. One strategy is to use light guides to channel light into the reactor volume and subsequently scatter the light into the media. Our reported approach employed cylindrical glass light distributors inserted into a culture tank to assist in distributing light. Sunlight harvested from arrays of Fresnel lenses was channeled to the reactor via optical fiber. Another reported approach used side-lit optical fibers inserted into the culture tank to improve light delivery. Another used optical fibers inserted into the culture chambers with the goal of scattering light collected from external solar collectors into the culture. Although these early studies indicate that increasing control and irradiated surface area within a photobioreactor can improve productivity, these technologies do not escape the fundamental limitation posed by the overexposure and shadowing issues accompanying direct irradiation of bulk cultures.
An evanescent field is a nearfield standing wave having an intensity that exhibits exponential decay with distance from the boundary at which the wave was formed. Evanescent waves are formed when waves traveling in a medium (e.g., an optical waveguide) via total internal reflection strike the boundary at an angle greater than the critical angle. Evanescent field phenomena are well known in the art.
In view of the problems and shortcomings identified above and known in the art, the embodied invention provides solutions and advantageous approaches that will benefit and advance the state of the art in this and related technologies.
SUMMARY OF THE INVENTION
An embodiment of the invention is directed to an optofluidic photobioreactor. The bioreactor includes an optical waveguide having an input, characterized by an evanescent optical field confined along an outer surface of the optical waveguide that is produced by radiation propagating in the optical waveguide, and a selected photosynthetic microorganism disposed substantially within the evanescent field. As will be more fully understood from the detailed description below, the evanescent field advantageously extends from the waveguide for a distance on the order of the thickness (i.e., minor diameter) of the photosynthetic microorganism that is being irradiated by the evanescent field, thus the microorganism will be understood to be disposed substantially within the evanescent field. According to various non-limiting, exemplary aspects:
the optical waveguide is an unclad optical fiber having a diameter, d, where 10 μm≦d≦100 μm, and an input end; the optical waveguide is a multi-mode optical fiber; the photobioreactor further includes two or more optical waveguides disposed in a side-by-side array configuration and having a center-to-center intra-waveguide separation, D, where d≦D≦1.5d; the photobioreactor further includes a photobioreactor enclosure having an input and an output, inside of which the two or more optical waveguides are disposed, wherein the photobioreactor enclosure is characterized by a plurality of optically-dark fluid channels created by a void space surrounding the plurality of optical waveguides; the optical waveguide further comprises a prism waveguide; the photobioreactor further includes means for inputting light to the input of the optical waveguide; the means for inputting light to the input of the optical waveguide comprises a laser output directly input to a prism waveguide; the means for inputting light to the input of the optical waveguide comprises solar radiation channeled to the input of the optical waveguide; the photobioreactor includes a liquid microorganism-nutrient media disposed in a void space of the photobioreactor; the photobioreactor includes a controller operably connected to the photobioreactor enclosure; the photosynthetic microorganism is at least one of a bacterium and algae; the photosynthetic microorganism is a cyanobacterium;
the cyanobacterium is Synechococcus; the cyanobacterium is Synechococcus elongatus;
the photosynthetic microorganism is a genetically-engineered, direct biofuel-producing microorganism; the photobioreactor includes a microfluidic chip in or on which a plurality of the optical waveguides are disposed;
the microfluidic chip is in the form of a high aspect ratio (thin) sheet;
the high aspect ratio (thin) sheet is corrugated;
the optical waveguide is a sheet waveguide;
the sheet waveguide is corrugated;
the selected photosynthetic microorganism is in the form of an adsorbed single layer of the microorganism; the photobioreactor includes an artificial adhesive disposed intermediate the outer surface of the waveguide and the selected photosynthetic microorganism such that the microorganism is purposefully adhered to the outer surface of the waveguide.
An embodiment of the invention is directed to a method for optically exciting a photosynthetic microorganism for generating a biofuel, a biofuel pre-cursor, or a biomass from the optically-excited photosynthetic microorganism. The method include the steps of providing an optical waveguide having an outer surface; inputting optical radiation to the optical waveguide; propagating the optical radiation in the optical waveguide; generating an evanescent optical field adjacent the outer surface of the optical waveguide from the optical radiation propagating in the optical waveguide; providing a photosynthetic microorganism within the evanescent optical field of the optical waveguide; and driving photosynthesis in the microorganism by irradiating at least a portion of a thylakoid membrane of the photosynthetic microorganism with the evanescent optical field. According to various non-limiting, exemplary aspects:
the step of providing an optical waveguide further comprises providing a prism waveguide; the step of inputting optical radiation to the optical waveguide further comprises directly injecting light from a laser into a prism waveguide in a manner to propagate the light by total internal reflection;
injecting light in a wavelength range 600 nm≦λ≦700 nm;
the step of providing a photosynthetic microorganism within the evanescent optical field of the optical waveguide further comprises providing the photosynthetic microorganism adjacent the outer surface of the optical waveguide in a region extending not more than about five microns (5 μm) from the outer surface of the optical waveguide; the step of providing a photosynthetic microorganism within the evanescent optical field of the optical waveguide further comprises providing an adsorbed layer of the microorganism on the outer surface of the optical waveguide; providing a plurality of the optical waveguides disposed in a side-by-side array configuration; providing a photobioreactor enclosure having an input and an output, inside of which a plurality of optical waveguides are disposed, wherein the photobioreactor enclosure is characterized by a plurality of optically-dark fluid channels created by a void space surrounding the plurality of optical waveguides;
providing a microorganism nutrient media in the plurality of optically-dark fluid channels; and
harvesting a biofuel, a biofuel pre-cursor, or a biomass from the photobioreactor; the step of providing a photosynthetic microorganism further comprises providing a free-floating microorganism media within a photobioreactor enclosure; inputting solar optical radiation to the optical waveguide; providing a controller and controlling a parameter of the optical radiation input to the optical waveguide; providing a suitable photosynthetic microorganism and directly harvesting a biofuel from the photobioreactor; providing a suitable photosynthetic microorganism and harvesting a biofuel precursor from the photobioreactor; providing a suitable photosynthetic microorganism and harvesting a biomass from the photobioreactor.
Additional features and advantages of the invention will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein according to the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates in perspective view an array of optical waveguides in the form of unclad optical fibers and a layer of algae disposed on the outer surface of each of the fibers, according to an illustrative embodiment of the invention;
FIG. 2 is a schematic overview of a photobioreactor system utilizing the array of optical waveguides shown in FIG. 1 , according to an illustrative embodiment of the invention;
FIG. 3 is a schematic view in cross section showing the evanescent field generated from an optical waveguide as illustrated in FIG. 1 and a Synechococcus elongatus cyanobacterium (algae) disposed on the surface of the waveguide being irradiated by the evanescent field, according to an illustrative embodiment of the invention;
FIG. 4 shows a schematic top view of the photobioreactor enclosure containing the array of optical fibers with adsorbed photosynthetic bacteria and the dark or void regions (fluid channels) where the evanescent field does not penetrate, according to an illustrative embodiment of the invention;
FIG. 5 is a photo of a bench-top optical fiber-based photobioreactor according to an exemplary embodiment of the invention;
FIG. 6 illustrates excitation process and apparatus for photosynthetic bacteria with an evanescent light field; (A) a schematic cross sectional illustration showing evanescent coupling of a photosynthetic bacterium on the surface of a waveguide. The characteristic decay of the light intensity, as plotted at the right of the figure, is on the order of the cell minor diameter size; (B) a schematic illustration of an experimental setup to generate the evanescent wave at the surface of a prism optical waveguide. The input beam is Gaussian and the evanescent field resulting from total internal reflection is elliptical in shape, as shown;
FIG. 7A : image of cyanobacteria growth pattern resulting from direct irradiation, showing distinct regions of photoinhibition (centre), growth, surrounded by negligible growth; B: plot correlating radial growth intensity to laser light intensity. Outlying peaks beyond 1.2 mm are artifacts of the imaging setup and do not correspond to growth. FWHM thresholds on the growth region correspond to radiant light intensities of 66 W/m 2 and 12 W/m 2 , shown as upper and lower bounds, respectively, according to illustrative aspects of the invention;
FIG. 8 graphically shows a spectral power distribution of daylight and an absorption spectrum of PSII plotted with measured absorbance of the S. elongatus culture. The photoinhibition threshold at λ=633 nn measured from experiments in FIG. 7 (66 W/m 2 ) correlates to established photoinhibition intensities of white light exposure, when related through the absorption spectrum shown, according to an illustrative aspect of the invention;
FIG. 9 illustrates the theoretical light intensity distribution in the evanescent light field, and corresponding predicted growth patterns: A: plot of the penetration depth as a function of incident laser angle for a glass-media interface. Penetration depth is defined as the location where field intensity drops e −2 , or 87%, from that at the surface. The dashed line indicates a penetration depth of 1 μm occurring at θ i2 =θ c +0.074°, and the geometry of S. elongatus is shown inset for reference; B: surface plot of evanescent field, 1 μm from the surface, with power intensity plotted to indicate the photoinhibited, growth, and negligible-growth regions, based on thresholds measured for radiant light. Based on these values an elliptical ring pattern of growth is predicted, as shown by the useful portion of the power spectrum shown in (green) shaded region 2 . The vertical line plot indicates the useful light intensity decay with distance, according to illustrative aspects of the invention; and
FIG. 10 illustrates the growth of photosynthetic bacteria using evanescent light: A-C: Images of cyanobacteria growth patterns resulting from evanescent excitation at the glass-media interface for incident light powers of 1 mW, 0.5 mW, and 0.25 mW, respectively. The elliptical growth patterns correspond to the evanescent field geometry, and show distinct regions of photoinhibition (centre), and growth, surrounded by negligible growth; D-F: Corresponding growth profiles for each light power with the corresponding evanescent field intensities plotted at the surface, 1 μm above the surface, and as a 5 μm average. The power range determined from the direct radiation experiments ( FIG. 7 ) is shown by the red band for reference. The full-width at half maximum indicating growth onset is observed at 1 μm intensity levels of 79±10 W/m 2 , and observed at 60±8 W/m 2 for the 5 μm average light intensity. These values bracket the 66 W/m 2 threshold determined for radiant light at this wavelength, according to illustrative aspects of the invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
FIG. 1 schematically illustrates in perspective view an array of optical waveguides 100 in the form of unclad optical fibers 101 having a diameter, d, where 10 μm≦d≦100 μm, and a single layer of algae 151 disposed on the outer surface of each of the fibers. By propagating light in the optical fibers, an exponentially decaying optical field (referred to as an evanescent field) 303 is created over the surface of the optical fiber. FIG. 3 is a schematic view in cross section showing the evanescent field 303 , and a Synechococcus elongatus cyanobacterium (algae) 351 adsorbed on the surface 107 of the waveguide 101 being irradiated by the evanescent field. In a non-limiting alternative aspect, the bacteria may be artificially attached to the waveguide surface with a suitable adhesive material.
FIG. 2 illustrates a photobioreactor system 200 in which solar radiation is collected ( 202 ) and coupled into the optical fibers than run through the reactor volume in a reactor enclosure 207 . The photosynthetic mechanics of the cyanobacteria is contained in the thylakoid membranes (˜100 nm) that surround the cyanobacteria, as illustrated in the inset 212 . The evanescent field extends up to about 1 μm from the unclad fiber surface ( FIG. 3 ) and provides the proper light intensity, I O (see 214 , FIG. 2 ), to the bacteria. Due to the exponential decay of the evanescent field, as illustrated by the graph inset 214 , a dark region 218 occurs in the interstitial space between the fibers, which serve as fluid channels (see also FIG. 4 ). These fluid channels can be used for transport of CO 2 and media to the bacteria, and for the collection of produced biofuel. The use of the evanescent field allows for the optimum utilization of light by the bacteria and for enhanced volume utilization for the reactor as a whole.
FIG. 4 shows a schematic top view of the photobioreactor enclosure 207 containing the array of optical fibers 101 with adsorbed photosynthetic bacteria 151 and the dark or void regions (fluid channels) 218 where the evanescent field 303 does not penetrate. The fibers have a center-to-center intra-waveguide separation, D, where d≦D≦1.5d.
FIG. 2 further illustrates a control component 237 that enables parameters including, but not limited to, wavelength, intensity, and duty cycle of light in the fibers to be tuned with precision such that the bacteria are optimally exposed.
For the direct conversion of CO 2 to biofuel, genetically modified S. elongatus SA665, produced at UCLA, has shown the ability to directly convert CO 2 to isobutyraldehyde, which may be converted to isobutanol (a gasoline substitute), at area-wise efficiencies comparable or greater to current biofuel production strategies.
An estimate of achievable density for the illustrated optofluidic bioreactor architecture is useful for comparison with current systems. A hexagonal packing of the optical fibers as shown in FIG. 4 would provide an absorbed layer of fuel producing Synechococcus Elongatus occupying 10% of the total volume, while the remaining 90% of the volume is required for optics and fluid. A density of 10% active bacteria by reactor volume is 4500-fold greater than demonstrated tube photobioreactors known in the art and eight orders of magnitude greater than that of a comparable pond reactor. This scaling suggests that the output of a one-story 5680 m 2 tube facility could be matched by a table-sized (2.5 m 3 ) optofluidic reactor 500 - 1 according to the embodied invention as shown in FIG. 5 . While such a reactor would require a separate photocollector and associated irradiated area, the separation of reactor with collection additionally offers the ability to tailor the light spectrum to the photosynthetically active range (400-700 nm); cycle light at an optimal frequency for photosynthetic activity (typically 100 Hz); collect incident solar light at high angles as required outside of equatorial regions; and control the reactor temperature making operation feasible in colder climates where fuel demand is high, such as North America and Europe.
Detailed Exemplary Embodiment
According to another exemplary embodiment and aspects thereof, FIGS. 6A and 6B , respectively, illustrate the evanescent excitation process 600 - 1 of a bacterium 651 and a prism waveguide-based photobioreactor 600 - 2 used to generate the evanescent excitation field 303 . As more particularly illustrated in FIG. 6B , a prism waveguide 627 is shown in cross section. Monochromatic red (λ=633 nm) light 606 provided by a HeNe laser 605 is directly injected into the side of the prism waveguide. The evanescent field 303 is generated at the interface surface 617 of a glass slide 642 where the light is totally internally reflected. Total internal reflection, and the corresponding evanescent field, result when the light is incident at the glass-media interface at angles greater than the critical angle; i.e., θ i2 >θ c . Reflecting a circular cross-section input beam creates an elliptical evanescent field profile on the prism surface at the point of reflection, as shown in the inset 653 in FIG. 6B . It will be appreciated by those skilled in the art that there are alternative ways to generate an evanescent field; however, the illustrated approach is simple and provides an evanescent light field distribution that can be reliably described with theory in all three dimensions.
In the experimental set-up of FIG. 6B , cavities to contain a bacteria culture solution were fabricated by moulding PDMS (Sylgard® 184 Elastomer Kit, Dow Corning) around a poly(methylmethacrylate) (PMMA) master to create cylindrical cavities 10 mm in diameter and 4.75 mm deep (0.373 mL). These culture cavities were bonded to the surface of a 1 mm thick BK7 glass microscope slide using oxygen plasma treatment.
Cells of the wild type S. elongatus (ATCC 33912) cyanobacteria were used to demonstrate the embodied invention. Cells were cultured under optimal conditions of 32-36° C. and under continuous irradiation of 50-75 μE·m −2 ·s −1 using fluorescent lamps. The stock culture was kept at a constant cell density (in the exponential growth phase) by regularly diluting the culture with fresh BG11 cyanobacteria growth medium (Sigma Aldrich C3061) to maintain a constant optical density of 0.2 at 750 nm (OD 750 ). The OD 750 was determined using a broad spectrum halogen light source (Thorlabs OSL1) and spectrometer (Edmond brc112e) and normalized to the OD 750 of fresh BG11 growth media. Samples of this culture were used in our experiments.
Once mounted to the glass plates and inoculated (dead end filling via syringe injection), the cultures were placed on the top faces of right angle BK7 prisms (Thorlabs PS908L-A), as shown in FIG. 6 . Optical contact was achieved using an index matched immersion oil (Leica 11513 859). Light was coupled to the chamber from a helium neon laser (632.8 nm Thorlabs HRR020) directed toward the prism by reflecting it off a broadband dielectric minor (Thorlabs CM1-4E; not shown) mounted to a precision rotation mount (Thorlabs CRM1P; not shown). The incident angle at the glass media interface was adjusted by changing the angle of the mirror in the rotation mount. The prism/culture assembly was mounted to a sliding stage (not shown), which allowed the laser beam to be maintained in the center of the culture chamber as the angle of incidence was varied. The prism assembly was aligned such that the reflection of the beam leaving the prism did not pass through the culture. This ensured that optical excitation of the bacteria was solely due to the evanescent field where the beam was totally internally reflected at the glass-bacteria culture interface.
Laser beam power into and out of the prism was measured using a photodiode power sensor (Thorlabs S120C) and measured once at the beginning of the experiment and once at the end. The entire experimental apparatus was optically isolated in enclosures made from 5 mm thick hardboard (Thorlabs TB4). These chambers were kept at a constant temperature of 32-36° C. for optimal cell growth rates for the duration of the evanescent growth experiments using a 950 W enclosure fan heater (CR030599, OMEGA Engineering Inc., USA).
Experimental Results and Discussion
Cell cultures were first placed under direct laser light exposure, to establish the effectiveness of using monochromatic red (λ=633 nm) at growing S. elongatus , and measure cell response to direct radiation light. The beam from a Helium-Neon (HeNe) laser was passed through a culture cavity perpendicular the bottom glass slide ( FIG. 6B ) and the culture was left to grow for 72 hours (under conditions described above). This type of direct irradiation experiment was done for various laser powers, yielding consistent results to those shown in FIG. 7 . FIG. 7A shows a typical growth ring pattern 700 - 1 , where the effect on growth from the three distinct intensity regions 712 (center), 714 (mid), 716 (outer) is evident as shown. There is a bleached (yellowish orange in color view) region 712 in the center, a growth region 714 (green in color view) and a negligible growth outer region 716 . To quantify growth in a radial profile, the image was filtered for green intensity and integrated in circumference. The resulting radial growth profile is plotted with the laser intensity profile in FIG. 7B . The threshold electric field intensities (low and high) between regions were determined from the intersection of the full width at half the maximum (FWHM) growth locations and the incident light power profile. The resulting threshold values of 66 W/m 2 and 12 W/m 2 (shown in FIG. 7B by the rectangle within the growth peak) indicate the productive growth intensities of S. elongatus under direct irradiation at λ=633 nm.
Relating these direct irradiation experiment results to known growth characteristics of S. elongatus requires determining the daylight equivalent power of red light at λ=633 nm. To do so, we compared radiometric measurements of daylight to optimal intensity ranges published in literature. At high light intensities, the rate of radiation induced damage to the cell's photosystems exceeds the cell's ability to repair itself and the result is a sharp decrease in photosynthetic activity, or photoinhibition. High light conditions that approach saturating intensities are reported as a Photosynthetic Photon Flux Density (PPFD) on the order of 150 μE·m −2 ·s −1 to 500 μE·m −2 ·s −1 in the Photosynthetically Active Radiation (PAR) wavelength range (400-700 nm), or 10%-25% of full daylight. To convert the photosynthetic photon flux density to radiometric units (i.e. W/m 2 ), the optical power of full daylight was measured at 635 nm to be 1.37 W/m 2 (48°25′43″ N, 123°21′56″ W). The spectral power distribution of normal daylight 806 was then calculated from this set point and the relative spectral power distribution defined by CIE Standard Illuminant D65, as shown in FIG. 8 . Total full daylight irradiance of photosynthetically active radiation was calculated to be 472 W/m 2 , which corresponds to a photosynthetic photon flux density of 2137 μE· −2 ·s −1 . This value was independently confirmed by a QSR-2100 (Biospherical Instruments Inc.) light meter measurement of 2100-2300 μE· −2 ·s −1 . Also shown in FIG. 8 , is the absorption spectrum 804 for Photosystem II (Sugiura M & Inoue Y (1999) Highly Purified Thermo-Stable Oxygen-Evolving Photosystem II Core Complex from the Thermophilic Cyanobacterium Synechococcus elongatus Having His-Tagged CP43, Plant Cell Physiol. 40(12):1219-1231). Photosystem II (PSII) is the link in the photosynthetic pathway most susceptible to light induced damage and is the first point of failure in high light environments. The characteristic shape of the published absorption spectrum can also be observed in the measured absorption spectrum of the sample culture 802 (OD 750 of 0.37), most notably at the ˜450 nm, 630 nm and 670 nm peaks as plotted FIG. 8 . Absorption in the red region of the spectrum contributes most significantly to photosynthesis while absorption of lower wavelengths is due to the presence of molecules not directly involved in the electron transport process. Under normal daylight conditions, S. elongatus PSII absorbs 30 W/m 2 of red light (600 nm<λ<700 nm) determined by weighing the spectral power distribution for daylight by the absorption spectrum of PSII and integrating across the red portion of the spectrum. In order to deliver an equivalent amount of energy using monochromatic laser light at λ=633 nm, the ability of PSII to absorb at that wavelength needs to be considered to determine the appropriate corresponding laser power. In this case, PSII absorbs approximately 13% of 633 nm light, which requires a laser power of 230 W/m 2 to simulate full daylight conditions. The threshold measured in the direct irradiation experiments, 66 W/m 2 , therefore suggests that ˜28% of full daylight is the upper limit for our cultures before severe photoinhibition occurs. This value agrees well with the upper bounds of what are considered high-light conditions as reported in the literature.
The light intensity distribution in an evanescent light field varies both in the plane of the surface and depth-wise into the media. Established theory was applied to describe the evanescent electric field intensity and used to correlate field strength to experimental growth results. FIG. 9A shows the penetration depth 904 (y-axis) of the evanescent light field as a function of incident angle (x-axis). Here, the penetration depth is quantified as the location where the field intensity drops e −2 , or 87%, of the peak intensity at the surface. The geometry of S. elongatus is shown inset ( 909 ) in FIG. 9A for reference, and the dashed line 910 indicates a penetration depth of about 1 μm, which occurs at an angle of incidence of θ i2 =θ C +0.074°. As shown, the penetration depth of the evanescent field is a strong function of incident angle, with values corresponding to the inherent lengthscale of the bacterium occurring only near the critical angle (below 0.5° past critical).
FIG. 9B shows the predicted evanescent field intensity in the plane, and the characteristic oval shape for an incident 0.5 mm diameter Gaussian beam at λ=633 nm. The intensity values indicated correspond to the evanescent light intensity at 1 μm from the glass-media interface, with an incident angle of 62° (θ i2 =λ C +0.5°) and penetration depth of 400 nm. Based on the above-determined threshold light intensity for the red light employed here (66 W/m 2 , at 633 nm), the expected growth regions can be predicted based on the calculated evanescent field intensity. As shown in FIG. 9B , in region 1 the evanescent field intensity exceeds the red component of 10% daylight and would be expected to lead to photoinhibition in a radiant light system. This analysis would predict an elliptical ring pattern of growth, as shown by the useful portion of the power spectrum, region 2 (green shading in color diagram). The vertical line plot indicates the useful light intensity decay with distance. Relatively intense growth is expected near the inside boundary where useful light intensities are high, and growth rates would decay with the light intensity outward. Although the sharpness of the inside edge of the growth profile is an artifact of the threshold boundary condition, the model provides the predicted pattern of growth for a photosynthetic microorganism cultured in this evanescent field.
Evanescent light based excitation of the culture was performed using the experimental setup shown in FIG. 6B . Three laser powers were employed (1 mW, 0.5 mW, 0.25 mW) with incident laser angles of 62° (θ i2 =θ c +0.5°), and total internal reflection was ensured by measuring the output intensity. Each experiment was performed in triplicate and the cultures were exposed to the evanescent field for 72 hours. FIGS. 10A-C show substantial bacteria growth in response to the evanescent light field at the surface of the glass-media interface. The growth patterns showed the elliptical shape mirroring the evanescent light field intensity, and delineate the three characteristic regions (photoinhibition, growth, negligible-growth), providing data on the onset of growth under evanescent light. As the laser power was reduced ( FIGS. 10A to C), the radial distribution moved inward, consistent with the change in the light intensity profile. To relate the observed growth to the evanescent field intensity, the images were filtered for green intensity, scaled along the axis of the beam, and integrated to provide growth profiles. FIGS. 10D-F show the growth profiles for each light power with the corresponding evanescent field intensities plotted at the surface, 1 μm above the surface, and as a 5 μm average. Due to rapidly decaying nature of the evanescent field, the surface intensity is much higher than that at 1 μm above the surface, which is also similar to the average intensity over the first 5 μm (both 1 μm and 5 μm are relevant lengthscales of this rod-shaped bacteria). The power range determined from the direct radiation experiments is shown by the red band 1090 for reference. The onset of growth occurs at a radial location where the evanescent light intensity—as measured at 1 μm and as a 5 μm average—drops to a value corresponding to the threshold of 66 W/m 2 , established from direct radiation experiments. As the total intensity of light is decreased ( FIGS. 10A-C and D-F), the location of the onset intensity moves inward, and remains consistent with the predicted power curves. Specifically, the full-width at half maximum, indicating growth onset, is observed at 1 μm intensity levels of 79±10 W/m 2 , and observed at 60±8 W/m 2 for the 5 μm average light intensity. These results both demonstrate growth of photosynthetic bacteria using evanescent light, and provide metrics for their successful cultivation within this unique light field.
The growth patterns shown in FIG. 10 show some downbeam bias, that is, growth intensity increases with distance from the laser source. When the cells interact with the evanescent field near the surface, some of the light is absorbed and utilized, while some of the light is scattered. The light will be scattered preferentially in the direction of the beam. With the present experimental setup, this scattered light would contribute to higher growth rates, and thicker biofilms, on the downbeam side of the ring pattern. This effect was noticed in most cases with downbeam growth biases of 1%, 8%, and 15% for the 0.25 mW, 0.50 mW, 1.0 mW cases plotted in FIG. 10 . Although the extent of this bias varied between trials, and some trials showed negligible, and even a small upbeam bias, the effect was in general small and in all cases less than 15%. While it is likely that downbeam bias and secondary scattering effects influence growth, the relative symmetry of the growth patterns indicates that the downbeam scattering effect is minor.
The additional effect of light penetration depth was investigated using incident light at larger angles past critical (θ C <θ i2 <θ C +5). At angles greater than 0.5° over critical (as plotted in FIG. 10 ), however, only faint growth rings were observed. We attribute the lack of growth at larger angles to the change in penetration depth, which diminishes rapidly with increasing incident angle, as shown in FIG. 9A . Specifically, the penetration depth corresponds to the minor-dimension of the rod-shaped bacterium (1 μm) only at angles less than θ C +0.074°. These results are thus consistent with the observed evanescent growth patterns in that the penetration depth approached the cell diameter only at small angles away from critical.
We have thus demonstrated an evanescent-light based approach to deliver light on the lengthscale of cyanobacteria for photosynthesis. In addition to demonstrating cultivation of bacteria in the evanescent field, analysis of the growth pattern provides guidelines for determining appropriate evanescent light based exposure conditions from known radiant light response. Growth can be predicted based on these metrics both with respect to light penetration depth and light intensity. In the context of photobioreactor technology, this approach to light distribution differs from conventional approaches of bulk irradiation in that it offers a means of controlling the energy delivered to individual cells rather than bulk cultures. A photobioreactor architecture based on the embodied evanescent light delivery approach could take several forms. For example, one approach could be to leverage the low cost and relative ubiquity of fiber optic technology in a reactor with a dense network of bacteria-absorbed fibers, or fabric, in a large media vessel. Paired with recent advances in the genetic modification of cyanobacteria for direct production of fuels such as ethanol or isobutyraldehyde/isobutanol, such a strategy presents new opportunities for solar fuel generation.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening.
The recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.
All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed.
No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. There is no intention to limit the invention to the specific form or 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, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | An optofluidic photobioreactor including an optical waveguide having an input, characterized by an evanescent optical field confined along an outer surface of the optical waveguide produced by radiation propagating in the optical waveguide, means for inputting light to the input of the optical waveguide, and a selected photosynthetic microorganism disposed substantially within the evanescent field. A method for optically exciting a photosynthetic microorganism for generating a biofuel, a biofuel precursor, or a biomass from the optically-excited photosynthetic microorganism involves irradiating the photosynthetic microorganism attached to the surface of the waveguide with an evanescent optical field from optical radiation propagating in the optical waveguide, and driving photosynthesis in the microorganism by the evanescent optical field. | 2 |
FIELD OF THE INVENTION
The present invention relates to a cargo balancing system for cargo trucks, and more particularly, to a cargo balancing system for a cargo truck which, when driving on an extreme slanted road or making sharp turns, prevents tilting of goods in a bed of the truck and maintains the same in a horizontal state to circumvent the possible overturning of the truck.
BACKGROUND OF THE INVENTION
When freight is loaded high in an open-bed cargo truck, the goods often tilt when driving on a slanted road or when making sharp turns. Namely, as the truck slants together with the slant of the road, the weight of the goods loaded in the bed of the truck forces the goods to tilt in the direction of the slant. Centrifugal forces when making sharp turns, especially at high speeds, often causes the same problem. Accordingly, the driver must stop the truck and re-fasten the goods in the bed of the truck in an upright state.
Further, a mix of the right factors--extreme slant in the road, overly top-heavy load, both a slant in the road and a turn in the opposite direction of the slant, high speed turning, etc.--can cause the truck carrying a large load to overturn.
SUMMARY OF THE INVENTION
The present invention has been made in an effort to solve the above problems.
It is an object of the present invention to provide a cargo balancing system for a cargo truck which maintains cargo in the bed of a truck in upright and horizontal states when turning or driving on a slanted road.
To achieve the above object, the present invention provides a cargo balancing system for a cargo truck having front, rear, right, and left sides. The cargo balancing system includes horizontal sensing means for sensing whether the cargo truck is driving on a flat surface or on a slant to the right or left of the cargo is truck, and inputting corresponding signals to a controller; a side panel tilting system side panel swing means for controlling a aide panel of the cargo truck according to electric power applied from the controller in response to the signals, the side panel being pivotally mounted to a truck bed of the cargo truck; and a side panel extender or elevating means for elevating an extension or elevating member above the side panel of the cargo truck according to electric power applied from the controller.
The horizontal sensing means includes a main body; a guide groove formed at a predetermined length in a longitudinal direction in the main body and curving upward in both directions from a center point thereof; a roll ball positioned in the guide groove and able to move freely therein; and center, left, and right contact sensors disposed in the guide groove, the contact sensors being activated by contact with the roll ball.
The side panel tilting system or side panel swing means comprises a plurality of tilt or swing actuators mounted at predetermined intervals to the side panel and to an upper surface of the truck bed.
Each actuator comprises a cylinder having a predetermined inner diameter, the cylinder being hingedly mounted to the upper surface of the truck bed; upper and lower field coils provided in the cylinder; a plunger provided between the upper and lower field coils; a rod integrally formed to an upper end of the plunger, the rod extending out of the cylinder to be is hingedly connected to the side panel; an upper elastic member interposed between an upper surface of the plunger and an upper inside wall of the cylinder; and a lower elastic member interposed between a lower surface of the plunger and a lower inside wall of the cylinder.
The elevating members comprise a bar having free ends, an upper portion formed protruding upward in a center, upper end of the bar, and catch ridges formed between the free ends and the upper portion.
The elevating means comprises a plurality of actuators mounted on the side panels of the cargo truck and connected to the elevating members to ascend the same according to electric signals from the controller.
The actuators comprise a cylinder disposed surrounding a free end of the elevating means, a plunger connected to the free end, a field coil disposed in an upper end of the cylinder, and an elastic member interposed between a top surface of the plunger and an inside upper wall of the cylinder.
A pair of locking actuators are provided on each elevating member, the locking actuators maintaining the elevating members in a descended state.
The locking actuators comprise a cylinder, a field coil disposed in the cylinder at the furthermost extreme from a bar of the elevating member, a plunger mounted in the cylinder and able to elide along a longitudinal direction of the cylinder, an elastic member interposed between an inside wall of the cylinder and the plunger, and a locking arm integrally mounted to the plunger and protruding out of the cylinder to contact a catch ridge of the elevating member when the locking actuator is in an elongated state.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and other advantages of the present invention will become apparent from the following description in conjunction with the attached drawings, in which:
FIG. 1 is a block diagram of a cargo balancing system according to a preferred embodiment of the present invention;
FIG. 2 is a perspective view of a horizontal detecting sensor according to a preferred embodiment of the present invention;
FIG. 3 is a perspective view of a cargo truck used to illustrate positioning of actuators according to a preferred embodiment of the present invention;
FIG. 4 is a plan view illustrating a cargo bed of the cargo truck shown in FIG. 3;
FIG. 5 is an enlarged perspective view of essential parts of the present invention;
FIG. 6 is a sectional view of an actuator shown in FIG. 3;
FIG. 7 is a rear schematic view illustrating the operation of the side panel swing actuators shown in FIG. 6;
FIG. 8 is a partial cross-sectional view of an elevating mechanism according to a preferred embodiment of the present invention;
FIG. 9 is a partial cross-sectional view illustrating the operation of the elevating mechanism shown in FIG. 8; and
FIG. 10 is a front view of the cargo truck shown in FIG. 3 where,
FIG. 10A shows the truck on a right slant,
FIG. 10B shows the truck on a flat surface, and
FIG. 10C shows the truck on a left slant.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.
Certain terminology will be used in the following description for convenience and reference only and will not be limiting. The words "right", "left", "upper", and "lower" will designate directions in the drawings to which reference is made.
Referring first to the block diagram of FIG. 1, the inventive cargo balancing system comprises a horizontal sensor 2; a controller 4; a plurality of side panel swing or tilt actuators, arranged in two groups of three, 6, 8, and 10, and 12, 14, and 16; a plurality of elevating actuators, also arranged in two groups of three, 18, 19, and 20, and 21, 22, and 23; and a plurality of locking actuators, also arranged in two groups of three, 24, 25, and 26, and 27, 28, and 29.
The horizontal sensor 2 detects whether a cargo truck is in a level or extreme slanted state. The positioning of the horizontal sensor 2 on the vehicle should be such that these detections can be accurately made, i.e., in a central position along a width of the vehicle.
As shown in FIG. 2, the horizontal sensor 2 of the present invention comprises a main body 30, a guide groove 32 formed at a predetermined length in a longitudinal direction in the main body 30 and curving upward in both directions from a center point thereof, and a roll ball 34 positioned in the guide groove 32 and able to move freely therein. Further, center, left, and right contact sensors 36, 38, and 40 are disposed in the guide groove 32, the contact sensors 36, 38, and 40 being activated by contact with the roll ball 34.
Accordingly, with the placement of the horizontal sensor 2 at a central position along the width of the cargo truck, when the truck is driving on a substantially flat surface, having no gradient in a direction along the width of the vehicle, the roll ball 34 is positioned in the guide groove 32 contacting the center contact sensor 36. However, when the vehicle encounters a road surface with an extreme slant, the ball 36 comes to be positioned in the guide groove 32 contacting either the left or right contact sensor 38 and 40, according to the direction of the slant in the road.
In either of the three cases above, a corresponding signal is sent to the controller 4 by the activation of the contact sensors 36, 38, and 40. From the signals input from the horizontal sensor 2, the controller 4 determines which, if any, of the actuators 6-29 need to be operated.
As shown in FIGS. 3 and 4, the side panel swing actuators 6, 8, 10 are mounted at predetermined intervals to a left side panel 44 of a truck bed 42, while the side panel swing actuators 12, 14, and 16 are mounted at predetermined intervals to a right side panel 46 of the truck bed 42 (only FIG. 4). The left and right side panels 44 and 46 are pivotally mounted to an upper surface of the truck bed 42.
Referring now to FIG. 5, the structure of the side panel swing actuators 6, 8, 10, 12, 14, and 16 will be described in more detail with reference to one side panel swing actuator 6. It is to be assumed that each side panel swing actuator 6, 8, 10, 12, 14, and 16 is identical in structure, with attachment positions realized as shown in FIG. 4, and operation to that of the side panel swing actuator 6 being described in detail.
As shown in the drawing, the side panel swing actuator 6 comprises a lower bracket 48 fixedly mounted to the upper surface of the truck bed 42, an upper bracket 50 fixedly mounted to an outside surface of the left side panel 44, a cylinder 52 hingedly fixed to the lower bracket 48, and a rod 64 hingedly fixed to the upper bracket 50.
As shown in FIG. 6, illustrating a sectional view of the side panel swing actuator 6, upper and lower field coils 54 and 56 are provided in the cylinder 52, and a plunger 58 is provided between the upper and lower field coils 54 and 56, upper and lower ends of the plunger 58 contacting the upper and lower field coils 54 and 56, respectively. The rod 64 is integrally formed to the upper end of the plunger 58, the rod 64 and the plunger 58 having identical longitudinal axes. The rod 64 extends out of the cylinder 52 to be connected with the upper bracket 50. In addition, an upper elastic member 60 is interposed between an upper end surface of the plunger 58 and an upper inside wall of the cylinder 52, and a lower elastic member 62 is interposed between a lower end surface of the plunger 56 and a lower inside wall of the cylinder 52.
In the side panel swing actuator 6 structured as in the above, when electricity is applied to the lower field coil 56 the plunger 58 descends in the cylinder 52, while when electricity is applied to the upper field coil 54 the plunger 58 ascends in the cylinder 52.
Accordingly, the left and right side panels 44 and 46 can be controlled to swing to the left and right by the two groups of actuators 6, 8, and 10, and 12, 14, and 16 operating in opposite directions. Namely, when the actuators 6, 8, and 10 mounted to the left side panel 44 are controlled to elongate, the actuators 12, 14, and 16 are controlled to contract. As a result, the left and right side panels 44 and 46 lean to the right as shown by the phantom lines in FIG. 7. When the two groups of actuators 6, 8, and 10, and 12, 14, and 16 are controlled to activate in the opposite of the above, the left and right side panels 44 and 46 lean to the left.
Referring back to FIG. 4, side panel extension or elevating members 66 are provided on both the left and right side panels 44 and 46 at locations corresponding to each of the side panel swing actuators 6, 8, 10, 12, 14, and 16.
Referring to FIG. 6, the side panel elevating members 66 comprise a bar 67 having free ends 68 and 70; an upper portion 72 formed protruding upward in a center, upper end of the bar 67: and catch ridges 74 and 76 formed between the free ends 68 and 70 and the upper portion 72.
Referring back to FIG. 5, the side panel elevating members 66 further comprise guides 78 and 80 fixedly attached to the left and right side panels 44 and 46 (although the drawing illustrates only one side panel elevating member 66, it is to be assumed that the same structure explained herein applies to each of the side panel elevating members 66 on both the left and right side panels 44 and 46). The free ends 68 and 70 of the bar 67 are slidably disposed respectively in the guides 78 and 80 such that the bar 67 is able to ascend and descend.
Describing in more detail, side panel elevating actuators 18-23 are provided corresponding to the free end 68 of each bar 67 of the side panel elevating member 66. To simplify the explanation, one side panel elevating actuator 18 will be described with reference to FIG. 8.
The side panel elevating actuator 18 comprises a cylinder 86 disposed surrounding the free end 68 and encased by the guide 78, a plunger 84 integrally connected to the free end 68, a field coil 88 disposed in an upper end of the cylinder 86, and an elastic member 90 interposed between a top surface of the plunger 84 and an inside, upper wall of the cylinder 86.
In the present invention, although the side panel actuator 18 is provided at only one of the free ends 68, the present invention is not limited to this configuration and it possible to provide the actuator 18 at both of the free ends 68 and 70.
Further, pairs of locking actuators 24-29 are provided on the catch ridges 74 and 76 of each of the bars 67. Here also, for ease of explanation, the locking actuator 24 provided corresponding to only the catch ridge 76 of the bar 67 in FIG. 8 will be described.
In the drawing, the locking actuator 24 comprises a cylinder 94, a field coil 96 disposed in the cylinder 94 at the furthermost extreme from the bar 67, a plunger 98 mounted in the cylinder 94 and able to slide left and right therein, an elastic member 100 interposed between a right inside wall of the cylinder 94 and the plunger 98, and a locking arm 102 integrally mounted to the plunger 98 and protruding out of the cylinder 94 to contact the catch ridge 76 when the locking actuator 24 is in an elongated state.
In a state where the locking actuator 24 is not activated, the locking arm 102 is maintained contacting the catch ridge 76 by the elastic force of the elastic member 100. However, when electric power is applied to the field coil 96, the plunger 98 moves to the right by the magnetic force generated by the field coil 96, overcoming the elastic force of the elastic member 100. As a result, the locking arm 102 of the locking actuator 24 is released from the catch ridge 76 as shown in FIG. 9.
From the above state, the side panel elevating member 66 is free to operate. Namely, by applying electric power to the field coil 88 of the side panel elevating member 66, the plunger 84 ascends from the magnetic force generated, overcoming the elastic force of the elastic member 90, and the bar 67 of the side panel elevating member 66 ascends as shown in FIG. 9. When the supply of electric power to the field coil 88 is discontinued, the plunger 64 is maintained in a downward position by the elastic force of the elastic member 90.
In the present invention structured as in the above, when the cargo truck is driving on a slanted road, if the inclination from the horizontal is extreme, the roll ball 34 of the horizontal sensor 2 repositions itself in the guide groove 32 to contact either the left or right contact sensor 38 and 40, depending on the direction of the slant. Accordingly, an electric signal is sent to the controller 4.
As a result, the controller 4 operates the two groups of side panel swing actuators 6, 8, and 10, and 12, 14, and 16 to activate in opposite directions to compensate for the slant in the road. Namely, as shown in FIG. 10A, when the slant in the road is to the left, the side panel swing actuators 6, 8, and 10 connected to the left side panel 44 are controlled by the controller 4 to elongate, and the side panel swing actuators 12, 14, and 16 connected to the right side panel 46 to contract such that the left and right side panels 44 and 46 of the cargo truck swing to the right to compensate for the slant in the road.
However, when the slant in the road is to the right, as shown in FIG. 10C, the controller 4 operates the side panel swing actuators 6, 8, 10, 12, 14, and 16 to activate in the opposite manner as in the above such that the left and right aide panels 44 and 46 swing to the left.
Further, when the vehicle returns to a level driving state, as shown in FIG. 10B, the roll ball 34 of the horizontal sensor 2 returns to contact the center contact sensor 36. Accordingly, the controller 4 discontinues the supply of electric power to the side panel swing actuators 6, 8, 10, 12, 14, and 16 such that the plungers 58 therein return to a central position by the upper and lower elastic members 60 and 62. As a result, the left and right side panels 44 and 46 of the cargo truck return to an upright position, to a position substantially perpendicular to the truck bed 42.
Simultaneously with the above, when the roll ball 34 of the horizontal sensor 2 contacts either the left or right contact sensors 38 and 40, the locking arms 102 of the locking actuators 24-29 are controlled by the controller 4 to be released from the catch ridges 74 and 76 of the side panel elevating members 66. Also, the bare 67 of the side panel elevating members 66 are controlled to ascend as shows in FIGS. 10A and 10C.
However, when driving on a substantially level road surface, the roll ball 34 of the horizontal sensor 2 contacts the center contact sensor 36 such that the locking actuators 24-29 remain engaged with the catch ridges 74 and 76 of the side panel elevating members 66, and the bars 67 of the side panel elevating members 66 remain in downward states as shown in FIG. 10B.
In the present invention structured and operating as in the above, as the side panels of the cargo truck compensate for extreme slants in the road and sharp turns in the road, the goods loaded in the cargo bed of the truck are prevented from shifting and tilting overly to one direction, thereby preventing overturning of the truck.
Although a preferred embodiment of the present invention has been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught which may appear to those skilled in the present art will still fall within the spirit and scope of the present invention, as defined in the appended claims. | Disclosed is a cargo balancing system for a cargo truck having front, rear, right, and rear sides. The cargo balancing system includes a horizontal sensor for sensing whether the cargo truck is driving on a flat surface or on a slant to the right or left of the cargo truck, and inputting corresponding signals to a controller; and side panel swing means for controlling a side panel of the cargo truck according to electric power applied from the controller in response to the signals, the side panel being pivotally mounted to a truck bed of the cargo truck. | 1 |
[0001] The present application claims the priority of U.S. Provisional Patent Application Ser. No. 60/969,673 filed Sep. 3, 2007, which provisional application is incorporated in it's entirety herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to amphibious vehicles and in particular to an amphibious vehicle capable of operation in rough water and high in-water speeds.
[0003] Amphibious vehicles have been known for many years. It has been reported that only one amphibious vehicle has been made in commercial production. That amphibious vehicle was the Amphicar, which was built in Germany from 1961 to 1968. This vehicle had a top speed of only 7 mph in water. The Amphicar, was driven in the water by a pair of propellers.
[0004] In June 2004, a Gibbs Aquada set a record for crossing the English Channel by averaging over 13 miles per hour and having a top speed of approximately 30 miles per hour.
[0005] Another amphibious vehicle, the Watercar disclosed in U.S. Pat. No. 6,808,430 filed by the present applicant, achieves in-water speeds of approximately 45 miles per hour. The Watercar has a frame which supports a body which has a buoyant hull portion. The Watercar suspension includes coil over shock absorbers and the top mounting points of the coil over shock absorbers are mounted to cylinders allowing the front and rear wheels to be retracted (raised) by lifting the coil over shock mounting points. A water jet pump assembly is supported in the body and has a water intake in the bottom of the hull portion. An impeller moves water rearwardly to a water outlet jet at the stern of the hull portion of the vehicle. An engine is supported by the frame and is mounted over the water jet pump assembly. The engine drives both the wheels and the water jet pump selectively through a power transfer assembly. The frame of the Watercar has two longitudinal frame members joined near the bow by a bridge frame supporting the front wheel controls, and at the rear by a rear bridge frame extending upwardly and connected by a cross member. Port and starboard front and rear wheel bottom plates extend from a recessed position to an extended position where they slide under the raised wheels. The in-water character of the Watercar is basically that of a flat bottom boat without a scag. A scag was not included because of road clearance during on-land use, and the cost and difficulty of including a deployable scag. As a result of the absence of the scag, the Watercar does not turn as well as it might had it included a scag and flat bottom boats generally have a poor ride in rough water. Further, some features of the Watercar are expensive to manufacture and results in a fairly expensive product. The '430 patent is herein incorporated in it's entirety by reference.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention addresses the above and other needs by providing an amphibious vehicle which achieves a stable ride, maneuverability, and high speed. The vehicle includes a hull having a “V” center portion with outboard sponsons. The sponsons reside between the front wheel wells and the rear wheels wells for improving lift and transition to planing. Shallow tunnels begin in rear portions of the front wheel wells and taper into the sponsons to release water trapped in the wheel wells. Inward facing turning edges also reside between the front and rear wheel wells and improve in-water handling. Wheels are retractable by pneumatic cylinders in parallel with air shock absorbers and suspension cutout in the hull allow the suspension to lower through the hull. Flaps reside under suspension members and rise to cover the suspension cutouts when the wheels are retracted to reduce drag. A Morse cable couples a rack and pinion unit to a jet drive.
[0007] In accordance with one aspect of the invention, there is provided an amphibious vehicle comprising a frame, two front wheels supported by the frame, two rear wheels supported by the frame, a hull carrying the frame, a body carried above the hull, a power plant providing power, a jet drive, and a drive mechanism. The hull includes a bow, a stern, a bow portion extending from the bow to the at least one front wheel, a mid portion between the at least one front wheel and the rear wheels, a stern portion extending form the rear wheels to the stern, a “V” shaped longitudinal center portion extending along a centerline of the hull from the bow to the stern, and sponsons extending along outside edges of the hull between the at least one front wheel and the rear wheels. The jet drive receives power from the power plant and resides inside the hull at the stern of the hull for providing in-water propulsion. The drive mechanism receives power from the power plant for driving the rear wheels for providing on-land propulsion. Front wheel wells are provided for the front wheels and rear wheel wells for the rear wheels and both the front and rear wheel wells are formed in the hull and/or the body. Port and starboard tunnels sweep downward and sternward behind each front wheel well and taper shallower towards the port and starboard rear wheel wells respectively for providing a smooth path for water caught in the front wheel wells to escape.
[0008] In accordance with another aspect of the invention, there is provided an amphibious vehicle comprising a frame, two front wheels supported by the frame, two rear wheels supported by the frame, a hull carrying the frame, a body carried above the hull, a power plant providing power, a jet drive, and a drive mechanism. The hull includes a bow, a stern, a bow portion extending from the bow to the at least one front wheel, a mid portion between the at least one front wheel and the rear wheels, a stern portion extending form the rear wheels to the stern, a “V” shaped longitudinal center portion extending along a centerline of the hull from the bow to the stern, and sponsons extending along outside edges of the hull between the at least one front wheel and the rear wheels. The jet drive receives power from the power plant and resides inside the hull at the stern of the hull for providing in-water propulsion. The drive mechanism receives power from the power plant for driving the rear wheels for providing on-land propulsion. Front wheel wells are provided for the two front wheels and rear wheel wells for the rear wheels, both the front and rear wheel wells formed in the hull and/or the body. Port and starboard, front and rear suspension cutouts are formed in the hull bottom vertically aligned with the port and starboard front and rear suspension respectively.
[0009] The front and rear suspension is lowerable to the lowered positions through the suspension cutouts when the wheels are extended for on-road driving, and the control arms raisable to the raised positions above the suspension cutouts then the wheels are retracted for in-water driving. Port and starboard front and rear flaps are vertically aligned with the suspension cutouts. The flaps reside planar to the bottom of the hull when the control arms are in the raised positions for smoothing at least a portion of the suspension cutouts with the hull, and the flaps are lowerable to vertically separate from the bottom of the hull to allow the suspension control arms to assume the lowered positions. The combination of cutouts and flaps is important because the cutouts allow greater wheel lowering and thus greater ground clearance to allow a “V” hull for on-road operation. The flaps reduce the drag which would otherwise result from the cutouts and the rear flaps in particular reduce drag near the stern to facilitate the transition to planing.
[0010] In accordance with yet another aspect of the invention, there is provided an amphibious vehicle comprising a frame, two front wheels supported by the frame, a rack and pinion steering unit for turning the front wheels for on-land steering, two rear wheels supported by the frame, a hull carrying the frame, a body carried above the hull, a power plant providing power, a jet drive, and a drive mechanism. The hull includes a bow, a stern, a bow portion extending from the bow to the at least one front wheel, a mid portion between the at least one front wheel and the rear wheels, a stern portion extending form the rear wheels to the stern, a “V” shaped longitudinal center portion extending along a centerline of the hull from the bow to the stern, and sponsons extending along outside edges of the hull between the at least one front wheel and the rear wheels. The jet drive receives power from the power plant and resides inside the hull at the stern of the hull for providing in-water propulsion. The drive mechanism receives power from the power plant for driving the rear wheels for providing on-land propulsion. A Morse cable is connected between the rack and pinion steering unit and the jet drive to turn the jet drive for in-water steering. The rack and pinion steering unit may be manual or a power rack and pinion steering unit and connection of the Morse cable to the steering arms provides a similar feel to on-land steering and to in-water steering. In a preferred embodiment, a sliding member and at least one spring allow for full lock to lock steering of the jet drive to correspond to about one half of the lock to lock steering of the front wheels. A more preferred embodiment includes a slotted bell crank which firmly holds the jet drive at a center position.
[0011] In accordance with yet another aspect of the invention, there is provided an amphibious vehicle comprising a frame, two front wheels supported by the frame, two rear wheels supported by the frame, a hull carrying the frame, a body carried above the hull, a power plant providing power, a jet drive, and a drive mechanism. The hull includes a bow, a stern, a bow portion extending from the bow to the at least one front wheel, a mid portion between the at least one front wheel and the rear wheels, a stern portion extending form the rear wheels to the stern, a “V” shaped longitudinal center portion extending along a centerline of the hull from the bow to the stern, and sponsons extending along outside edges of the hull between the at least one front wheel and the rear wheels. The jet drive receives power from the power plant and resides inside the hull at the stern of the hull for providing in-water propulsion. The drive mechanism receives power from the power plant for driving the rear wheels for providing on-land propulsion. Port and starboard, front and rear, control arms are moveably connected between the wheels and the frame inboard of the wheels for allowing vertical motion of the wheels. The control arms have control arm lowered positions for extending the wheels for on-road driving and control arm raised positions for retracting the wheels for in-water driving. Port and starboard, front and rear shock absorbers are connected between the control arms and the frame. Port and starboard cylinders are connected between the control arms and the frame in parallel with the shock absorbers for lifting the control arms to retract the wheel for in-water driving. Front and rear air bags are preferably included for supporting the frame (i.e., in place of spring). The air bags are filled with air to extend the wheels and the air is released from the air bags and pressure is applied to the air cylinders below internal pistons to retract the wheels. The front air bags are preferably air bag elements of the front shock absorbers and the rear air bags are preferably connected between the rear suspension and the frame in parallel with the rear shock absorbers.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0012] The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0013] FIG. 1 is a side view of an amphibious vehicle according to the present invention.
[0014] FIG. 2A is a front view of the amphibious vehicle.
[0015] FIG. 2B is a rear view of the amphibious vehicle.
[0016] FIG. 3 is a second side view of the amphibious vehicle.
[0017] FIG. 4 is a cross-sectional view of the amphibious vehicle taken along line 4 - 4 of FIG. 3 .
[0018] FIG. 5 is a cross-sectional view of the amphibious vehicle taken along line 5 - 5 of FIG. 3 .
[0019] FIG. 6 is a cross-sectional view of a port side leading edge flaring into a sponson according to the present invention, residing behind a front port side wheel taken along line 6 - 6 of FIG. 4 .
[0020] FIG. 7A is a top view of an amphibious vehicle frame and suspension according to the present invention.
[0021] FIG. 7B is a side view of the amphibious vehicle frame and suspension.
[0022] FIG. 7C is a front view of the amphibious vehicle frame and suspension.
[0023] FIG. 7D is a rear view of the amphibious vehicle frame and suspension.
[0024] FIG. 7E is a top view of a second embodiment of the rear suspension.
[0025] FIG. 7F is a rear view of the second embodiment of the rear suspension.
[0026] FIG. 8A is a side view of the amphibious vehicle with the wheels extended for on-road driving.
[0027] FIG. 8B is a side view of the amphibious vehicle with the wheels retracted for in-water driving.
[0028] FIG. 9A is a side view of the amphibious vehicle frame with suspension lowered to extend the wheels for on-road driving.
[0029] FIG. 9B is a side view of the amphibious vehicle frame with the suspension raised to retract the wheels for in-water driving.
[0030] FIG. 9C is a side view of the amphibious vehicle frame with the second embodiment of the rear suspension lowered to extend the wheels for on-road driving.
[0031] FIG. 9D is a side view of the amphibious vehicle frame with the second embodiment of the rear suspension raised to lift the wheels for in-water driving.
[0032] FIG. 10A is a side view of a hull according to the present invention with flap according to the present invention laying against the bottom of the hull.
[0033] FIG. 10B is a bottom view of the hull showing control arm cutouts and the flaps covering the cutouts to smooth the cutouts with the bottom of the hull.
[0034] FIG. 10C is a side view of the hull showing the flaps vertically separated from the hull to allow the control arms to move to a lowered control arm position for on-road driving.
[0035] FIG. 11A shows front control arms lowered and pushing front flaps down according to the present invention.
[0036] FIG. 11B shows front control arms raised and pulling front flaps up against the hull according to the present invention.
[0037] FIG. 12A shows the rear suspension lowered and pushing rear flaps down according to the present invention.
[0038] FIG. 12B shows the rear suspension raised and pulling the rear flaps up against the hull according to the present invention.
[0039] FIG. 12C shows the second embodiment of the rear suspension lowered and pushing the rear flaps down according to the present invention.
[0040] FIG. 12D shows the second embodiment of the rear suspension raised and pulling the rear flaps up against the hull according to the present invention.
[0041] FIG. 13A shows a first embodiment of a land and water steering unit according to the present invention.
[0042] FIG. 13B shows a second embodiment of a land and water steering unit according to the present invention.
[0043] FIG. 14 shows a Morse cable attached to the jet drive.
[0044] FIG. 15A shows a top view of the second embodiment of a land and water steering unit in a centered position.
[0045] FIG. 15B shows a top view of the second embodiment of a land and water steering unit in a partial left turn position.
[0046] FIG. 15C shows a top view of the second embodiment of a land and water steering unit in a full left turn position.
[0047] FIG. 16A shows a top view of the third embodiment of a land and water steering unit in a centered position.
[0048] FIG. 16B shows a top view of the third embodiment of a land and water steering unit in a partial left turn position.
[0049] FIG. 16C shows a top view of the third embodiment of a land and water steering unit in a full left turn position.
[0050] FIG. 17B shows the amphibious vehicle in-water.
[0051] FIG. 17B shows an interior side wall according to the present invention for allowing the doors to open while in-water without allowing water to enter the amphibious vehicle.
[0052] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0053] The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
[0054] A side view of an amphibious vehicle 10 according to the present invention is shown in FIG. 1 , a front view of the amphibious vehicle 10 is shown in FIG. 2A , and a rear view of the amphibious vehicle 10 is shown in FIG. 2B . The amphibious vehicle 10 includes a bow portion 10 a ahead of front axles 35 (see FIG. 7B ), a mid portion 10 b between front and rear axles 43 (see FIG. 7B ), a stern portion 10 c behind rear axles, a bow 11 , and a stern 13 . A hull 20 of the amphibious vehicle 10 resides on the bottom of the amphibious vehicle 10 . The amphibious vehicle 10 is carried by front wheels 14 a and rear wheels 14 b for on-land driving. The front wheels 14 a reside in front wheel wells 12 a and the rear wheels 14 b reside in stern wheel wells 12 b . Port and starboard sponsons 16 a and 16 b (also see FIGS. 4 , 5 , and 10 B) reside on lower outboard port and starboard sides of the amphibious vehicle 10 between the front and rear wheel wells 12 a and 12 b , and a jet drive 18 resides at the stern of the amphibious vehicle 10 to provide in-water propulsion.
[0055] The hull 20 includes a “V” shaped longitudinal center portion 20 a providing a better in-water ride in rough water and a narrow flat center most portion 20 b towards the rear of the hull 20 . Unlike boat hulls, the hull 20 includes two bow wheel wells 12 a and two stern wheel wells 12 b interrupting the bottom surface of the hull 20 . The presence of the four wheel wells 12 a and 12 b both creates drag and reduces lift. Such drag and loss of lift affects a vehicle at moderate speeds when the vehicle is attempting to plane and a large portion of the hull is still wet. The sponsons 16 a and 16 b overcome these difficulties by providing additional surface (or lifting) area in the center portion 10 b of the hull 20 of the amphibious vehicle 10 , which center portion 10 b is wet at moderate speed providing lift. The wet area shifts back towards the stern of the hull 20 as speed increases, and planing at high speed does not require substantial lift from the sponsons 16 a and 16 b , although aft ends of the sponsons 16 a and 16 b generally remain wet during high speed planing to provide improved stability.
[0056] The design of the sponsons is a balance between drag and lift and an optimal design is dependent on the length and design of the hull, and the weight and balance of the amphibious vehicle. A greater wet area improves lift, but also adds some to drag. Maintaining at least a small rear portion of the sponsons in the water at high speed improves stability. Generally, the depth of the sponson D S relative to the depth of the hull D H (see FIG. 4A ) has the greatest affect on sponson hydrodynamics. The sponson design goal is to make the depth of the sponson D S great enough to obtain lift at moderate speed and stability at high speed. The exact design to accomplish this goal for a specific hull design may require in-water testing.
[0057] A second side view of the amphibious vehicle 10 is shown in FIG. 3 , a cross-sectional view of the amphibious vehicle 10 taken along line 4 - 4 of FIG. 3 is shown in FIG. 4 , a cross-sectional view of the amphibious vehicle 10 taken along line 5 - 5 of FIG. 3 is shown in FIG. 5 , and cross-sectional view of a leading edge 22 a , according to the present invention, of the sponson 16 a taken along line 6 - 6 of FIG. 4 is shown in FIG. 6 . Port and starboard leading edges 22 a and 22 b reside between the port and starboard front wells 12 a and 12 b and the port and starboard sponsons 16 a and 16 b on each side of the “V” shaped longitudinal center portion 20 a of the hull 20 . The port and starboard leading edges 22 a and 22 b sweep downward and sternward just behind the port and starboard front wheel wells 12 a and 12 b respectively and merge into the port and starboard sponsons 16 a and 16 b respectively for providing a smooth path for water caught in the front wheel wells 12 a and 12 b to escape to improve in-water lift and stability. The length of the sponsons L S , measured from the transition of the leading edges 22 a and 22 b to the sponsons 16 a and 16 , is preferably between one half and two thirds of the length between the wheel wells L W , and is more preferably approximately two thirds of the length between the wheel wells L W .
[0058] Inward facing port and starboard turning edges 17 a and 17 b preferably form inside edges of the sponsons 16 a and 16 b respectively. The turning edges 17 a and 17 b provide the important function of catching the water when the amphibious vehicle 10 is turned in the water, thus improving in-water responsiveness. The turning edges 17 a and 17 b are preferably between inside and outside edges of the wheel wells 12 a and 12 b , and are more preferably aligned with inside edges of the wheel wells 12 a and 12 b (see FIG. 10B ). The turning edges 17 a and 17 b are preferably vertical edges, but may be sloped, and preferably extend down a sponson depth D S between 25 percent and 75 percent of a hull (or “V”) depth D H below a highest point 20 ′ of the hull seen in the cross-sectional view of FIG. 4A , and more preferably extend down the sponson depth D S of approximately 50 percent of the hull depth D H measured from the base of the turning edges 17 a and 17 b . In the embodiment of FIG. 4A , the cutting edge 17 A had a cutting edge height equivalent to the sponson depth D S .
[0059] While sponsons with an inside edge formed by the turning edges and sloping outward and upward from the turning edges (see FIGS. 4 and 5 ) are preferred, any amphibious vehicle with hydrodynamic surfaces between the wheel wells providing lift at low and moderate speeds is intended to come within the scope of the present invention. any combination of turning edge and sponson between the wheel wells providing improved turning (the turning edges) and improved lift at low and moderate speeds (the sponsons) is intended to come within the scope of the present invention. For example, the turning edges may be at the outside edge of the sponsons (i.e., aligned with the outside edges of the wheel wells) and the sponsons may slope upward and outward to the turning edges. Further, when the turning edges are on the inside edge of the sponsons, the sponsons may have a flat nearly horizontal bottom, not rising or lowering.
[0060] Port and starboard negative chines 19 a and 19 b run along outside edges of the sponsons 16 a and 16 b between the front and rear wheel wells 12 a and 12 b . The chines 19 a and 19 b reach outward and downward and reduce or eliminate water splashing into the amphibious vehicle 10 interior.
[0061] A top view of an amphibious vehicle frame 30 , front suspension control arms 34 , and rear suspension control arms 42 according to the present invention is shown in FIG. 7A , a side view of the amphibious vehicle frame and suspension is shown in FIG. 7B , a front view of the amphibious vehicle frame and suspension is shown in FIG. 7C , and a rear view of the amphibious vehicle frame and suspension is shown in FIG. 7D . The front suspension control arms 34 preferably comprise upper and lower lateral control arms (i.e., extending laterally between the front wheels 14 a and the frame 30 ) connecting the front wheels 14 a to the frame 30 to allow normal suspension motion for on-road driving and for allowing the front wheels 14 a to be retracted for in-water driving. Front axles 35 are carried by the front control arms 34 .
[0062] While the embodiment described herein includes upper and lower front control arm and trailing arm rear suspension, such is merely a single embodiment of the present invention. Other embodiments may include trailing arm front suspension, A arm rear suspension, or McPherson struts at the front and/or rear. An amphibious vehicle including sponsons, turning edges, flaps for covering suspension openings, or steering according to the present invention is intended to come within the scope of the present invention regardless of the type of suspension used for on-road driving.
[0063] The rear suspension control arms 42 preferably comprise trailing control arms 42 connected between the frame 30 and the rear wheels 14 b . The trailing control arms pivot at a forward mounting point to allow normal suspension motion for on-road driving and for allowing the rear wheels 14 b to be retracted for in-water driving. Rear axles 43 are carried by the rear suspension 42 .
[0064] Continuing with FIGS. 7A-7D , front shock absorbers 36 a are connected between the suspension control arms 34 and the frame 30 to damping motion of the front wheels 14 a . Front cylinders 38 a are mounted in parallel with the front shock absorbers 36 a and are connected to a pressure source so that when pressure is applied to bases of the cylinders 38 a (i.e., below pistons in the cylinders 38 a ), the front wheels 14 a are retracted for in-water driving. Similarly, rear shock absorbers 36 b are connected between the rear suspension control arms 42 and the frame 30 to damping motion of the rear wheels 14 b . Rear cylinders 38 b are mounted in parallel with the rear shock absorbers 36 b and are connected to the pressure source so that when pressure is applied to bases of the cylinders 38 b (i.e., below pistons in the cylinders 38 b ), the rear wheels 14 b are retracted for in-water driving. Both the front shock absorbers 36 a and cylinders 38 a are preferably connected between the control arms and towers 44 . The towers 44 are preferably molded into the body for added strength and to seal the wheel wells to keep water out of the interior and engine compartment.
[0065] A top view of a second embodiment of the rear suspension 42 ′ is shown in FIG. 7E , and a rear view of the second embodiment of the rear suspension 42 ′ is shown in FIG. 7F . The rear suspension 42 ′ replaces the rear lifting cylinders 38 b with second rear air bags 40 ′. The air bags 40 ′ are attached to the frame through a bracket at the air bag bottom, and to the rear suspension at the air bag top. When the air bags 40 ′ are inflated, the rear suspension 42 ′ is raised.
[0066] A side view of the amphibious vehicle 10 with the wheels 14 a and 14 b extended for on-road driving is shown in FIG. 8A , a side view of the amphibious vehicle 10 with the wheels 14 a and 14 b retracted for in-water driving is shown in FIG. 8B , a side view of the amphibious vehicle frame 30 with suspension control arms 34 and 42 lowered to extend the wheels 14 a and 14 b for on-road driving is shown in FIG. 9A , and a side view of the amphibious vehicle frame 30 with the control arms raised to retract the wheels 14 a and 14 b for in-water driving is shown in FIG. 9B . Preferably, air bags 41 and 40 are included to support the amphibious vehicle 10 , in place of more common springs. More preferably, the front shock absorbers 36 a are air shock absorbers and most preferably the front shock absorbers include air bags 41 serially integrated into the front shock absorbers. More preferably, the rear suspension includes rear air bags 40 mounted in parallel with the rear shock absorbers 36 b and cylinders 38 b . Such preferred arrangement of air bags 40 and 41 and cylinders 38 a and 38 b allows a simple and low cost extending (by removing the pressure from the cylinders and providing pressure to the air bags) of the wheels 14 a and 14 b , and retracting (by providing the pressure from the cylinders and removing the pressure to the air bags) of the wheels 14 a and 14 b.
[0067] A side view of the amphibious vehicle frame with the second embodiment of the rear suspension 42 ′ lowered to extend the wheels for on-road driving is shown in FIG. 9C , and a side view of the amphibious vehicle frame with the second embodiment of the rear suspension 42 ′ raised to lift the wheels for in-water driving is shown in FIG. 9D . The air bags 40 ′ replace the cylinders 38 b and are attached to the frame through brackets at the air bag bottom, and to the rear suspension at the air bag top. When the air bag 40 ′ are inflated, the rear suspension 42 ′ is raised.
[0068] A side view of the hull 20 according to the present invention with port front flap 52 a and port and rear flap 52 b according to the present invention laying against the bottom of the hull 20 is shown in FIG. 10A , a bottom view of the hull 20 showing port front and rear control arm cutouts 50 a and 50 b and starboard front flap 52 a and starboard rear flap 52 b covering starboard front cutout 50 a and starboard rear cutout 50 b respectively (not shown), to smooth the cutouts 50 a and 50 b with the bottom of the hull 20 , is shown in FIG. 10B , and a side view of the hull 20 showing the flaps 52 a and 52 b vertically separating from the hull 20 to allow the control arms 34 and 42 (see FIG. 7A-7D ), to move to a lowered control arm position for on-road driving, is shown in FIG. 10C . The two front flaps 52 a and the two rear flaps 52 b cover control arm cutouts 50 a and 50 b respectively when the suspension is raised for in-water operation to reduce drag, allowing easier transition to planing. A water inlet 54 for the jet drive 18 resides laterally centered on the flat center most bottom portion 20 b of the hull 20 near the stern 13 . The sponsons 16 a and 16 b are seen to reside in outside portions of the hull 12 ′ between the wheel wells 12 a and 12 b.
[0069] A front view of the front suspension in a lowered position with the flap 52 a pushed down by the lower control arm 34 a is shown in FIG. 11A and a front view of the front suspension in a raised position with the flap 52 a pulled up by a strap 53 a attached to the lower control arm 34 a is shown in FIG. 11B (also see FIGS. 10A-10C ). The strap 53 a is preferably an elastic strap and allows for some freedom on tolerances. When the flaps 52 a are raised, water is kept out of the front wheel suspension cutouts 50 a reducing the potential for increased drag. The flaps 52 a include vertical edge on the outside edge of the flap 52 a to reduce the entry of water into the suspension cutout 50 a . The vertical edge may be from one to three inches high and vary along the length of the flap.
[0070] A rear view of the rear suspension in a lowered position with the flap 52 b pushed down by the lower control arm 42 a is shown in FIG. 12A and a front view of the rear suspension in a raised position with the flap 52 b pulled up by a rear strap 53 b attached to the lower control arm 42 a is shown in FIG. 12B . The strap 53 b is preferably not elastic (for example, is a cable or chain) and holds the flap 52 b firmly against the hull 20 during in-water operation (also see FIGS. 10A-10C ). The rear flaps 52 b generally experience much greater water forces than the front flaps 52 a , and holding the rear flaps tightly against the bottom of the hull 20 is very important in reducing drag. The flaps 52 b also have about a one inch vertical edge on the outside edge of the flap 52 b to reduce the entry of water into the suspension cutout 50 b.
[0071] The second embodiment of the rear suspension 42 ′ lowered and pushing the rear flaps 52 b down is shown in FIG. 12C , and the rear suspension 42 ′ raised and pulling rear flaps 52 b up against the hull according to the present invention is shown in FIG. 12D . The air bags 40 are seen inflated to support the amphibious vehicle 10 during on road operation is seen in FIG. 12C , and the air bags 40 ′ are shown inflated to lift the suspension 42 ′ for in-water operation is seen in FIG. 12D .
[0072] A first embodiment of a land and water steering unit 60 a , according to the present invention, having a Morse cable 74 connected to a rack and pinion unit 64 is shown in FIG. 13A . The connection of the Morse cable to the jet drive 18 through a rod 76 is shown in FIG. 14 . A sliding inner cable 70 is connected to steering arms 66 which are connected to the front wheels 14 a (see FIG. 1 ) for on-land steering. The cable 70 is connected to a rod 76 connected to the nozzle of the jet drive 18 to steer in-water. The rack and pinion unit 60 may be a power rack and pinion steering unit or a manual rack and pinion steering unit. Such a direct cable connection between the steering arms 66 and the jet drive 18 provides a similar feel to on-land and in-water steering thus making the transition between in-water and on-land more natural.
[0073] A perspective view of a second embodiment of a land and water steering unit 60 b , according to the present invention, with the Morse cable 74 connected to the rack and pinion steering unit 64 is shown in FIG. 13B and top views of the second embodiment of a land and water steering unit 60 b in different positions are shown in FIGS. 15A-15C . In order to have the same land and water steering feel, some drivers prefer that the water steering is quicker than the land steering and with less turn lock to lock. To obtain such results, the land and water steering unit 60 b including a spring 84 and slot 82 mechanism shown in FIG. 13A in a centered position. A rod 88 is connected to one of the steering arms 66 and translates with the steering arm 66 along arrow A 1 (arrow A 2 shows the same translation of the opposite steering arm 66 ). The opposite end of the rod 88 is attached to a sliding member 81 which slides in a slot 82 in a coupling device comprising an “L” shaped bell crank 80 . The bell crank 80 pivots at pivot 86 in the corner of the crank. A spring 84 is in tension between the pivot 86 and the sliding member 81 thereby pulling the sliding member 81 towards the pivot 86 . An inner Morse cable 70 attached to a cable end 87 of the bell crank 80 and motion of the steering arm 66 is thus translated into a motion of the inner Morse cable 70 . Preferably, the first approximately three inches of rack movement is directly translated to three inches of translation of the inner Morse cable. Additional motion of the rack is transmitted only to the front wheels.
[0074] While a land and water steering unit with an “L” shaped bell crank is disclosed above, any coupling device providing for a sliding member to couple initial movement of the steering arm away from center with a Morse cable, and to decouple further movement of the steering arm from the Morse cable is intended to come within the scope of the present invention.
[0075] A preferred steering ratio for on-land steering is between 2:1 and 3:1, and a more preferred ratio is approximately 3:1. A preferred steering ratio for in-water steering is between 1.5:1 and 2.5:1, and a more preferred ratio is approximately 1.5:1. The on-land steering is preferably 3 turns lock to lock, and the in-water steering is preferably 1.5 turns lock to lock.
[0076] Initial translation of the steering arms 66 along arrows A 1 and A 2 is shown in FIG. 15B . The translation of the steering arms 66 results in a similar translation along arrow A 3 of the rod 88 . The spring 84 holds the sliding member 84 at the end of the slot 82 nearest to the pivot 86 , and the translation of the rod 88 causes the bell crank 80 to rotate along arrow A 4 . The rotation of the bell crank 80 causes translation along arrow A 5 of the inner Morse cable 70 . The inner Morse cable 70 is attached to the rod 76 (see FIG. 14 ). Turning the steering wheel thus causes both turning of the front wheel for land steering and turning of the jet drive 18 (see FIG. 12 ).
[0077] Full motion of the steering arm 66 is shown in FIG. 15C . The bell crank 80 is prevented by stops from further rotation past the rotation shown in FIG. 15B , and the spring 84 is stretched allowing the sliding member 84 to slide to the end of the slot 82 farthest from the pivot 86 , and there is no additional translation by the inner Morse cable 70 past the translation shown in FIG. 15B . Thus full motion of the jet drive 18 is obtained during an initial translation of the steering arm 66 .
[0078] A top view of a third embodiment of a land and water steering unit 60 c , according to the present invention, with the Morse cable 74 connected to the rack and pinion steering unit 64 is shown in FIG. 16A and top views of the third embodiment of a land and water steering unit 60 c in different positions are shown in FIGS. 16B and 16C . The third embodiment of a land and water steering unit 60 c provides the same benefits as the second embodiment 60 b , except without the bell crank 80 . The rod 88 slides through a second guide 90 b and a third guide 90 c , both attached to the rack and pinion steering unit 64 . A second sliding member 93 slides on the rod 88 and is sandwiched between springs 92 a and 92 b which are retained between locks 91 a and 91 b . The second sliding member 93 may thus slide on the rod 88 , but is pushed to a center position between the locks 91 a and 91 b by the springs 92 a and 92 b . The inner Morse cable 70 is fixed to the second sliding member 93 and translates with the second sliding member 93 . The inner Morse cable 70 further slides through the guide 90 b and second locks 95 a and 95 b are attached to the inner Morse cable 70 on each side of the guide 90 b to limit the translation of the inner Morse cable 70 through the guide 90 b in either direction. The Morse cable 74 is held by a first guide 90 a attached to the rack and pinion steering unit 64 .
[0079] Initial translation of the steering arms 66 along arrows A 1 and A 2 is shown in FIG. 16B . The translation of the steering arms 66 results in a similar translation along arrow A 3 of the rod 88 . The springs 92 a and 92 b hold the second sliding member 93 centered between the locks 91 a and 91 b , and the translation of the rod 88 causes the second sliding member 93 and inner Morse cable 70 to translate along arrow A 6 . Turning the steering wheel thus causes both turning of the front wheel for land steering and turning of the jet drive 18 (see FIG. 14 ).
[0080] Full motion of the steering arm 66 is shown in FIG. 16C . The second sliding member 93 is prevented by stops 95 a and 95 b from further translation past the translation shown in FIG. 16B , and the spring 84 is compressed allowing the rod 88 to slide through the second sliding member 93 , and there is no additional translation by the inner Morse cable 70 past the translation shown in FIG. 16B . Thus full motion of the jet drive 18 is obtained during a first translation of the steering arm 66 .
[0081] While the spring and sliding members of the third embodiment of a land and water steering unit 60 c are described above at the rack and pinion steering unit end of the Morse cable 74 , a similar apparatus may reside at the jet drive 18 to provide the same result.
[0082] A significant advantage of the second embodiment of a land and water steering unit 60 b is that in the centered position, the slot 82 and the spring 84 are perpendicular to the rod 88 . While the third embodiment of a land and water steering unit 60 c provides a somewhat more simple and intuitive design, the springs 92 a and 92 b , and the sliding direction of the sliding of the second sliding member 93 are aligned with the rod 88 . As a result, the second sliding member 93 may not hold the jet drive 18 in a centered position at high speed straight running when water impacts the sides of the jet drive 18 , i.e., water forces on the jet drive 18 may be sufficient to compress the springs 92 a and/or 92 b and somewhat turn the jet drive 18 . Because neither the spring 84 nor the slot 82 of the second embodiment of a land and water steering unit 60 b are aligned with the rod 88 when the steering is centered, the jet drive 18 is better held when in the center position.
[0083] The amphibious vehicle 10 is shown in-water with a water line 106 above the lower edge of the door 104 is shown in FIG. 17A , and an interior side wall 100 according to the present invention for allowing the doors to open while in the water is shown in FIG. 17B . The interior side wall 100 is a height H WL above the water line 106 . The height H WL is preferably at least three inches and more preferably between four and six inches, and may vary due to vehicle loading. The combination of the running boards 21 a and 21 b and the interior side walls 100 allow the doors to be opened in-water, and, for example, a skier, to simply step onto either running board, and into the interior 102 of the amphibious vehicle 10 . Further, because the interior side wall 100 prevents entry of water into the amphibious car 10 in normal operation, (i.e., not in overly rough water), the doors 104 do not require sealing.
[0084] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | An amphibious vehicle achieves a stable ride, maneuverability, and high speed. The vehicle includes a hull having a “V” center portion with outboard sponsons. The sponsons reside between the front wheel wells and the rear wheels wells for improving lift and transition to planing. Shallow tunnels begin in rear portions of the front wheel wells and taper into the sponsons to release water trapped in the wheel wells. Inward facing turning edges also reside between the front and rear wheel wells and improve in-water handling. Wheels are retractable by pneumatic cylinders in parallel with air shock absorbers and suspension cutout in the hull allow the suspension to lower through the hull. Flaps reside under suspension members and rise to cover the suspension cutouts when the wheels are retractable when the wheels are raised to reduce drag. A Morse cable couple a rack and pinion unit to a jet drive. | 1 |
INTRODUCTION TO THE INVENTION
This invention relates to a method and medication for the treatment of an ulcer. A composition comprising an antibiotic adsorbed onto a disaccharide polysulfate-aluminum compound is contacted with the ulcer site. The composition adherently coats the ulcer, protecting it while imparting an antibiotic activity which accelerates healing.
In a preferred embodiment, this method is utilized for treatment of an internal ulcer. After ingestion, the disaccharide polysulfate-aluminum compound with adsorbed antibiotic preferentially binds to the ulcer. Thus concentrated, its protective and healing properties are enhanced.
BACKGROUND OF THE INVENTION
Numerous attempts have been made to solve the problem of treating ulcers. No entirely satisfactory solution is available. There is a real need for a safe and effective product which will provide for their relief and cure.
Disaccharide polysulfate-aluminum compounds are accepted medications for the treatment for peptic ulcers. Such compounds are disclosed in U.S. Pat. No. 3,432,489 to Nitta et al (Nitta), which is incorporated herein by reference. Typical compounds are sucrose polysulfate-aluminum compounds, lactose polysulfate-aluminum compounds and maltose polysulfate-aluminum compounds. The sulfur and aluminum contents are commonly from 7-13% and 11-24%, respectively and, therefore, generally contain from 1-4 aluminum atoms per sulfur atom.
Nitta discloses the internal use of these compounds in the treatment of peptic ulcers by oral administration. Such ulcers have a pathology characterized by erosion of the mucosa of the alimentary canal. The major areas where mucosa occurs include the mouth, the esophagus, the stomach (gastric mucosa) and the duodenum (duodenal mucosa). The mucosa is located anatomically in areas bathed by acid and which normally have a pH ranging from about 1.0 to 4.0.
One of the compounds disclosed in Nitta is a sucrose polysulfate aluminum compound referred to in The Merck Index, Merck & Co., Inc., Rahway, N.J., 10th Edition, 1983 at number 8755 as sucralfate. This compound is currently marketed as an anti-ulcerative agent. Disaccharide polysulfate-aluminum complexes are frequently referred to herein for the purposes of simplicity as sucralfate.
Sucralfate is now also recognized by those skilled in the art as being useful in the treatment of peptic ulcer disease (Borrers et al, Am. J. Surg., 148 (1984) pp 809-12) and in short term duodenal and gastric ulcer healing (Halter, S. Afr. Med. Journal 23 (1984) 996-1000). In addition, oral ulcers or mucositis which have developed as a direct consequence of treatment of patients receiving chemotherapy or radiation or both have been treated with sucralfate suspension. (Solomon, Cell 351, 459 (August, 1986).
Disaccharide polysulfate-aluminum compounds such as sucralfate have also previously been developed and are known for the purpose of protecting other kinds of ulcers. In, for example, U.S. Pat. No. 4,945,084, there is described a method for treating hemorrhoids. There a composition comprising a thick paste of disaccharide polysulfate-aluminum compound on a pharmaceutical carrier is described. The composition may further contain any number of pharmacological agents including anesthetics, vaso-constructors, protectants, counterirritants, astringents, wound healing agents, antiseptics, keratolytics and anticholinergics. These agents may also include antibiotics.
In addition to the treatment of internal ulcers of the alimentary canal as described above, these compounds may be applied to topical or external ulcers. This includes scrapes or other injuries of the skin. Indeed, they may be employed to treat virtually any such tissue wound, wherever situated on the body.
These treatments, however, do not adequately address one of the problems of ulcers. They are commonly a site of infection. Disaccharide polysulfate-aluminum compounds do not combat infection. Moreover, the coatings they develop over a wound tissue may actually interfere with the treatment of the infection and thereby retard the healing process.
It is, therefore, an object of the present invention to provide an improved composition for use in the treatment of ulcers.
It is a further object of the instant invention to provide a method for treating ulcers to control or relieve their symptoms at a wound site.
It is a still further object of the instant invention to provide an improved means for treatment of internal ulcers.
Another object of the instant invention to provide a preparation which forms a protective barrier over an ulcer and also acts as a carrier which enhances antibiotic activity at the wound site.
This invention provides a method for treating ulcers through contact with a composition which is safe, effective and comprises an antibiotic adsorbed onto a disaccharide polysulfate-aluminum compound.
DESCRIPTION OF THE INVENTION
This invention provides a composition and a method for treating ulcers. These ulcers may be situated anywhere on or within the body.
The composition of the instant invention comprises an antibiotic adsorbed (or complexed) onto a disaccharide polysulfate-aluminum compound such as sucralfate. This composition may be used in the same manner as sucralfate alone. It may be applied to an external ulcer in powdered form or, more typically, in a pharmaceutically acceptable dispersant. With internal ulcers, these compositions are normally ingested so as to reach the involved area. They may simply be taken orally or injected into the area of the body where the ulcer is located.
Treatment of ulcer wounds is often complicated by infection. Infection presents a particular problem when the ulcer being treated is internal to the body. A localized application is difficult to achieve. Large doses of antibiotic must normally be ingested to obtain an effective therapeutic concentration over sufficient time to combat such an infection within the body.
This problem is only compounded where sucralfate or other disaccharide polysulfate-aluminum compounds are employed to treat an ulcer. The protective covering formed by sucralfate may shield the infection. This makes it difficult for an effective amount of the antibiotic to reach it. Consequently, healing may be greatly retarded.
In accordance with the present invention, however, this drawback is avoided. With the present compositions, antibiotic is adsorbed onto the disaccharide polysulfate-aluminum compounds prior to application. As a consequence, antibiotic is carried directly and preferentially to the ulcer site by these compounds. The antibiotic is also retained there when the disaccharide polysulfate-aluminum compound adheres to the wound. This increases its effective concentration in the region of infection. Consequently, healing is accelerated, rather than retarded.
An important aspect of this invention is the selection of an appropriate antibiotic. The antibiotic must be one which adsorbs onto (or complexes with) the disaccharide polysulfate-aluminum compound. This interaction ensures that the antibiotic is selectively carried to the ulcer site, and is held there by the compound. This increases its effective concentration and pharmacological effect.
Most antibiotics have no affinity towards a disaccharide polysulfate-aluminum compound. They do no more than mix with a sucralfate. Consequently, in an aqueous environment such as that in the alimentary canal of the body, they are rapidly diluted. They are also eluded from the sucralfate and/or wound site, and their effectiveness is rapidly lost.
It has been discovered, however, that select antibiotics adsorb onto sucralfate. The resultant combination or complex is stable and permits targeting of the location of antibiotic. Representative adsorbable antibiotics include nalidixic acid, doxycycline hyclate and tetracycline. Others may readily be determined.
The absorbability or affinity of an antibiotic to complex with a disaccharide polysulfate-aluminum compound may be determined by dissolving an antibiotic in an aqueous slurry of sucralfate. The concentration of dissolved antibiotic can be monitored by spectroscopic analysis or other technique. If adsorbable, the concentration of dissolved antibiotic will drop, only to stabilize when the sucralfate-antibiotic complex reaches equilibrium or saturation.
Antibiotics having an affinity toward sucralfate are desirably incorporated into the present compositions in from 0.2% to 5% by weight of compound. These antibiotics may be concentrated on an ulcer through their linkage to sucralfate and its property of preferentially binding to a wound site. This ensures that a therapeutically effective amount of antibiotic is present to combat infection and to facilitate healing of the ulcer.
Once the complex of antibiotic and disaccharide polysulfate-aluminum compound has been formed as described above, it can be separated from the aqueous dispersant and dried. It remains stable in this form and can be administered directly as a powder or mixed with a pharmaceutically acceptable dispersant to permit formation of a tablet or another slurry. The composition is normally administered from 1 to 4 times over the course of a single day. The administration is continued for as many days as are necessary to relieve the condition being treated.
The dosage amount of sucralfate composition administered in accordance with the invention need not be great. Sucralfate has been found to bind preferentially to a wound site as opposed to normal tissue. As a result, the present compositions concentrate on and adhere to an ulcer. This significantly reduces the amount(s) of disaccharide polysulfate-aluminum compound and/or antibiotic which would otherwise be needed for optimum therapeutic effect.
For an external or topical application, a very light coating may be applied directly to the ulcer site. As little as 10 milligrams per square centimeter, more desirably at least 25 mg/cm 2 of particulate composition may be applied. This may be performed by dusting the ulcer with a free-flowing, powder form of the present composition.
The composition may also be diluted with a pharmaceutically acceptable dispersant and then applied directly to the ulcer. The dispersant may be any conventional material for topical application. It may conveniently be an ointment composed, for example, of petroleum jelly or lanolin or other suitable carriers. Other representative dispersants which may be used are disclosed in U.S. Pat. No. 4,626,433 of Gros, the disclosure of which is incorporated herein by reference.
For internal ulcers which cannot be treated directly, the composition may be ingested in any dispersed form. Thus, the composition may be compacted into a tablet with a solid such as lactose or starch or other conventional binder. Similarly, it may be mixed with an organic liquid such as alcohol or glycol and then encapsulated. An aqueous slurry may also be employed. Such a slurry normally comprises at least 70% liquid by total weight. The normal dosage for internal application will range from 2 to 8 grams of composition in a twenty-four hour period.
Any of these forms of the present composition may be used to treat internal ulcers. After ingestion, the tablets readily disintegrate forming an aqueous slurry within the alimentary canal. This or one of the other slurries of the present invention constitutes a preferred means of transmitting the composition to an ulcer site. For ulcers of the large intestine, bladder and/or certain other regions, rather than causing the composition to pass through most of the alimentary canal, it may be desirable to inject the composition directly into the area where the ulcer is located.
Normally, the composition is maintained at the ulcer site for a sufficient time to ensure that a desirable amount of the composition will bind to the ulcer. In most cases, this occurs inherently during administration because as little as 15 seconds, more desirably 30 seconds, is usually enough. Only in rare cases is any special effort necessary. Thus, for example, where an oral ulcer is being treated, the slurry should be held temporarily in the mouth and then may be expectorated or swallowed.
The following examples are not intended to limit the present invention, but are merely illustrative thereof. It is understood that one of ordinary skill in the art would be able to make substitutions, change proportions, or make other variations, all within the scope of the teachings and without departing from the spirit of the invention and without undue experimentation.
EXAMPLE 1
The affinity of various antibiotics toward disaccharide polysulfate-aluminum compound was tested employing a series of nine compounds.
Each antibiotic was placed in water and stirred at a temperature of 37° C. until equilibrium was reached. An aliquot was then removed and the concentration of dissolved antibiotic was determined by UV spectroscopic analysis.
Sucralfate was then added to the remaining solution. The resultant slurry was stirred for at least thirty minutes until equilibrium was again obtained. The slurry was filtered to remove its solids and a second aliquot of solution was removed. Its concentration of antibiotic was determined by the same technique used previously.
A comparison of the results of these paired analyses for representative antibiotics showed:
______________________________________Antibiotic Change from initial analysis______________________________________Cephaloridine NoneNalidixic Acid DecreaseDoxycycline Hyclate DecreaseBenzylpenicillin NoneErythromycin NoneSulfamethizole NoneNitrofurantoin NoneGentamycis Sulfate NoneTetracycline Decrease______________________________________
A decrease in the concentration of antibiotic reflects adsorption of soluble antibiotic onto particulate sucralfate. Thus, these results reveal that only three of these sample antibiotics, nalidixic acid, doxycycline hyclate and tetracycline possess the affinity required for the present invention.
EXAMPLE 2
The effectiveness of the present antibiotic-sucralfate complexes was measured in the treatment of gastric ulcers artificially induced in rabbits.
Six antral stomach wall injuries were produced by pinch biopsy in each of ten anesthetized rabbits weighing about 2.5 kg. This was performed by laparotomy. The rabbits then received 800 cGy irradiation and appropriate post-operative care.
Six days later the rabbits were food deprived for twenty-four (24) hours before administering an aqueous slurry of tetracycline-sucralfate complex by feeding tube. The rabbits were then sacrificed and their stomachs rinsed with cold saline. Biopsies of each of the six ulcer sites as well as adjacent, non-ulcerated sites were obtained. These were then quantitatively analyzed for aluminum content by electrothermal atomic adsorption spectroscopy.
A comparison of the median aluminum content for ulcer biopsies to the median content of non-ulcerated (control) biopsies was performed. The average ratio for the rabbit biopsies was 2.5. Thus the complexed antibiotic did not negate the preference of sucralfate to bind preferentially to a wound site. Its adherence there was approximately 150% greater than for non-ulcerated tissue.
EXAMPLE 3
The antimicrobial activity of a doxycycline hyclate-sucralfate complex having a weight ratio of 1:70 was determined using a modified U.S.P. turbidimetric method.
A control sample of a dilute culture of staphylococcus aureus in U.S.P. medium 3 was analyzed at 530 nm for percent transmission.. This control and samples additionally containing varying concentrations of the antibiotic alone, sucralfate alone and the complex were incubated in a 37° C. water bath. After four (4) hours, the samples were removed and their transmissions were measured as previously described. The results were as follows:
______________________________________ Percent Transmissions Initial Final______________________________________Control 100% 56%Sucralfate -- 51.6% at 70 ug/mL 55.5% at 35 ug/mL 53.9% at 7 ug/mLDoxycycline -- 99.2% at 1.25 ug/mLHyclate 92.2% at 0.125 ug/mL 91.3% at 0.1 ug/mL 86.4% at 0.08 ug\mLComplex -- 97.5% at 70 ug\mL 84.4% at 35 ug\mL 69.1% at 7 ug\mL______________________________________
This data reflects that sucralfate alone exhibits no antimicrobial activity. On the other hand, complexed antibiotic has only a slightly lessened activity as compared to the uncomplexed, antibiotic control. Therefore, this example shows that a targeted medication of desired therapeutic activity is readily obtained.
EXAMPLE 4
The procedure of Example 3 is repeated substituting tetracycline and a tetracycline-sucralfate complex having a weight ratio of 1:160. The results were as follows:
______________________________________ Percent Transmissions Initial Final______________________________________Control 100% 57.5%Sucralfate -- 59.9% at 160 ug/mL 57.9% at 80 ug/mL 57.5% at 16 ug/mLTetracycline -- 101.2% at 2.4 ug/mL 95.6% at 0.3 ug/mL 92.7% at 0.24 ug/mL 85.9% at 0.192 ug/mLComplex -- 94.1% at 160 ug/mL 83.3% at 80 ug/mL 63.2% at 16 ug/mL______________________________________
Again the antibiotic-sucralfate complex exhibits a significant anti-microbial activity, only slightly lessened from that of the antibiotic control.
The foregoing Examples are illustrative of the present invention. The scope of this invention is indicated by the appended claims, and all changes which come within the meaning and range of equivalency of these claims are intended to be embraced therein. | Pharmaceutical compositions comprising an antibiotic adsorbed onto a disaccharide polysulfate-aluminum compound such as sucralfate are effective for the treatment of ulcers. The composition adherently coats the ulcer, protecting it while imparting an antibiotic activity which accelerates healing. | 0 |
FIELD OF THE INVENTION
The present invention relates to a computer that can be operated easily in dimly-lit or dark environments and, more particularly, to a technique that can improve the visibility of the keys on a computer keyboard in such environments.
BACKGROUND OF THE INVENTION
Generally, on the key top of each key of a keyboard provided for a personal computer (PC) is denoted a character, symbol, or the like that defines the key. Such PCs are typically operated in well-lit environments such as offices or homes, so that users are not usually concerned about the visibility of the characters and symbols on the keys when they are operating the keyboards of those PCs.
However, when such a PC is used in a dimly-lit environment, like in a meeting room in which the lighting is limited so as to use a projector, for example, the user will come to realize the difficulty of discerning the characters and symbols on the key tops in such an environment.
In order to address this problem, there has been proposed and implemented in the past a method that provides, for example, a lap-top PC with an additional light source that lights up the keyboard. When using such a lap-top PC, a user will be able to reliably read the characters and symbols on the key tops despite the lack of ambient light.
A technique utilizing such an additional light source cannot prevent the manufacturing cost of the PC from an increase to be caused by the light source and the light source circuit provided for the PC. Laying the cables for the light source and the circuit also increases the workload for assembling the lap-top PC. In addition, it is difficult to locate the light source such that the lighting of the keyboard is even and free from shadows. Finally, such a light source adds to the weight and complexity of the lap-top PC.
Therefore, it is an object of the present invention to provide a computer that can significantly improve the visibility of the keyboard when it is being used in locations with little or no ambient light while avoiding the increases in manufacturing cost, complexity and weight and the problems of uneven lighting inherent in previous solutions. It is another object of the present invention to provide a key top for each key of a keyboard preferred for such a computer.
SUMMARY OF INVENTION
In order to attain these objects, a light accumulator is employed for the characters and symbols on each key top to avoid the problems associated with the more conventional solution of providing an external light source. More specifically, the character, symbol or the like is printed out with use of a light accumulator so that light energy is accumulated in the light accumulator while the key is being used in locations having sufficient ambient light. Thereby, when the key is used in a darkened environment, the light accumulator emits the character, symbol, or the like so that the user can recognize the character/symbol.
The method that prints out characters and symbols on key tops with use of such the light accumulators is less expensive than the above-described conventional technique that provides a keyboard with a light source that lights up the keyboard. It also avoids any increase in the workload for assembling the lap-top PC. The light accumulating material adds no measurable weight to the PC and, finally, since the light is emitted from the light accumulator on the key top itself, there is no problem with uneven lighting or shadows.
One problem that arises when using light accumulating material on the key tops is providing a coating of light accumulator thick enough to provide a satisfactory emission performance. The emission performance means a measurement of the emission brightness after a light irradiation for light accumulation and/or a measurement of the emission brightness recognized in a predetermined time. The emission performance, when the light-accumulation coating is the same, is proportional to the thickness of the light accumulator per unit area. Consequently, as the light accumulator increases in thickness, the emission performance improves. At a sufficient thickness, the emission performance is satisfactory for continuous operation of the PC in a dark place.
Another problem that arises is that, sometimes, it is difficult to maintain emission performance from a light accumulator even when the thickness should be sufficient, since the light accumulator coating on the key top is worn out as the user operates the key. This is why it is no use to simply increase the thickness of the light accumulator on each key top so as to obtain necessary emission performance.
In order to solve the above-mentioned problems, the present invention proposes a method that forms a groove in each key top in accordance with the shape of the key's respective character or symbol and dispose a light accumulator in the groove at a thickness that can assure the predetermined emission performance necessary for satisfactory performance. Because the light accumulator is disposed in such a groove, the light accumulator is not worn out nor comes off even when the user continues the operation of the key. The shape of the groove for embedding the light accumulator therein such way can be varied. For example, it is possible to use the groove to form an area denoting a character/symbol or to place the groove along the frame of such an area for denoting the character/symbol. It is also possible to form a groove so as to surround such an area for denoting the character/symbol. According to the present invention, a groove formed in accordance with the shape of a character/symbol means a concept that includes all of these groove forming methods and any others whereby the groove with its applied light accumulator indicates to the use the identity of the key's respective character/symbol.
The computer of the present invention, which is composed on the basis of the above concept, is provided with a main body on which such a key to be operated by the user is disposed. The key on the main body has a body opened to the key operation surface and including a light accumulator recess formed in accordance with the shape of the key operation type and a light accumulator embedded in the light accumulator recess.
The computer of the present invention is enabled to decide a depth of the light accumulator recess by considering the residual light brightness of the light accumulator. Consequently, it is possible for the computer to use a light accumulator having a thickness enough to endure a long continuous use at a dark place. Considering the emission performance of each existing light accumulator, the depth of the light accumulator recess, that is, the thickness of the light accumulator itself should be at least 150 Fm and preferably at least 200 Fm.
On the other hand, this light accumulator, since it is embedded in the light accumulator recess, never comes off or comes off very slightly even when it comes off while the user operates the keyboard of the PC. Thus, there will never arise a problem that the user fails in recognition of the key operation type due to a lack of light accumulator or emission performance.
In the concept of the light accumulator disclosed above are included any of the well-known light-accumulator coatings such as photo-accumulating pigments, photo-accumulating inks, and other general materials having a photo-accumulating function respectively and any other photo-accumulating materials appropriate for this application, whether now-know or later-developed.
In the concept of the key mentioned above are included all the keys of the keyboard used to enter characters or symbols. Pointing devices such as track pads are also included in the concept of the key to be operated by the user according to the present invention. Consequently, a display that makes the user recognize the presence of a pointing device is considered to be equivalent to a display that corresponds to each operation type in the present invention.
A typical example of the key of the present invention is input keys disposed on a keyboard. On the key top of each of those input keys is denoted a character or symbol. Specifically, the user can identify the operation type of each of those input keys with the character or symbol denoted on the key top. And, as described above, the light accumulator recess can be formed in various ways. For example, a light accumulator recess can be formed in an area in which a predetermined character or symbol is denoted, as well as in an area that surrounds the area in which the predetermined character or symbol is denoted. In any of the ways, the user can recognize the character or symbol at the key top.
The computer of the present invention should preferably be provided with a residual emission level meter that displays a residual emission level of the light accumulator embedded in each light accumulator recess. This is to prevent the user from an accidental stop of the emission of the light accumulator during an operation at a dark place and assure continuation of a smooth operation for the user. This residual emission level meter can have a light accumulator as an element. It is still another object of the present invention to provide a computer that includes a meter for displaying such a residual emission level.
In order to achieve the above object, the computer of the present invention comprises a main body provided with a keyboard on which a plurality of input keys are disposed; a display unit that displays an image in accordance with an operation executed for the main body and enabled to be opened from/closed to the main body; and a display meter provided at the main body or display unit and composed of a plurality of light accumulating films that differ from each other in residual emission brightness in a predetermined way.
The display meter of the present invention is composed of a plurality of light accumulating films that differ from each another in residual emission brightness in a predetermined way as described above. Consequently, a time lapse can be known by comparing the residual emission brightness among the light accumulating films. For example, assume that a plurality of the light accumulating films are composed of the same light accumulator respectively. In this case, when the film thickness differs among those films, the residual emission brightness also differs among the films under a predetermined condition. Typically, when there are two light accumulating films and the emission from one light accumulating film stops in a predetermined time while the other light accumulating film keeps the emission. At this time, the user can know the lapse of the predetermined time by recognizing the emission of the other light accumulator film.
In the case where an input key has a character or symbol displayed by such a light accumulator on its key top, the display meter can be composed so as to display the residual emission level of the light accumulator that displays the character or symbol. For example, it is just required in this case that at least one of a plurality of light accumulating films is provided with a light accumulator that displays the character or symbol and the same emission performance as those of others under a predetermined condition. When a display meter is composed of two light accumulating films, the meter is composed so as to cause one light accumulating film to continue the emission while the other light accumulating film stops the emission in a predetermined time. In the case where the same emission performance is given to both of the light accumulating films, when one of the light accumulating films stops the emission, the user can recognize that the residual emission of the light accumulator that is displaying the character or symbol is also now at a low level.
The computer of the present invention may be a lap-top PC, of course. As known well, such a lap-top PC enables the display unit, which is typically a liquid crystal display, to be opened from/closed to the main body. And, the liquid crystal display is provided with a light source referred to as a back light unit. Part of the light supplied from the light source leaks from the screen of the liquid crystal display. The computer of the present invention can use this leaked light as a light energy source for the display meter or light accumulators used to display characters and symbols. More specifically, when the display meter denotes a low level of the residual emission of each light accumulator, the liquid crystal display may be closed, thereby supplying the leaked light to the display meter and/or each of the key-top light accumulators. In this case, when the liquid crystal display is closed, the lap-top PC must be set in a proper mode so as to continue the emission of the back light unit, of course. Also in this case, the screen of the liquid crystal display should preferably be white so as to enable more light energy to be supplied to the display meter and each light accumulator.
Furthermore, it is still another object of the present invention to provide a keyboard preferred for the above-described computer. The keyboard includes a plurality of operation keys disposed thereon. Each of those operation keys has a key body having a key top surface and a character/symbol display member recognized on the key top surface. The display member is composed of a light accumulator that can keep a residual emission brightness of at least 50 mcd/m2 for 30 minutes after the light accumulator is exposed to a 400-lux light from a D 65 standard light source for 20 minutes. The display meter composed as described above can assure enough visibility for the characters/symbols during continuous operation of the lap-top PC in a dark place. Such a display meter composed of a light accumulator must be formed so as not to be protruded from the key top surface on the keyboard of the present invention. This is to prevent the light accumulator from coming off due to the operation of the user.
According to the present invention, such a conventional well-known measuring instrument as a spectral radiance meter can be used for measuring the residual emission brightness. While the values obtained for the aperture (solid angle), the measured distance, and the RGB filtering differ slightly among measuring instruments, any of the existing radiance meters can correct emission brightness values automatically. Measured emission brightness values will thus become identical among those radiance meters.
As described above, while the present invention provides a computer provided with a display meter composed of a light accumulator, this display meter may be independent of the computer. More specifically, the present invention provides a display meter provided with a first display member composed of a first light accumulator and a second display member composed of a second light accumulator, which is different from the first light accumulator in emission performance when measured at a predetermined time after a light is accumulated therein under the same condition as that of the first light accumulator.
This display meter enables a time lapse to be known as described above by observing whether the second display member maintains the emission at a predetermined time after light is accumulated in the member under the same condition as that of the first member while the emission from the first display member stops. For example, the display member can be used as a meter for displaying a residual emission level just like a residual battery level meter of a lap-top PC.
As described above, it is well known that a residual emission level differs among the thickness values of the light accumulators when the same material is used for those light accumulators. Consequently, in the case where the first and second light accumulators are made of the same material and composed so as to be different from each other in thickness, those first and second light accumulators can be combined into a display meter.
While a description has been made for only two (first and second) display members, this is because a display meter can be composed of a minimum of two display members. As to be described in the embodiment of the present invention, the display meter of the present invention may of course also be composed of more display members (the third, the fourth, . . . ).
BRIEF DESCRIPTION OF DRAWINGS
Hereafter, the present invention will be described in detail in accordance with the embodiment(s) shown in the accompanying drawings, in which:
FIG. 1 is a perspective view of a lap-top PC in an embodiment of the present invention;
FIG. 2 ( a ) is a top view of the structure of a key of the lap-top PC in an embodiment of the present invention;
FIG. 2 ( b ) is a cross sectional view of the structure of a key of the lap-top PC in an embodiment of the present invention, taken at the line A—A shown in FIG. 2 ( a );
FIG. 2 ( c ) is a partially expanded (zoomed) view of FIG. 2 ( b );
FIG. 3 ( a ) is a top view of another structure of the key of the lap-top PC in the embodiment of the present invention;
FIG. 3 ( b ) is a cross sectional view of the key structure shown in FIG. 3 ( a ), taken at the line B—B shown in FIG. 3 ( a );
FIG. 3 ( c ) is a partially expanded (zoomed) view of FIG. 3 ( b );
FIG. 4 ( a ) is a top view of a structure of a residual emission level meter of the lap-top PC in an embodiment of the present invention;
FIG. 4 ( b ) is a cross sectional view of the residual emission meter shown in FIG. 4 ( a ), taken at the line C—C shown in FIG. 4 ( a );
FIGS. 5 ( a ) through ( c ) shows an emission state of each light accumulator L with respect to a time lapse of a residual emission level meter of the lap-top PC in an embodiment of the present invention, with the representation passing from (a) to (b) to (c) with respect to the passage of time;
FIG. 6 shows how a light is accumulated in a light accumulator L in the lap-top PC in an embodiment of the present invention;
FIG. 7 ( a ) is a top view of another structure of the key of the lap-top PC in an embodiment of the present invention;
FIG. 7 ( b ) is a cross sectional view of the key structure shown in FIG. 7 ( a ), taken at the line D—D shown in FIG. 7 ( a );
FIG. 8 ( a ) is a top view of still another structure of the key of the lap-top PC in an embodiment of the present invention;
FIG. 8 ( b ) is a cross sectional view of the key structure shown in FIG. 8 ( a ), taken at the line E—E shown in FIG. 8 ( a ); and
FIG. 9 is another example of the residual emission level meter of the lap-top PC in the embodiment of the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1 , the lap-top PC 1 is composed of a main body 2 and a liquid crystal display 5 . The main body 2 and the liquid crystal display 5 are connected to each other by hinges (not shown) so that the liquid crystal display 5 can be opened from/closed to the main body 2 .
The main body 2 is provided with a keyboard 3 used as input operation means. This keyboard 3 is composed of a plurality of keys 31 used to enter characters, symbols, etc., as well as to control various operations of the lap-top PC 1 . On the keyboard 3 is also disposed a pointing device 32 . The lap-top PC 1 may also include other types of pointing devices such as touch pads, joysticks, etc. (not shown). In the main body 2 is disposed a built-in battery (not shown) used to drive the lap-top PC 1 . A residual emission level meter 4 is also disposed on the surface of the main body 2 . This residual emission level meter 4 will be described in detail later.
The liquid crystal display 5 is provided with a liquid crystal display panel 6 used to display images and a frame 7 used as a housing for the liquid crystal display panel 6 . The liquid crystal display panel 6 displays an image in accordance with each operation executed for the main body 2 .
FIG. 2 shows the details of a key 31 of the keyboard 3 . As shown in FIG. 2 , the key 31 is composed of a ceiling part 31 a having a predetermined thickness and a leg part 31 b trailed from the ceiling part 31 a . The surface of the ceiling part 31 a forms a key top 31 c to be pressed by the user. The key 31 shown in FIG. 2 denotes a character “T” on its key top 31 c.
In the ceiling part 31 a is formed a light accumulator recess 31 d opened to the key top 31 c . This light accumulator recess 31 d has a groove formed in accordance with the character “T”. The groove can be formed by, for example, a laser processing. The laser processing fuses the ceiling part 31 a by means of a thermal fracture in accordance with the area denoting the character “T” to form a groove. Then, a light accumulator L is embedded in the groove-like light accumulator recess 31 d . The light accumulator L should preferably be an aluminate one. This light accumulator L looks light whitish yellow at bright places.
As shown in FIG. 2 , the keys 31 of the laptop PC 1 in this embodiment are black. On the other hand, because each light accumulator L is whitish yellow, the light accumulator L displays the character “T” in white at bright places. And, because the key 31 is black, the white “T” is visible enough even at bright places. On the other hand, for example, when the key 31 is white, the (white) color of the key 31 is similar to the color of the light accumulator L, so that it is not visible enough at bright places. Therefore, when the present invention employs such the whitish yellow light accumulator L, the color of the key 31 should be black or a dark color. However, because the light accumulator L can be colored with an added colorant or the like, there is no need to limit the color of the key 31 in such a case.
As described above, in the case of the lap-top PC 1 , a light accumulator L displays the character “T” of the key 31 . And, this is why the user can recognize the character “T” satisfactorily due to the emission of the light accumulator L even in a use at a dark place after a use in a light place.
Assume now that the lap-top PC 1 is used for a long time at a dark place. In this case, a problem arises from the residual emission level of the light accumulator L. The emission from the light accumulator L attenuates with time and the brightness in this attenuated state is referred to as a residual emission brightness. And, because the residual emission brightness is proportional to the thickness of the light accumulator L, the residual emission brightness must be considered so as to set a depth of the light accumulator recess 31 d and an embedding depth of the light accumulator L.
It has been found that a 400-lux light from a D 65 standard light source maintains a residual emission brightness of at least 50 mcd/m 2 30 minutes after being exposed to the light for 20 minutes, and this is preferable for the use of the lap-top PC 1 at dark places. This is why it is important for the present invention to give consideration to this residual emission brightness to set a depth of the light accumulator recess 31 d and an embedding depth (d in FIG. 2 ( b )) of the light accumulator L. And, in order to achieve this residual emission brightness, the (preferably) aluminate light accumulators L should be at least 150 μm deep, preferably at least 200 μm deep. Consequently, the depth of the light accumulator recess 31 d and the thickness of the light accumulator L should be at least 150 μm, preferably at least 200 μm. For example, “N Nightglow (LumiNova)” of Nemoto & Co., Ltd. may be used as the light accumulator L. Or, instead of the light accumulator L, any of the well-known paints and inks that include a light accumulating pigment may be embedded in the light accumulator recess 31 d . In order to secure a thickness of about 200 μm, the coating process may be divided into several processes. The depth of the light accumulator recess 31 d and the embedding depth of the light accumulator L may not necessarily be the same; the depth of the light accumulator recess 31 d may be deeper than the embedding depth of the light accumulator L. In this case, however, the embedding depth of the light accumulator L should be at least 150 μm, preferably at least 200 μm. While the embedding depth of the light accumulator L is not defined specifically in terms of the residual emission brightness, the depth should be determined by giving consideration to the required residual emission brightness. It should also be considered that, when the embedding depth of the light accumulator L is excessive, the manufacturing costs associated with the lap-top PC 1 increases. Also, the depth of the light accumulator recess 31 d may be limited by the depth of the ceiling part 31 a of the key 31 . Finally, a transparent protective film C may be formed on the key top 31 c so as to protect the light accumulator L as shown in FIG. 3 .
While the area for displaying the character “T” is formed as a light accumulator recess 31 d in the above embodiment, the area may also be formed as shown in FIG. 7 . FIG. 7 ( a ) shows a top view of the recess 31 d and FIG. 7 ( b ) shows a cross sectional view at the D—D line shown in FIG. 7 ( a ). In the case of the key 31 shown in FIG. 7 , a light accumulator recess 31 d is formed in the key top except for the character “T” portion. Consequently, the light accumulator L comes to be disposed on the full surface of the key top 31 c except for the “T” character portion. In this form, the character “T” portion takes the same color (black) as that of the key 31 and the rest surface of the key top 31 c looks white at bright places, since a light accumulator L is disposed there. And, the black “T” comes up due to the emission from the light accumulator L.
The key 31 in the above embodiment may also be formed as shown in FIG. 8 . FIG. 8 ( a ) shows a top view of such the key 31 and FIG. 8 ( b ) shows a cross sectional view at the E—E line shown in FIG. 8 ( a ). In the case of the key 31 shown in FIG. 8 , the light accumulator recess 31 d is formed at a predetermined width around the portion for displaying the character “T”. Consequently, a light accumulator L comes to be disposed at a predetermined width around the character “T”. In this case, only the predetermined width around the character “T” looks white at bright places and the rest portion looks black. In other words, the character “T” is also displayed as an outline character. Thus, the character “T” is displayed as an outline character even at dark places due to the emission from the light accumulator L.
While a description has been made for a specific key 31 that displays the character “T” so far, the light accumulator recess 31 d may also be formed for each of the rest of the keys 31 of the keyboard 3 in the same way so that a light accumulator L is embedded therein. It is also possible to form the light accumulator recesses 31 d just for the keys 31 used frequently and embed those keys 31 therein, not for all the keys 31 of the keyboard 3 . In other words, the method for forming the light accumulator recess 31 d and embedding a light accumulator L therein may be employed for any of the keys 31 on the keyboard 3 . In addition to those keys 31 , the method may also be employed for the pointing device 32 so as to compose the device 32 and display an operation type thereof just like the key 31 .
As shown in FIG. 4 , the residual emission level meter 4 is provided with a function that notifies the user of a residual emission level of the light accumulator L of each key 31 . The residual emission level meter 4 is composed of four display films 41 to 44 . Basically, each of the display films 41 to 44 is identical to the above-described configuration that a light accumulator L is embedded in each of the light accumulator recesses 41 a to 44 a . However, the depth of each of the light accumulator recesses 41 a to 44 a , that is, each of the film thickness values d 1 to d 4 , differs among the display films 41 to 44 . As shown in FIG. 4 , the film thickness among d 1 to d 4 takes a relationship of d 1 >d 2 >d 3 >d 4 .
As described above, the residual emission brightness is proportional to the thicknesss of the light accumulator L. Consequently, when a light is accumulated in light accumulators L under the same condition, the residual emission brightness differs among display films 41 to 44 after a predetermined time lapse. More specifically, because the residual emission brightness after a predetermined time lapse differs among the thickness values of light accumulators L, the residual emission brightness among the display films 41 to 44 takes a relationship of d 1 >d 2 >d 3 >d 4 . Of course, it is natural that the residual emission brightness can be recognized by human eyes after a predetermined time lapse. Consequently, when the thickness of each light accumulator L is adjusted as needed, it is possible to configure the residual emission level meter 4 so that the light emission of each of the display films 44 , 43 , etc. stops sequentially over time. As shown in FIG. 5 , the number of the display films decreases sequentially; for example, at first, the four display films 41 to 44 begin the emission (so as to be recognized by human eyes) (FIG. 5 ( a )), then only the three display films 41 , 42 , and 43 maintain the emission with time (FIG. 5 ( b )), and then only the two display films 41 and 42 maintain the emission (FIG. 5 ( c )).
Assume now that the thickness d 1 of a light accumulator L in the display film 41 of the thickest light accumulator L matches with the thickness d of the light accumulator L of the above-described key 31 here. Then, when only the two display films 41 and 42 (or only the display film 41 ) maintain the emission as shown in FIG. 5 ( c ), the user can recognize that the residual emission time of the light accumulator L in the key 31 has reached a low level. In the case where the thickness d of the light accumulator L of the key 31 is 200 μm, the depths d 1 to d 4 of the light accumulator recesses 41 a to 44 a may be decided as d 1 =200 μm, d 2 =150 μm, d 3 =100 μm, and d 4 =50 μm respectively. While four display films 41 to 44 are used in this example, differing numbers of display films may be employed in the residual emission level meter 4 , as long as at least two display films are used.
As described above, the residual emission level meter 4 functions so as to notify the user of a residual emission level of the light accumulator L of a key 31 in this embodiment. In other words, in this embodiment, the meter 4 is combined with a light accumulator L that displays the character “T”. However, the residual emission level meter 4 may also be composed so as to realize another function independently. One of such the functions to be realized by the meter 4 is a clock function. The user can know a time lapse after the light accumulation from how many display films 41 to 44 are still emitting in the residual emission level meter 4 . Specifically, in the case where the thickness d is decided so as to stop the emission from each of the display films 44 , 43 , 42 , and 41 in response to each predetermined time lapse, it is possible to know a time lapse approximately according to how many display films of those 41 to 44 maintain their emission. Consequently, the present invention can also provide an independent embodiment of a meter provided with a plurality of display films ( 41 to 44 ). In the example shown in FIG. 4 , the display films 41 to 44 are disposed adjacently while they may also be disposed differently. In the case where the user can recognize a plurality of display films 41 to 44 in the same visibility range, the user can also combine the display films so as to function as a residual emission level meter 4 or as a clock. For example, as shown in FIG. 9 , it is possible to dispose the four display films 41 to 44 around the main body 2 of the lap-top PC 1 . The configuration of each of those display films 41 to 44 is the same as each of those shown in FIG. 4 in this case.
Sometimes, the user, when using the lap-top PC 1 at a dark place, is required to accumulate a light in the light accumulators L during the operation. The user can charge a light in those accumulators L by exposing them to a light energy from a sunlight, lighting, etc. The present invention, however, proposes another method that a light energy is supplied to the light accumulators L from the liquid crystal display 5 of the lap-top PC 1 as described above in this embodiment. Hereinafter, this proposal of the present invention will be described with reference to FIG. 6 .
As known well, the liquid crystal display 5 has a back light (not shown in FIG. 1 ) used as a sheet-like light source for lighting. The back light is disposed at the rear side of the liquid crystal display panel 6 and composed so as to irradiate a uniform light all over the liquid crystal screen having a predetermined expanse, thereby visualizing images on the surface of the liquid crystal display panel 6 . In other words, a light emitted from the back light leaks from the surface of the liquid crystal display panel 6 . And, this leaked light is accumulated in the light accumulators L.
For this purpose, the lap-top PC 1 is “closed” as shown in FIG. 6 . Then, the liquid crystal display panel 6 , the keys 31 , and the residual emission level meter 4 each another. Consequently, a leaked light (shown with an arrow) from the liquid crystal display panel 6 supplies a light energy to the light accumulators L existing in the keys 31 and in the residual emission level meter 4 provided on the main body 2 , thereby the light is accumulated in those light accumulators L respectively.
At this time, the mode of the lap-top PC 1 must be set properly so as to continue the emission from the back light of the liquid crystal display 5 after the lap-top PC 1 is closed. And, in order to increase the leaked light from the liquid crystal display panel 6 at this time, the display image of the panel 6 is preferably configured to be primarily white.
The method shown in FIG. 6 has an advantage that there is no need to move the lap-top PC 1 to another place nor use a light source so as to supply a light to the light accumulators L. The method can also cope with a case in which no room light for charging the light accumulators L is available due to circumstances. While the lap-top PC 1 is “closed”, the liquid crystal display panel 6 comes very close to the keys 31 and the residual emission level meter 4 respectively, so that a strong light energy can be supplied to those light accumulators L. The light accumulating method recommended in this embodiment can thus have many advantages. In other words, the lap-top PC 1 in which the light accumulators L are disposed on the surface of the main body 2 that faces the liquid crystal display panel 6 when the lap-top PC 1 is closed will be a favorable apparatus from the viewpoint of light accumulation. | The computer of the present invention is provided with a main body on which keys to be operated by the user are disposed and a display unit that displays an image in accordance with each operation executed for the main body. Each key disposed on the main body is composed of its body having a key top and a light accumulator recess opened in the key top. The light accumulator recess is formed in a manner indicative of the character or symbol associated with such key. The light accumulator recess has embedded in it a light accumulating material such that the character or symbol associated with the key is illuminated by the residual light emission of the light accumulating material when the computer is operated in a location with little or no ambient light. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Stage filing of International Application No. PCT/US2007/019638, filed on Sep. 10, 2007 titled “Vehicle Seat Power Track Enhancements, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
The present disclosure relates generally to adjustable vehicle seat assemblies utilizing power track systems. More particularly, the present disclosure relates to enhancements to a power track system and its transmission.
Vehicle seat assemblies are typically provided with a track system that enables the forward and rearward positioning of the seat assembly. Such adjustment capability is desirable to enable vehicle operators of various sizes to be seated comfortably within the motor vehicle. Such seat assemblies typically include a track assembly including two tracks that move relative to one another and a latching mechanism that retains the tracks (and therefore the seat assembly) in a locked position relative to one another until the latch mechanism is released. The tracks may be moved relative to one another, which allows the occupant of the seat assembly to adjust the seat assembly to a new position.
Some vehicle seat assemblies include an electric motor, a transmission and a lead screw positioned within the track assembly for power adjustment of the vehicle seat. In such arrangements, the lead screw may generally be fixed and does not rotate. The transmission includes a worm gear assembly rotatably coupled to the lead screw and the electric motor causes the worm gear to rotate causing the transmission to translate along the fixed non-rotating lead screw to adjust the vehicle seat assembly forward or rearward.
In such configuration, the electric motor, mounted on a traverse beam is positioned relative to each of the tracks, for example in the center of the tracks or at one end of the tracks. A transmission mounting bracket couples the transmission, which may float inside of the mounting bracket, and the stationary lead screw to one of the rails. Thus, the strength of the power track is realized through the transmission mounting bracket. In the event of a collision, the load on the bracket could cause the bracket to bend. Using a larger bracket to provide more strength to the power track could be problematic due to space constraints inside the track section that limits the size of the mounting bracket.
Occasionally, the movement of the seat forward can place the occupant of the vehicle too close to airbags that are located in front of the occupant. In such arrangement, the power to the air bag could be diminished or turned off. Generally, it is known to provide a seat position sensor for controlling the airbag based upon seat position. However, such known seat position sensors are affected by debris (such as dirt and dust) in the passenger cabin of the vehicle.
Therefore there is a need for a stronger transmission mounting bracket that can withstand the extra load encountered in situations such as a vehicle collision. There is also a need for a compact design of a sensor arrangement that can detect the position of the seat in reference to the proximity of an airbag and adjust the airbag power down or off as needed.
SUMMARY
In one exemplary embodiment, a vehicle seat power track for an automobile vehicle seat includes a lower rail for being fixed to a vehicle floor and an upper rail for having a seat fixed thereto and the upper rail may be mounted and traveled freely with support of the lower rail. The power track system includes a lead screw member which may extend in longitudinal direction of the rails and a transmission member located inside the rails and mounted using a bracket. A motor is provided and may be coupled to the transmission member to cause movement of the transmission along the lead screw in the longitudinal direction of the track. In the exemplary embodiment, the lead screw may be mounted on the upper rail and the transmission and bracket member on the lower rail to enable relative movement of the upper to the lower rails. A position sensor may be mounted at a predetermined position on the top surface of the upper rail to detect a magnet or a plate member (or detecting cell) generating a magnetic field near the sensor. In the one exemplary embodiment, the detecting cell (plate member) is mounted on a surface of the bracket member facing a top surface of the upper rail such that when the vehicle seat is moved to a predetermined position the plate member is aligned with the seat position sensor and affects the signal status of the seat position sensor.
In one exemplary embodiment, the bracket member includes flanges extending along the lower rail and the bracket member clip front and back surfaces of the transmission.
In one exemplary embodiment, a support member fixedly couples the lead screw to the upper rail. The support member contacts a rear surface of the transmission to form a stop surface and functions to control or limit the seat movement. Further, in the one exemplary embodiment, one end of the detecting cell is aligned at the level of the stop surface of the transmission. Further, in the one exemplary embodiment, another end of the detecting cell extends, or is cantilevered, in one direction from the bracket member.
In an exemplary embodiment, the detecting cell is fixed to the bracket member using a welding process and in particular a laser welding process to minimize any welding projections from the resulting combination of the detecting cell and bracket member.
In one exemplary embodiment, the seat position sensor includes a magnet and a detection member for detecting a magnetic field.
In one exemplary embodiment, the seat position sensor is located toward a rear end of the upper rail and the bracket member and detecting cell are located toward the front end of the lower rail to detect a seat position which is a front most position and to control or prevent deployment of a front airbag. In one exemplary embodiment, the front airbag is deployed with a lower force when the seat is detected as being the front most position. In one exemplary embodiment, the front airbag is not deployed when the seat is detected as being the front most position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a seat assembly according to an exemplary embodiment.
FIG. 2 is a top view of a track system as used with a seat assembly shown in FIG. 1 according to an exemplary embodiment.
FIG. 3 is a cross section of a track system of FIG. 2 along line 3 - 3 according to an exemplary embodiment.
FIG. 4 is a magnified view of a track system transmission according to an exemplary embodiment.
FIG. 5 is a perspective view of a track system of FIG. 2 according to an exemplary embodiment.
FIG. 6 is a magnified view of a seat position sensor according to an exemplary embodiment.
FIG. 7 is a cross section of a track system of FIG. 2 according to an exemplary embodiment.
FIG. 8 is a magnified view of a shunt member according to an exemplary embodiment.
FIG. 9 is a cross section of a seat track system of FIG. 2 according to an exemplary embodiment.
FIG. 10 is a magnified view of a seat position sensor according to an exemplary embodiment.
FIG. 11 is a perspective view of a lead screw illustrating a spacer between the lead screw bracket and saddle bracket according to an exemplary embodiment.
FIG. 12 is a magnified view of the lead screw in FIG. 11 according to an exemplary embodiment.
DESCRIPTION
Referring to FIG. 1 , a seat assembly 10 is shown according to an exemplary embodiment. Seat assembly 10 includes a seat 12 and a track system 14 . Seat 12 generally includes a back portion 16 and a seat cushion portion 18 , which each may take any one of a variety of well known configurations. Track system 14 is generally configured to enable an occupant of seat 12 to adjust the position of seat 12 in forward and/or rearward directions.
Referring to FIG. 2 , a track system 14 is shown according to an exemplary embodiment. Track system 14 includes an inboard track arrangement 20 and an outboard track arrangement 22 . Inboard track arrangement 20 and outboard track arrangement 22 are coupled to seat cushion portion 18 (shown in FIG. 1 ) of seat 12 in a generally parallel relationship with inboard track arrangement 20 being located proximate the inboard side of seat cushion portion 18 and outboard track arrangement 22 being located proximate the outboard side of seat cushion portion 18 .
Referring now to FIG. 3 , a cross section of track system 14 illustrated in FIG. 2 , is shown according to an exemplary embodiment. For simplicity, only track arrangement 20 will be described below, it being understood that the description applies equally to track arrangement 22 . Track arrangement 20 includes a lower track (rail) 24 coupled to the vehicle and an upper track (rail) 26 coupled to seat 12 , a lead screw 28 located between lower track 24 and upper track 26 and mounted to the upper track 26 , a transmission 30 rotatably coupled to lead screw 28 , and a transmission mounting bracket 32 partially enclosing the transmission 30 and movably coupled with respect to the lead screw 28 and coupled to the lower track 24 . The track system 14 may also include a motor and flexible drive cables for interconnecting the motor and the transmission.
In an exemplary embodiment, a motor turns drive cables which are coupled to transmission 30 which transmits power to the lead screw 28 . The lead screw 28 is fixed and does not rotate. A worm gear assembly 29 within the transmission 30 and coupled with the lead screw 28 causes transmission 30 to translate along the fixed non-rotating lead screw 28 thereby moving the vehicle seat assembly 10 forward or rearward depending upon the rotation direction.
Referring now to FIG. 4 , a magnified view of transmission 30 illustrated in FIG. 3 , is shown according to an exemplary embodiment. Transmission 30 causes the upper track 26 to move along the lead screw 28 . In this configuration, the upper track 26 and seat 12 move relative to the lower track 26 . The seat 12 may be moved in the opposite direction by reversing the direction that the motor turns. One end of the lead screw 28 is fixedly coupled to upper track 26 through the bracket or support 34 and the other end of the lead screw 28 is coupled to the upper track 26 through the bracket or support 48 .
In the event excessive forces are applied to the vehicle, e.g. a vehicle collision, the load path of the force is from the seat 12 to the upper track 26 through the support 34 to the transmission mounting bracket 32 . Excessive loading on the transmission mounting bracket 32 may cause the bracket to bend, putting a high load onto the transmission 30 and potentially causing it to fail.
To lessen the bending of the bracket 32 , a brace portion 36 may be utilized to support the transmission mounting bracket 32 at the point of interface between the lead screw 28 and transmission 30 . The brace portion 36 may be located on one or both sides of the transmission mounting bracket 32 . The brace portion 36 may be highly and efficiently achieved utilizing an extension of the head 39 of the fastener 77 used to connect the transmission mounting bracket 32 to the lower track 24 thereby also providing an efficient load path back to lower track 24 .
Another exemplary embodiment of track system 14 is illustrated in FIGS. 5 through 8 . As mentioned above, vehicle seat 12 moves with upper track 26 forward and rearward through track system 14 . Generally, the movement of seat 12 too far forward may cause the occupant of seat 12 to be located close to an airbag (not shown in the FIGURES) situated in front of the occupant, such as a driver's position in a passenger vehicle. To determine the location of seat 12 relative to an airbag, a seat position sensor 38 may be mounted to the upper track 26 using an attachment nut 40 . The seat position sensor 38 detects the location of the seat 12 relative to a shunt (plate) member or detecting cell 42 affixed to the top of transmission mounting bracket 32 . The shunt (plate) member 42 may be a magnet. Seat position sensor 38 may be affixed to the top of the upper rail of the track assembly and the shunt plate 42 may be coupled to the transmission mounting bracket 32 . The shunt plate 42 may be coupled to the transmission mounting bracket 32 using a laser weld process to prevent weld matter from extending from the laser welded surfaces. Alternatively, the shunt plate 42 may be coupled to the transmission mounting bracket 32 using other appropriate materials such as adhesives or other welding procedures.
Referring now to FIG. 7 , the seat position sensor 38 is located at the rear end of the track system 14 given the particular seat position. In this vehicle seat position, the shunt member 42 is not located near the seat position sensor 38 . Therefore, the seat position sensor 38 is considered “off” in proximity to the shunt plate 42 and the seat position sensor 38 will send a signal to the airbag to remain on or in full power mode or, alternatively, the seat position sensor 38 will not prevent activation of the airbag.
As the seat 12 moves forward, the seat position sensor 38 will be positioned aligned over the shunt member 42 , as best illustrated in FIGS. 9 and 10 . When the seat position sensor 38 is over the shunt member 42 , the seat is considered in full forward position. In this position, the seat position sensor 38 is considered “on” in proximity to the shunt plate and the airbag will receive a signal to power down or turn off due to the close proximity of the occupant.
In the exemplary embodiment shown, the seat position sensor 38 and shunt plate 42 located inside the seat rails allow for utilization of a narrow space within the seat rails as well as for sensing of the seat position. With the sensor or shunt 42 located inside of the slide rail, foreign objects may be prevented from entering the seat position sensor thereby improving the accuracy of detection of the full forward seat position and limiting the affects of foreign objects and dirt and dust since the sensor is set on the top surface of the upper rail. The seat position sensor 38 and shunt plate 42 design provide greater flexibility in design for the vehicle seat.
In an exemplary embodiment, as illustrated in FIGS. 11 and 12 , an annular ring, or spacer 46 may be located between the lead screw bracket 48 and transmission mounting bracket 32 . Spacer 46 may function as a stopping member to minimize the force felt by the occupant when the track assembly comes to a stop. Spacer 46 may be comprised of any non-metallic, resilient flexible material such as Acetal (POM) Copoly (Acetal (POM) Copolymer) plastic material available as CELCON™ M90 available from Ticona Company in Florence, Ky., USA.
For purposes of this disclosure, the term “coupled” means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.
It should be noted that the construction and arrangement of the track system as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments. | A vehicle seat power track for an automobile vehicle seat which includes a sensor arrangement to detect the seat position along the track relative to a front airbag apparatus and generate a signal to control the apparatus of the airbag. The vehicle seat power track also includes brackets configured to reduce horizontal movement of the track components. | 1 |
FIELD OF THE INVENTION
The present invention relates to the field of antenna technology and particularly to a stackable antenna concept for multiband operation.
BACKGROUND OF THE INVENTION
A number of currently available Radio Frequency (RF) configurations may implement multiple RF systems (ex.—antennas) on a single platform. These multiple antennas on the single platform add cost, weight, drag and configuration problems for such RF configurations. Further, for many of these currently available systems, providing separate bands has required separate antenna installations and has required separate connections to separate radios. Previously, Ultra-wideband (UWB) antennas have been implemented to obviate some of the above-referenced problems. However, UWB antennas are typically large and often require a diplexor to connect multiple radios.
Thus, it would be desirable to provide an antenna system which obviates the problems associated with currently available RF system implementations.
SUMMARY OF THE INVENTION
Accordingly, an embodiment of the present invention is directed to an antenna assembly, including: a first feed board, the first feed board including a ground plane; a first plurality of radiators, the first plurality of radiators being connected to the first feed board; a first RF feed, the first RF feed being connected to the first feed board and the first plurality of radiators, the first RF feed configured for feeding the first plurality of radiators via the first feed board, wherein the first plurality of radiators, in response to receiving said feeding, is configured for radiating electromagnetic energy in a radiation pattern; a second feed board, the second feed board including a ground plane, the second feed board being connected to and stacked upon the first plurality of radiators; a second plurality of radiators, the second plurality of radiators being connected to the second feed board; a second RF feed, the second RF feed being connected to the second feed board and the second plurality of radiators, the second RF feed configured for feeding the second plurality of radiators via the second feed board, wherein the second plurality of radiators, in response to receiving said feeding from the second RF feed, is configured for radiating electromagnetic energy in a radiation pattern; a third feed board, the third feed board including a ground plane, the third feed board being connected to and stacked upon the second plurality of radiators; an antenna element, the antenna element being connected to the third feed board; and a third RF feed, the third RF feed being connected to the third feed board and the antenna element, the third RF feed being configured for feeding the antenna element via the third feed board, wherein the antenna element, in response to receiving said feeding from the third RF feed, is configured for radiating electromagnetic energy in a radiation pattern, wherein the first plurality of radiators is configured for operating over a first frequency band, the second plurality of radiators is configured for operating over a second frequency band, and the antenna element is configured for operating over a third frequency band.
A further embodiment of the present invention is directed to an antenna device, including: a housing; and an antenna assembly, the antenna assembly being connected to and at least substantially contained within the housing, the antenna assembly including: a first feed board, the first feed board including a ground plane; a first plurality of radiators, the first plurality of radiators being connected to the first feed board; a first RF feed, the first RF feed being connected to the first feed board and the first plurality of radiators, the first RF feed configured for feeding the first plurality of radiators via the first feed board, wherein the first plurality of radiators, in response to receiving said feeding, is configured for radiating electromagnetic energy in a radiation pattern; a second feed board, the second feed board including a ground plane, the second feed board being connected to and stacked upon the first plurality of radiators, a second plurality of radiators, the second plurality of radiators being connected to the second feed board and a second RF feed, the second RF feed being connected to the second feed board and the second plurality of radiators, the second RF feed configured for feeding the second plurality of radiators via the second feed board, wherein the second plurality of radiators, in response to receiving said feeding from the second RF feed, is configured for radiating electromagnetic energy in a radiation pattern; a third feed board, the third feed board including a ground plane, the third feed board being connected to and stacked upon the second plurality of radiators; an antenna element, the antenna element being connected to the third feed board; and a third RF feed, the third RF feed being connected to the third feed board and the antenna element, the third RF feed being configured for feeding the antenna element via the third feed board, wherein the antenna element, in response to receiving said feeding from the third RF feed, is configured for radiating electromagnetic energy in a radiation pattern; at least one radio, the at least one radio being at least substantially contained within the housing and being connected to the first RF feed, the second RF feed and the third RF feed; and at least one of: a power cord and a USB cable for electrically connecting the antenna device to a second device, wherein the first plurality of radiators is configured for operating over a first frequency band, the second plurality of radiators is configured for operating over a second frequency band and the antenna element is configured for operating over a third frequency band.
A still further embodiment of the present invention is directed to an antenna assembly, including: a first feed board, the first feed board including a ground plane; a first plurality of radiators, the first plurality of radiators being connected to the first feed board; a first RF feed, the first RF feed being connected to the first feed board and the first plurality of radiators, the first RF feed configured for feeding the first plurality of radiators via the first feed board, wherein the first plurality of radiators, in response to receiving said feeding, is configured for radiating electromagnetic energy in a radiation pattern; a second feed board, the second feed board including a ground plane, the second feed board being connected to and stacked upon the first plurality of radiators; an antenna element, the antenna element being connected to the second feed board; and a second RF feed, the second RF feed being connected to the second feed board and the antenna element, the second RF feed configured for feeding the antenna element via the second feed board, wherein the antenna element, in response to receiving said feeding from the second RF feed, is configured for radiating electromagnetic energy in a radiation pattern, wherein the first plurality of radiators is configured for operating over a first frequency band and the antenna element is configured for operating over a second frequency band.
A further embodiment of the present invention is directed to an antenna assembly, including: a feed board, the feed board including a ground plane; a plurality of radiators, the plurality of radiators being connected to the feed board, the plurality of radiators being generally wedge-shaped radiators, the plurality of radiators being arranged in a generally circular arrangement on the feed board; an RF feed, the RF feed being connected to the feed board and the plurality of radiators, the RF feed configured for feeding the plurality of radiators via the feed board, wherein the plurality of radiators, in response to receiving said feeding from the RF feed, is configured for radiating electromagnetic energy in a radiation pattern.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
FIG. 1 is a view of an antenna assembly in accordance with an exemplary embodiment of the present invention;
FIG. 2 is a view of an antenna device implementing the antenna assembly of FIG. 1 in accordance with an exemplary embodiment of the present invention; and
FIG. 3 is a cross-sectional view of a feed board of the antenna assembly of FIG. 1 in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring to FIG. 1 , an antenna assembly 100 in accordance with an exemplary embodiment of the present invention is shown. In an exemplary embodiment of the present invention, the antenna assembly 100 includes a first Radio Frequency (RF) substrate 102 (ex.—a first feed board 102 ). For example, the first feed board 102 may be formed of Printed Circuit Board (PCB) material. In still further embodiments of the present invention, the first feed board 102 may include a power divider 104 (ex.—a 1:N power divider, N being the number of radiators connected to the power divider).
In exemplary embodiments of the present invention, the antenna assembly 100 further includes a first plurality of (ex.—3 or more) antenna elements or radiators 106 . For instance, the radiators 106 included in the first plurality of radiators 106 may be generally wedge-shaped or generally triangular-shaped radiators 106 as shown in the illustrated embodiment in FIG. 1 , or may be one or more of various other shapes. In further embodiments of the present invention, the radiators 106 included in the first plurality of radiators 106 may be connected to (exs.—may be mounted upon or supported upon) a first surface 108 (ex.—a top surface 108 ) of the first feed board 102 and may further be electrically connected to the first feed board 102 . In still further embodiments of the present invention, the antenna assembly 100 may further include a first ground plane 110 . The first ground plane 110 may be configured upon a second surface 112 (ex.—a bottom surface) of the first feed board 102 , the second surface 112 being configured generally opposite the first surface 108 . For instance, the first ground plane 110 may be a metal layer, metallization layer and/or metal foil layer (ex.—95% copper foil layer) which has been formed upon (ex.—patterned upon) the bottom surface 112 of the first feed board 102 . In further embodiments, the radiators 106 included in the first plurality of radiators 106 may be electrically connected to the first ground plane 110 via the first feed board 102 .
In current exemplary embodiments of the present invention, the antenna assembly 100 further includes a second RF substrate 114 (ex.—a second feed board 114 ). For example, the second feed board 114 may be formed of PCB material. In further embodiments of the present invention, the second feed board 114 may include a power divider (ex.—a 1:N power divider, N being the number of radiators connected to the power divider) 116 . In still further embodiments of the present invention, the second feed board 114 may include a first surface 118 (ex.—a top surface 118 ) and a second surface 120 (ex.—a bottom surface 120 ), the second surface 120 being configured generally opposite the first surface 118 .
In exemplary embodiments of the present invention, the antenna assembly 100 may further include a second ground plane 122 . The second ground plane 122 may be configured upon the second (ex.—bottom) surface 120 of the second feed board 114 . For instance, the second ground plane 122 may be a metal layer which has been formed upon (ex.—patterned upon) the bottom surface 120 of the second feed board 114 . In further embodiments of the present invention, the radiators 106 included in the first plurality of radiators 106 may be connected to the second ground plane 122 . In still further embodiments of the present invention, the second feed board 114 may be supported upon (exs.—mounted upon, stacked upon) the radiators 106 included in the first plurality of radiators 106 .
In current exemplary embodiments of the present invention, the first feed board 102 may be configured with a first feed aperture 124 (ex.—a feed port 124 ). The first feed aperture 124 may be configured for receiving a first RF feed 126 , the first RF feed 126 configured for being connected to the power divider 104 of the first feed board 102 . In further embodiments of the present invention, the first feed board 102 , the power divider 104 and the first RF feed 126 may be included as part of and/or may form a first feed network which is configured for feeding (ex.—providing a feed to) the radiators 106 included in the first plurality of radiators 106 . For example, the first feed network may be a microstrip or stripline feed network. In still further embodiments of the present invention, the radiators 106 included in the first plurality of radiators 106 may be configured, based upon the feed provided by the first feed network, for radiating electromagnetic energy in a radiation pattern. In further embodiments of the present invention, the design of the first feed network may determine the shape of the radiation pattern provided by the radiators 106 included in the first plurality of radiators 106 . For example, in at least one exemplary embodiment of the present invention, the first feed network may be configured for feeding the radiators 106 of the first plurality of radiators 106 in-phase, thereby causing the radiators 106 included in the first plurality of radiators 106 to provide an omni-directional radiation pattern (ex.—an omni-directional beam). In alternative embodiment(s) of the present invention, the first feed network may be configured for feeding the radiators 106 of the first plurality of radiators 106 out-of-phase, thereby allowing the antenna assembly 100 to produce a directional beam.
In exemplary embodiments of the present invention, the antenna assembly 100 may further include a second plurality of (ex.—3 or more) antenna elements or radiators 128 . For instance, the radiators 128 included in the second plurality of radiators 128 may be generally wedge-shaped or generally triangular-shaped radiators 128 , as shown in the illustrated embodiment of FIG. 1 , or may be one or more of various other shapes. In further embodiments of the present invention, the radiators 128 included in the second plurality of radiators 128 may be connected to (exs.—mounted upon or supported upon) the top surface 118 of the second feed board 114 , and may further be electrically connected to the second feed board 114 . In still further embodiments of the present invention, the radiators 128 included in the second plurality of radiators 128 may be electrically connected to the second ground plane 122 via the second feed board 114 .
In current exemplary embodiments of the present invention, the antenna assembly 100 further includes a third RF substrate 130 (ex.—a third feed board 130 ). For example, the third feed board 130 may be formed of PCB material. In further embodiments of the present invention, the third feed board 130 may include a first surface 132 (ex.—a top surface 132 ) and a second surface 134 (ex.—a bottom surface 134 ), the second surface 134 being configured generally opposite the first surface 132 .
In exemplary embodiments of the present invention, the antenna assembly 100 may further include a third ground plane 136 . The third ground plane 136 may be configured upon the second (ex.—bottom) surface 134 of the third feed board 130 . For instance, the third ground plane 136 may be a metal layer which has been formed upon (ex.—patterned upon) the bottom surface 134 of the third feed board 130 . In further embodiments of the present invention, the radiators 128 included in the second plurality of radiators 128 may be connected to the third ground plane. In still further embodiments of the present invention, the third feed board 130 may be supported upon (exs.—may be mounted upon, stacked upon) the radiators 128 included in the second plurality of radiators 128 .
In current exemplary embodiments of the present invention, the first feed board 102 may be configured with a second feed aperture 138 . The second feed aperture 138 may be configured allowing passage of a second RF feed 140 through or via the second feed aperture 138 . For example, the second feed aperture 138 may be a generally central-located channel formed through the first feed board 102 , extending longitudinally through the top surface 108 and ground plane 110 of the first feed board 102 . In further embodiments of the present invention, the second RF feed 140 may be configured for being positioned (exs.—threaded, routed) through the second feed aperture 138 and connected to the power divider 116 of the second feed board 114 via a first feed aperture 142 of the second feed board 114 . The second feed board 114 , power divider 116 and the second RF feed 140 may be included as part of and/or may form a second feed network which is configured for feeding (ex.—providing a feed to) the radiators 128 included in the second plurality of radiators 128 . For example, the second feed network may be a microstrip or stripline feed network.
In further embodiments of the present invention, the radiators 128 included in the second plurality of radiators 128 may be configured, based upon the feed provided by the second feed network, for radiating electromagnetic energy in a radiation pattern. In still further embodiments of the present invention, the design of the second feed network may determine the shape of the radiation pattern provided by the radiators 128 included in the second plurality of radiators 128 . For example, in at least one exemplary embodiment of the present invention, the second feed network may be configured for feeding the radiators 128 of the second plurality of radiators 128 in-phase, thereby causing the radiators 128 included in the second plurality of radiators 128 to provide an omni-directional radiation pattern (ex.—an omni-directional beam). In alternative embodiment(s) of the present invention, the second feed network may be configured for feeding the radiators 128 of the first plurality of radiators 128 out-of-phase, thereby allowing the antenna assembly 100 to produce a directional beam.
In exemplary embodiments of the present invention, the first feed board 102 may be configured with a third feed aperture 144 . The third feed aperture 144 may be configured for allowing passage of a third RF feed 146 through or via the third feed aperture 144 . For example, the third feed aperture 144 may be a generally central-located channel formed through the first feed board 102 , extending longitudinally through the top surface 108 and ground plane 110 of the first feed board 102 . In further embodiments of the present invention, the third RF feed 146 may be configured for being positioned (exs.—threaded, routed) through the third feed aperture 144 . In still further embodiments of the present invention, the second feed board 114 may include a second feed aperture 148 , said second feed aperture 148 being a longitudinally extending channel formed through the second feed board 114 (ex.—formed through the top surface 118 of the second feed board 114 and the ground plane 122 of the second feed board). As mentioned above, the third RF feed 146 may be configured for being positioned (exs.—threaded, routed) through the third feed aperture 144 of the first feed board 102 , and in further exemplary embodiments of the present invention, is further configured for being positioned (exs.—threaded, routed) through the second feed aperture 148 of the second feed board 114 .
In current exemplary embodiments of the present invention, an antenna element 150 may be connected to (exs.—mounted upon or supported upon) the top surface 132 of the third feed board 130 . For example, the antenna element 150 may be a monopole antenna element 150 . In alternative embodiments of the present invention, the antenna element 150 may be a more complex antenna type. In further embodiments of the present invention, the antenna element 150 may be electrically connected to the third ground plane 136 via the third feed board 130 . In still further exemplary embodiments of the present invention, the third feed board 130 includes a feed aperture 152 (ex.—feed port 152 ). As mentioned above, the third RF feed 146 may be configured for being positioned (exs.—threaded, routed) through the third feed aperture 144 of the first feed board 102 , through the second feed aperture 148 of the second feed board 114 , and in further exemplary embodiments of the present invention, is further configured for being received by the feed aperture 152 of the third feed board 130 . In further embodiments of the present invention, the third RF feed 146 and third feed board 130 may form a third feed network 315 which is configured for feeding (ex.—providing a feed to) antenna element 150 . For example, the third feed network 315 may be a microstrip or stripline feed network. In still further embodiments, the antenna element 150 may be configured, based upon the feed provided by the third feed network 315 for radiating electromagnetic energy in a radiation pattern.
In exemplary embodiments of the present invention, the first plurality of radiators 106 , the second plurality of radiators 128 and antenna element 150 may each be broadband (ex.—30 to 50 percent bandwidth). In further embodiments of the present invention, the stackable antenna assembly 100 of may be configured for supporting multiple frequency bands (ex.—may be a multiband antenna 100 ). For instance: the first RF feed 126 may be a low band RF feed 126 (ex.—a L band RF feed) and the first plurality of radiators 106 may be configured for operating over the L band range of frequencies (exs.—within the 1 Gigahertz (GHz) to 2 GHz frequency band); the second RF feed 140 may be a mid band RF feed 140 (ex.—a C band RF feed) and the second plurality of radiators 128 may be configured for operating over the C band range of frequencies (ex.—within the 4 GHz to 8 GHz frequency band); the third RF feed 146 may be a high band RF feed 146 (ex.—a K u band RF feed) and antenna element 150 may be configured for operating over the K u band range of frequencies (ex.—within the 12 GHz to 18 GHz frequency band). In alternative embodiments of the present invention, the stackable antenna assembly 100 may be configured with additional radiators/antenna elements, feed boards, and RF feeds as needed for supporting additional (ex.—more than 3) frequency bands.
In current exemplary embodiments of the present invention, the top surface 118 of the second feed board 114 may be a high impedance surface. For instance, the top surface 118 of the second feed board 114 may include or may be at least partially formed of metal (exs.—corrugated metal, aluminum), said metal having grooves 154 (ex.—¼ wavelength-deep grooves) formed therein (as shown in FIG. 3 ). In still further embodiments of the present invention, the high impedance surface (ex.—the top surface 118 of the second feed board 114 ) may prevent scattering effects caused by the first plurality of radiators 106 from adversely affecting performance of the second plurality of radiators 128 and antenna element 150 . For example, the grooves 154 may act as a choke for changing the phase of reflection of signals and for mitigating undesired scattering caused by the first plurality of radiators 106 .
In exemplary embodiments of the present invention, the first plurality of radiators 106 , the second plurality of radiators 128 and antenna element 150 may each be configured for providing monopole-like radiation patterns (ex.—0 dBi). In further embodiments of the present invention, each radiator 106 included in the first plurality of radiators 106 , each radiator 128 included in the second plurality of radiators, and antenna element 150 may be configured (ex.—shaped) to provide optimal bandwidth and may be further configured (ex.—sized) for minimizing the profile of the antenna assembly 100 . For example, each radiator 106 included in the first plurality of radiators 106 may be sized so that the distance between the first feed board 102 and the second feed board 114 is approximately ⅛ lamda in height, while the first feed board 102 may have a diameter of ½ lamda.
In current exemplary embodiments of the present invention, one or more of the first RF feed 126 , the second RF feed 140 and the third RF feed 146 may each include or may each be at least partially enclosed in (ex.—fed through) a protective casing (exs.—a conduit, hollow casing). For example, in the illustrated embodiment of the present invention shown in FIG. 1 , a conduit 156 surrounding the second RF feed 140 may function as a central post 156 upon which the second feed board 114 may be at least partially supported and around which the first plurality of radiators 106 may be located or positioned. Further, a conduit 158 surrounding the third RF feed 146 may function as a central post 158 upon which the third feed board 130 may be at least partially supported and around which the second plurality of radiatiors 128 may be configured. In alternative embodiments of the present invention, the number of conduits which are implemented for protecting the RF feeds ( 126 , 140 , 146 ) may vary, for instance, one conduit may be used to enclose multiple feeds, etc. In further alternative embodiments of the present invention, the number of feed apertures implemented in the feed boards ( 102 , 114 , 130 ) may vary as well, for instance, one feed aperture may allow for passage of multiple RF feeds, etc.
In exemplary embodiments of the present invention, the antenna assembly 100 may include one or more radios 160 , the one or more radios 160 configured for being connected to the RF feeds ( 126 , 140 , 146 ). In further embodiments of the present invention, the antenna assembly 100 may be implemented as part of an antenna device 300 as shown in FIG. 2 . The antenna device 300 may include a housing (ex.—a low-profile, circular puck-shaped housing 302 ) which is configured for enclosing (ex.—at least substantially containing and being connected to) the antenna assembly 100 . In further embodiments, the antenna device 300 may include a power cord or USB cable 304 configured for electrically connecting the antenna device 300 (ex.—the antenna assembly 100 of the antenna device 300 ) to a computer.
In current exemplary embodiments of the present invention, the antenna assembly 100 and antenna device 300 may be implemented in various applications. For example, the antenna assembly 100 and antenna device 300 may be configured for implementation in or with: military systems; Traffic Collision Avoidance Systems (TCAS), Ultra High Frequency Communication (UHF com) systems, Mini Common Data Link (MiniCDL) antenna systems, Quint Networking Technologies (QNT) systems, Remotely Operated Video Enhanced Receiver (ROVER) systems, and/or Global Positioning System (GPS) systems. The integrated hardware of the antenna assembly 100 as disclosed herein provides significant Size Weight and Power (SWAP) over implementing separate antenna assemblies.
It is believed that the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes. | The present invention is directed to an antenna assembly. The antenna assembly may include multiple sets of radiators (ex.—antenna elements) with each set of radiators being fed by its own RF feed network. The multiple sets of radiators may be arranged in a stackable configuration for providing a low profile antenna assembly which concurrently supports multiple frequency bands (exs.—L band, C band, K u band). | 7 |
This application claims the benefit of the filing date of provisional application No. 61/752,398, filed on Jan. 14, 2013 and provisional application No. 61/887,901 filed on Oct. 7, 2013.
BACKGROUND
Hair coloring systems currently available on the market typically comprise a series of capped dye tubes, such as collapsible aluminum tubes, each containing a different color high-viscosity paste, or a bottle-type container holding a liquid. During the hair coloring process, a stylist dispenses the desired amount of a particular base pigment into a mixing receptacle. Additional pigments must be dispensed and mixed with the base to achieve a desired color. A developer or fixing agent will be added as well. Once the pigments and developer dispensed and blended, the mixture may be applied to a client's hair.
These hair coloring systems have several drawbacks. When adding color from a tube, a user one is prompted to “squeeze to a line,” wherein it is impossible to identify small amounts, such as milliliters. Because hair dye is obtained by hand from tubes or bottles, it is impossible to know the quantity of a particular pigment dispensed. Dyes must be measured accurately since a change of even 0.1 ml can alter the hue of a color mixture from one batch to the next. Independent studies have found that the best efforts using tube markings were only accurate to +/−50% of the total volume. The accuracy of color dispensed with a syringe is to within +/−1% of the total volume. Accurate measuring equipment, which is common in a laboratory setting, is rarely found in conventional salons. For this reason, exactly reformulating a color can be difficult if not impossible.
The bottles and tubes from which colors are dispensed are also not easily organized in a salon setting. Due to the speed at which hair professionals work and the numerous clients on which they work over the course of a given day, containers usually end up haphazardly thrown in drawers or on shelves, forcing stylists to search for a desired color among many disorganized dyes.
Furthermore, because of the nature of aluminum tubes, i.e., capped cylinders similar to toothpaste tubes, it is difficult to dispense all of the dye from a single tube, resulting in wasted product. Approximately 25% of the product in a typical dye tube may be wasted due to a user's inability to completely dispense the product, or through drying and discoloration caused by oxidation of the dye from leaving off the cap. Tube-based dyes are also high in viscosity which makes them difficult to manage.
Some attempts have been made to solve these problems. U.S. Pat. No. 7,407,055 to Rodriquez discloses a hair roots coloring kit, including a squeeze tube of hair dye and measuring devices such as syringes, a measuring cup and a pipette for establishing a dye quantity. In particular, a syringe may be inserted into a squeeze tube to retrieve hair dye. This invention contemplates conventional aluminum or similar hair dye squeeze tubes, and a dye comprising a viscous, high viscosity paste. For this reason, the dye must be pushed into a syringe by compressing the dye tube, rather than extracting dye with the syringe plunger. Furthermore there is no sealing arrangement between the tube and syringe, so that users must maintain them together under manual pressure to avoid leakage. Additionally, since there is no oxygen barrier between the syringe and the distribution end of the dye tube when uncapped, oxidation will occur.
U.S. Pat. No. 7,963,303 to Saranow, et al. discloses a hair dye apparatus and method having a computer screen for selecting a color from a color palette, and a dye quantity. The apparatus indicates the dyes a user will mix, and the user dispenses the dyes in a bowl atop a small electronic scale. While this apparatus keeps individual color containers separate and organized, it is bulky, complicated to use, and lacks the accuracy needed for professional applications. Also, it fails to solve the problem of wasted product.
U.S. Pat. Publication No. 2012/0048880 to Damolaris also discloses a dispensing apparatus for hair dye. In Damolaris, a user enters information relating to a desired color using a computer terminal, and the apparatus dispenses a predetermined amount of developer. While this apparatus presumably dispenses all of the dye in a container, it requires an expensive computer processor and substantial user training to operate. This invention fails to teach measurement or dispensing color. Rather, it's sole function is to measure developer.
For these reasons, commercial hair dye systems as known in the art are both wasteful and prone to error. Consequently, there is a need for a hair coloring system for commercial salons and professional stylists that allows users to accurately measure the pigments they use, and which also allows users to extract virtually all of a dye product from its packaging. Further, there is a need for a system that remains organized, allowing stylists to quickly and easily find colors to mix.
SUMMARY
An apparatus for preparing an accurate and repeatable hair coloring includes a graduated measuring and dispensing vessel and a container having a hair dye contained in an air-tight configuration in the container. The container includes an air-tight chamber, an opening, and further includes a means for engaging the container with a container holder to support it. This may take the form of a rack in which the container sits, may include pegs from which the container hangs or provide a similar arrangement in which the container is suspended for easy access by a hair color professional.
An air-tight reclosing seal is preferably located at the opening, such that when the measuring and dispensing vessel engages the air-tight reclosing seal, the hair dye may be extracted from the air-tight chamber, and when the measuring and dispensing vessel is disengaged from the container, the air-tight reclosing seal closes off the air-tight chamber. In this manner, a user may withdraw a known quantity of the hair dye from the container into the measuring and dispensing vessel, combine it with known quantities of other color hair dyes, thereby allowing an accurate quantity of total hair dye to be dispensed from the container enabling the hair professional to mix an accurate and repeatable hair dye color.
In one embodiment, the container includes an engaging device at the opening for releasably connecting the measuring and dispensing vessel to the container in an air-tight manner to prevent the measuring and dispensing vessel from inadvertently disengaging from the container. Additionally, the container may include an outer layer made of a semi-rigid poly-plastic material, such that in one embodiment the container is essentially a collapsible bag while in another, it retains a uniform outer shape while an interior collapsible bag deforms. Preferably, the opening is at the bottom of the container relative to a container label.
In addition to an engaging device for retaining the container and the measuring and dispensing vessel in a locking configuration, in an alternative embodiment, to prevent hair dye from exiting the container when the measuring and dispensing vessel disengages the container, an air-tight reclosing seal, for instance a self-sealing orifice reducer may be used instead of or along with the engaging device for added security.
The container holder of the apparatus may take the form of a rack capable of holding multiple containers including a complete color line from a hair dye manufacturer. The multiple containers may hang suspended from the rack. In this manner the rack may hold multiple containers of the same color in a row, such that a full container can be brought forward when an empty container is removed from the rack. The rack may also be a holder in which multiple containers are seated. In this arrangement access to the bottom of the containers is provided by slots or holes in the rack.
Preferably the measuring and dispensing vessel comprises a graduated reusable device capable of accurately dispensing a known quantity of hair dye. In a preferred embodiment a syringe or syringe-type vessel is used. To assist in securely connecting the syringe with the opening of a container, the opening and the syringe may be equipped with a a luer-lock arrangement and the opening include a shut-off valve similar to an IV bag. In another embodiment an orifice reducer alone may be used.
Regardless of the locking arrangement of the syringe and opening, the syringe preferably includes an oxygen-free barrier to prevent oxidation or similar degradation of the hair dye and its color. One contemplated method of presenting an oxygen free barrier that resists the corrosive qualities of ammonia-based hair dye is a fluorination barrier treatment with which the surfaces of a syringe or similar vessel may be treated.
Once the syringe has extracted a desired quantity of hair color from one color, a user may engage the syringe with a second container bearing a second color. Once each quantity of hair dye is extracted from a container, the dyes may be mixed to obtain a predetermined color in a mixing bowl. Preferably the mixing bowl is made from a material that will not affect or take on the hues of the hair dye.
In an alternative embodiment, an apparatus for preparing hair dyes includes a graduated measuring and dispensing vessel, such as a syringe as described above, which is filled, i.e., pre-filled, with a predetermined amount of hair dye. Preferably a re-sealable cap is provided for covering an opening of the graduated measuring and dispensing vessel in an air-tight configuration to prevent oxidation and leakage of the hair dye prior to and after use.
A rack for storing multiple graduated measuring and dispensing vessels in an organized arrangement according to color is preferably provided in this embodiment, and allows them to be stored in rows of the same color to prevent running out of a particular hair dye. In this embodiment, the graduated measuring and dispensing vessel also includes an oxygen-free barrier.
Since the oxygen free barrier is opaque, a label may be included on the exterior of the graduated measuring and dispensing vessel corresponding to hair dye's color. Like prior embodiments, the surfaces of the measuring and dispensing vessel may be treated with a fluorination barrier treatment or similar preservative for oxygen-free storage. Furthermore, since the graduated measuring and dispensing vessel in this embodiment is essentially the container for a hair dye, it may include a handle for engaging the rack.
In order to use the hair coloring apparatus to mix an accurate color, a first container is provided having a quantity of hair dye contained in it. A first opening is provided in the first container, the opening presenting an air-tight re-closable seal on the first container. A graduated measuring and dispensing vessel, such as a syringe, capable of holding a predetermined quantity of hair dye is then provided, and is used to access the first opening with the graduated measuring and dispensing vessel, withdrawing a first predetermined quantity of hair dye from the first container and dispensing it in a mixing bowl.
A second container is then provided having a quantity of hair dye contained therein. Like the first container, the second container has a second opening with an air-tight re-closable seal on the second container. The second container is accessed with the graduated measuring an dispensing vessel and a second predetermined quantity of hair dye withdrawn from the second container. The second predetermined quantity of hair dye is then dispensed into the mixing bowl and mixed with the first predetermined quantity of hair dye.
Preferably, an oxygen barrier may be provided on the graduated measuring and dispensing vessel (e.g. syringe) to prevent degradation of the hair dye, particularly in an embodiment where the container takes the form of a syringe, obviating the need for connecting a syringe to a separate container of hair dye. Additionally a rack may be provided for the first container and the second container, or in an alternate embodiment hair dye-containing syringes to keep the colors organized. In a preferred embodiment, additional containers having quantities of different hair dye colors may be loaded in and dispensed from the rack.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a series of hair dye containers disposed in a rack.
FIG. 2 is a side view of a graduated piston syringe with a locking adapter at the tip.
FIG. 3 is a perspective view of a syringe preparing to connect and withdraw hair dye from a container.
FIG. 4 is a perspective view of a syringe connected to a hair dye container.
FIG. 5 is a perspective view of a syringe extracting dye from a hair dye container.
FIG. 6 is a perspective view of a syringe disconnecting from a hair dye container without leakage.
FIG. 7 is a perspective view of a syringe dispensing hair dye in to a mixing container.
FIG. 8 is a side view of a series of bag-type hair dye containers disposed in a horizontal hanging rack.
FIG. 9 is a close-up perspective view of a syringe extracting hair dye from a bag-type container having re-sealable closure.
FIG. 10 is a plan view of a variety of bag-type hair dye containers and a connecting syringe.
FIG. 11 is a side view of individual dye-containing syringes
FIG. 12 is a side view of dye-containing syringes in a rack.
FIG. 13 is a side view of an alternate embodiment of dye-containing syringes in a rack.
FIG. 14 shows an orifice reducer to be incorporated into the neck of a hair dye container
REFERENCE NUMBERS
10 . Individual Dye Containers
11 . Labels
12 . Rack
14 . Syringe
15 . Calibrated Scale
16 . First Locking Adapter
17 . Inner layer
18 . Neck
19 . Outer Layer
20 . Second Locking Adapter
22 . Air-Tight Seal
23 . Locking Connector
24 . Oxygen Free Barrier
26 . Syringe Barrel
28 . Syringe Graduations
30 . Plunger
32 . Marker
34 . Handle
36 . Syringe Rack
38 . Indicia
40 . Cap
42 . Orifice Reducer
DESCRIPTION
Referring to FIG. 1 , the system comprises a series of individual dye containers 10 . Like the aluminum hair dye tubes currently known in the art, each container preferably holds a different pigment, including base colors, highlighting tones, and developer (also known as “fixing solution”). Unlike tubes known in the art, the containers 10 are collapsible, and may comprise single-layer flex-packaging (e.g. IV bag type pouch (see FIG. 10 )), or the containers 10 may be multi-layered, comprising a flexible and collapsible air-tight inner layer 17 containing a liquid dye, and an outer layer 19 made of a semi-rigid poly-plastic material (see FIG. 4 ).
In one embodiment the a laminated material forming a flexible container for holding hair dye or similar materials is contemplated. The laminated material may include a first, internal surface, and a second, external surface. Optionally, an intermediate foil barrier layer (not shown) may be included, separating the first and second surfaces.
The containers 10 are adapted to dispense their contents from the bottom relative to their labels 11 , and are designed to removably install into a rack 12 , which is adapted to hold multiple containers 10 . Preferably, the rack 12 comprises a polymer-type horizontal and expandable storage adapted to hold numerous containers 10 .
Referring to FIG. 2 , A graduated piston syringe 14 , having a calibrated scale 15 on the barrel for reading volume, and preferably clear to see the color of its contents, is used in connection with the containers 10 . The syringe 14 preferably comprises a first locking adapter 16 such as a luer-lock at the tip, and is sized appropriately for normal volumes of hair dye. The first locking adapter 16 is designed to lockably engage a neck 18 (see FIG. 4 ) on a container 10 . In the illustrated embodiment, the male portion of a luer-lock is shown at the tip of the syringe 14 .
Referring to FIG. 3 , each container 10 neck 18 is equipped with a second locking adapter 20 , complimentary to the first locking adapter 16 , for example, the complimentary component of a luer-lock. Preferably, the neck 18 of each container 10 will also incorporate an air-tight seal 22 , such as a ring-stopper (see FIG. 14 ) to prevent leakage and oxidation of a container's 10 contents when the syringe 14 is removed. In this manner a syringe 14 can make a leak-proof connection to any container 10 .
Referring to FIG. 4 , in order to use the system, a user selects a color from among the containers 10 disposed in the rack 12 . With the desired color selected, the piston syringe 14 is brought to the neck 18 of a container such that the first locking adapter 16 engages the second locking adapter 20 , and the air-tight seal 22 is broken, allowing dye to enter the syringe 14 under negative pressure as shown in FIG. 5 . Preferably, when the first locking adapter 16 and second locking adapter 20 are connected, they form an air-tight seal. Users may locate and dispense a known quantity of a known dye quickly when preparing a hair coloring mixture due to the organization of the containers in the rack 12 (not shown).
Referring to FIG. 6 , after a desired quantity of a given dye has been transferred to a syringe 14 , the syringe may be disengaged with the container 10 . In the case of a luer-lock adapter 16 , 20 , the user would simply turn the syringe 14 relative to the container 10 while the container 10 is held in the rack 12 and prevented from turning by a pressure fit or obstruction fit between the rack 12 and the neck 18 of the container 10 . Importantly, once the syringe 14 disengages the second locking adapter 20 and seal 22 , the seal 22 closes, re-creating an air-tight seal, and preventing the contents of the container 10 from leaking. In this manner, no dye is wasted during dispensing. Also, a low viscosity dye may be easily used without spillage.
Referring to FIG. 7 , once a user obtains a syringe 14 with the desired quantity of dye, the dye may be dispensed into a mixing receptacle 24 where it will be combined with other pigments, and developer as desired to achieve a specific, easily and accurately duplicated hair color. After the syringe 14 dispenses the dyes, it may be easily cleaned under running water before being re-used with other dyes or developers for other salon customers.
Referring to FIGS. 8-10 , embodiments of the invention comprising the aforementioned “IV Bag” type of container 10 are shown. FIG. 8 shows a series of color containers 10 assembled in a rack designed to suspend individual containers in an organized and easy to access manner. The system may comprise horizontal and expandable storage racks 12 that holed the containers 10 such that an entire professional hair color product line and developer is contained in a rack 12 . The containers 10 securely hung from the storage racks 12 may be mounted on a wall in a salon in a highly organized and accessible manner. In FIG. 9 , the containers are shown on an alternative carousel type rack. In this view re-sealable locking connectors 23 at the base of a bag-type color container 10 is shown connected to a syringe 14 . The container may also include a shut-off valve 24 for stopping the flow of hair dye once the syringe is removed. FIG. 10 shows a variety of bag-type dye container with an adjacent syringe prepared for extracting dye from the container.
Referring to FIG. 11 , in an alternative embodiment, a single barrel syringe 14 may be manufactured with a predetermined quantity of dye pre-installed in the syringe 14 . Each syringe in this embodiment may have a unique color or shade inside, while a multi-layered oxygen-free barrier 24 lines the inside of the syringe barrel 26 . Due to the opacity of the oxygen-free barrier 24 , the color of the dye contained in the syringe 14 may be applied or labeled on the barrel 26 exterior. In order to ensure accurate dispensing, the syringe graduations 28 are preferably located on the plunger 30 designed to align with a marker 32 . In one embodiment, a screw-cap (not shown) may be installed at the end of the barrier, to provide a measurement guide. A handle 34 may be installed on the plunger 30 for incorporating multiple single syringes 14 into a rack system (not shown) bearing a variety of colors.
In this manner, syringes 14 with commonly used colors may be purchased separately from other, less used colors. A plurality of these syringes 14 may be used to store the entire color line of a manufacturer. In one embodiment a single pre-loaded syringe may be a common 150 ml syringe, in other embodiments larger or smaller syringes may be employed as desired, including using a larger, 250 ml or greater syringe for commonly used colors to avoid syringe replacement.
Referring to FIG. 12 , the single pre-loaded syringes 14 may be stored in vertical rows on a horizontal rack 36 and removed by a stylist to dispense a desired quantity of pigment into a mixing bowl. Other syringes 14 of the same color may be stored behind the syringe-in-use. In an embodiment where individual syringes are removed and re-installed on a rack, each syringe plunger and/or barrel may also include indicia 38 matching indicia on the rack to ensure proper replacement of a syringe 14 after use. A cap 40 is preferably provided for each individual syringe 14 to prevent contamination by other colors.
Referring to FIG. 13 , an alternative embodiment may include a syringe 14 securely suspended from a rack 12 . In this embodiment, a front syringe in use is shown however other syringes of the same color may be stored on the rack behind the secured front syringe for replacing it when empty. In this embodiment, a stylist may hold a mixing bowl (not shown) under the securely mounted syringe 14 and depresses the plunger 30 to dispense color into the bowl. It is anticipated the viscosity typical of hair dyes is such that without pressure on the plunger 30 , even when inverted with the hub of the syringe 14 pointing downward, dye will not leak from the syringe 14 . Notwithstanding this property of the dye, a cap (not shown) may be proved for the tip of each syringe 14 to prevent cross-contamination and oxidation from occurring.
In this manner a complete hair color line may be pre-packaged into a plurality of single-barreled, disposable plastic dose syringes 14 . The syringes 14 are preferably manufactured and packaged with predetermined quantities of hair color pre-loaded into the syringe 14 . Each syringe 14 has a unique color or shade inside each barrel 26 . A handle 34 or similar structure such as a hanger hole may be located at the top of the plunger 30 for holding multiple syringes in a vertical rack system storing a variety of colors in a color line. TO ensure accurate dispensing, the syringes 14 may be milliliter graduations located on the plunger 30 designed to alight with a marker 32 (such as an MDR ring) at the barrel 26 to provide a measurement guide and plunger 26 actuator.
The system is entirely oxygen-free so that the colorant and developer is protected from being contaminated by oxygen, as oftentimes occurs with the conventional formulation methodology. To prevent oxidation and/or corrosion from occurring from highly corrosive ammonia-based hair dye, a multi-layered barrier may line the inside and in some embodiments including the exterior of the plastic syringe barrel 26 . An alternative feature to prevent oxidation and corrosion may include a fluorination barrier treatment, whereby fluorine atoms bonded to inner and outer surfaces of the syringe create a double-sided barrier.
Due to the opacity of the oxygen-free barrier, the color of the dye contained in the syringe 14 may be applied or labeled on the barrel 26 exterior. A screw-cap may also be incorporated into the end of the barrier to prevent dripping and also serve as an oxygen barrier.
As discussed, a plurality of the syringes may be used to store the entire color line of a manufacturer in a horizontal storage rack, and syringes containing commonly used colors may be purchased separately from other, with less used colors purchased more infrequently. A single pre-loaded syringe may be a common 150 ml syringe, in other embodiments larger or smaller syringes may be employed as desired, including using a larger, 250 ml or greater syringe for commonly used colors to avoid syringe replacement.
In the embodiment with separate containers 10 , a manually operated, a clear, metrically calibrated reusable, needle-less 60 mL luer-lock syringe may be used. An assembly of multiple, multi-layer flex-packing containers 10 are each filled with a unique shade of hair color and developer. The color is withdrawn by the syringe to the exact millimeter from various containers 10 according to a predetermined formula and dispensed into a mixing bowl for combination.
Two unique container designs are contemplated, one for color and one for developer. A first container may contain 6 fl. ounces (i.e., 180 mL) of color. Incorporated into a spout at the bottom of the container 10 may be an airtight seal consisting of a permanently installed female to male in-line luer-lock connector with a shut off valve to prevent dripping and leakage. An oxygen barrier and highly secure connection between the pouch and syringe allows the system to be entirely oxygen-free so that the color and developer is protected from being contaminated by oxygen, as oftentimes occurs with the conventional formulation methodology.
A second container design includes a self-sealing orifice reducer 42 (see FIG. 14 ) that creates an airtight seal. A catheter syringe is inserted into the orifice reducer 42 to withdraw the required amount of color according to a formula. Upon withdrawal of the syringe, the opening in the orifice reducer closes firmly, preventing leakage and protecting the color from oxidation. Another container design (not shown) may be included for developer and hold approximately 33 oz.
Although preferred embodiments of the present invention have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. For instance, in place of a luer-lock, another hermetically re-sealable locking connector may be used. Accordingly, it is to be understood that the invention has been described by way of illustration and not limitation. | An apparatus and system for preparing a hair coloring includes a graduated syringe and a container filled with a pigmented hair dye. The container includes an air-tight chamber and an opening, and also includes an engagement mechanism for installing the container on a rack for support. An air-tight reclosing seal at the opening allows the syringe to engage the air-tight reclosing seal, and extract the hair dye from the air-tight chamber. When the syringe is disengaged from the container, the air-tight reclosing seal closes off the air-tight chamber and permitting a known quantity of the hair dye to be withdrawn from the container into the syringe, allowing an accurate and repeatable quantity of hair dye to be dispensed from the container. | 0 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to picket fence assemblies, and more particularly to a picket fence assembly including pickets having a unique configuration for facilitating easy and fast construction of a picket fence assembly without the need for the use of additional mechanical fasteners.
[0003] 2. Background of Related Art
[0004] Picket fences and picket fence assemblies are well known in the art. A picket fence assembly typically includes a plurality of vertical pickets secured to at least two horizontal support members. A picket fence assembly may be constructed of wood, plastic, or the like. Picket fence assemblies may also include two or more vertical support members which receive and support the ends of the horizontal members.
[0005] The vertical pickets of picket fence assemblies may be secured to the horizontal members using any number of fastening devices or techniques. Generally, pickets are secured to horizontal support members using mechanical fasteners, such as nails, nuts and bolts, glue, and screws. Alternately, pickets can be secured to the horizontal support members by inserting the vertical pickets through openings in the horizontal support members and securing the vertical pickets to the horizontal support members with pins, rods, or a combination of pins or rods. Notches may be formed in the pickets to at least partially receive the pins or rods to effect securement. In either case, securing each individual vertical picket to each of the two or more horizontal members using mechanical fasteners is time consuming and requires additional material and equipment. Accordingly, a continuing need exists in the fence arts for a picket fence assembly which can be easily and quickly constructed at minimal cost.
SUMMARY
[0006] The present disclosure relates to a picket fence assembly having rotatably securable pickets. The picket fence assembly has a plurality of vertical pickets secured to a horizontal support member. The horizontal support member defines non-circular openings configured and dimensioned to slidably receive the vertical pickets. Each vertical picket defines at least one notch that is rotatably engagable with a portion of the horizontal support member defining the openings of the horizontal support member. A horizontal locking member is provided which also defines non-circular openings configured and dimensioned to non-rotatably receive pickets that have been previously rotatably engaged within the horizontal support member. The openings in the horizontal support member have a first orientation and the openings in the horizontal locking member have a second orientation angularly offset from the first orientation. The angular offset of the first and second orientations allows pickets which have been rotatably engaged with the horizontal support member to be slidably received in the horizontal locking member openings. In one embodiment, the first and/or second horizontal members have an inverted U-shaped cross section. Alternately, other configurations are envisioned. The picket fence assembly may be constructed of plastic, wood, metal, composites or the like.
[0007] In one preferred embodiment, the openings in the horizontal members are constructed such that rotation of a horizontal support member 180° about a vertical axis (an axis transverse to the longitudinal axis of the horizontal support member) reorients the openings in the horizontal support member from the first orientation to the second orientation. As such, each of the horizontal support members can be also used as horizontal locking members simply by rotating the horizontal support members 180° and each of the horizontal locking members can be used as horizontal support members by rotating the horizontal locking members 180°.
[0008] Vertical support members may be used to support the picket fence assembly. In one embodiment, the vertical support members define a channel and include side openings configured to receive and support the ends of the horizontal members. The ends of the horizontal members may be secured to the vertical member by a connector rod passing through the support member channel and openings formed in the ends of the horizontal members. Other securement techniques are envisioned, e.g., screws, pins, etc. The picket fence assembly may also include a connector sleeve for connecting the horizontal members to the vertical support members. The connector sleeve may be sized to receive one end of a horizontal member and may be received in a side opening formed in the vertical support member. The vertical and/or the horizontal members may also be provided with end caps.
[0009] In one embodiment, each of the vertical pickets has a triangular cross section having at least one notch formed therein. In a preferred embodiment, the pickets have an equilateral triangular cross-section. Correspondingly shaped openings are formed in the first and the second horizontal members and are dimensioned to receive the vertical pickets. The second horizontal member may be substantially identical to the first horizontal member, including the size and configuration of the openings. The notches formed in each vertical picket facilitate rotation of each picket with respect to the first horizontal member to axially secure each picket with respect to the first horizontal member. The vertical pickets and notches may be formed to rotate about 60° (degrees) within the opening formed in the horizontal member to effect securement. Alternately, other degrees of rotation are envisioned. Rotation of the vertical picket within the opening formed in the horizontal member prevents the vertical picket from sliding through, or being withdrawn from, the horizontal member. After the vertical picket has been axially secured to the first horizontal member, the picket can be inserted through the opening in the second horizontal member to rotatably fix the vertical picket in relation to the horizontal members. Other picket configurations are envisioned, e.g., square, pentagonal, star-shaped, rectangular, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Various embodiments of the presently disclosed picket fence assembly are described herein with reference to the drawings, wherein:
[0011] FIG. 1A is an isometric view of one embodiment of a picket fence assembly constructed in accordance with the present disclosure;
[0012] FIG. 1B is an exploded isometric view of the picket fence assembly shown in FIG. 1A ;
[0013] FIG. 2A is an enlarged isometric view of a portion of a vertical picket including horizontal notches;
[0014] FIG. 2B is an enlarged isometric view of a portion of a horizontal support member defining an opening for receiving the vertical picket shown in FIG. 2A ;
[0015] FIG. 3A is an isometric view of the vertical picket shown in FIG. 2A inserted through the horizontal support member shown in FIG. 2B and prior to rotation of the vertical picket and prior to insertion of the vertical picket through a horizontal locking member;
[0016] FIG. 3B is an isometric view of the vertical picket and horizontal members shown in FIG. 3A after rotation of the vertical picket about its longitudinal axis within the opening of horizontal support member, and prior to insertion of the vertical picket through the horizontal locking member;
[0017] FIG. 3C is an isometric view of the vertical picket shown in FIG. 3A rotatably secured within the opening of the horizontal support member shown in FIG. 3A and extending through the opening of the horizontal locking member shown in FIG. 3A ; and
[0018] FIGS. 4A-4F are top cross sectional views of various alternate embodiments of the present disclosure showing a vertical picket rotatably secured within the opening of a horizontal support member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Embodiments of the presently disclosed picket fence assembly will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views.
[0020] As used herein, the term “notch” is understood to mean any cutout, recess, indentation or the like which is formed in a portion of the picket to facilitate rotational movement of a picket in relation to a horizontal support member to axially fix the picket to the horizontal support member.
[0021] FIGS. 1A and 1B illustrate a picket fence assembly constructed in accordance with the principles of the present disclosure. Referring to FIG. 1A , picket fence assembly 10 includes a plurality of vertical pickets 12 , a horizontal support member 14 and a horizontal locking member 16 . As shown, horizontal members 14 and 16 of picket fence assembly 10 are supported between vertical support members 18 and are coupled with vertical support members 18 by connector sleeves 20 . Referring to FIG. 1B , vertical pickets 12 are dimensioned to be received through openings formed in horizontal member 14 and horizontal member 16 as will be discussed in detail below.
[0022] Connector sleeves 20 are configured and dimensioned to receive the ends of horizontal members 14 and 16 and be received in side openings 18 a ( FIG. 1B ) formed in vertical support members 18 . Connector sleeves 20 further define an opening 20 a sized to receive a connector rod 22 . Connector rod 22 is received through a vertical channel 18 b ( FIG. 1B ) formed in supports 18 and openings 20 a in connector sleeves 20 to fixedly secure horizontal members 14 and 16 to vertical support members 18 . In a preferred embodiment, the connector rod can be in the form of a picket. In one embodiment, end caps 21 ( FIG. 1A ) may be added to vertical members 18 for aesthetics and/or prevent water from leaking into picket fence assembly 10 . For these same reasons, end caps 23 may be provided for horizontal members 14 and 16 or connector sleeves 20 . Additionally, appropriately configured end caps may be used on the top and bottom ends of the pickets. Side openings 18 a of vertical support 18 may be positioned to receive two or more horizontal members wherein additional horizontal members may be provided to provide greater support or enhance picket locking. Further, openings 18 a in vertical support members 18 may be provided and positioned such that the horizontal support members are aligned, are offset from each other by about 90 degrees, or alternately disposed.
[0023] FIGS. 2A and 2B illustrate the components of one preferred embodiment of the presently disclosed picket fence assembly. Referring to FIG. 2A , vertical picket 112 has a triangular configuration and cross-section and defines a plurality of notches 124 . Horizontal member 114 includes openings 114 a (only one is shown) which has a shape which corresponds to the cross-section or configuration of vertical picket 112 , i.e., triangular. When vertical picket 112 is positioned through (longitudinally inserted) openings 114 a of horizontal member 114 , notches 124 are positioned and configured to align with openings 114 a such that when picket 112 is rotated about its longitudinal axis, notches 124 engage a portion of horizontal member 114 defining opening 114 a . Notches 124 may be of any depth, width, height or configuration so long as axial rotation of vertical picket 112 portion of horizontal member 114 defining opening 114 a within notches 124 to prevent picket 112 from being slid axially from opening 114 a . Vertical picket 112 may be constructed of metal, wood, plastic, composites, or other compositions suitable for fence construction. Although vertical picket 112 is shown as being hollow, picket 112 may be solid. A vertical picket constructed in accordance with the principles of the present disclosure may have any non-circular cross sectional profile, including triangular, square, rectangular, pentagonal, trapezoidal, hexagonal, oval, star-shaped, etc.
[0024] As illustrated in FIG. 2B , horizontal member 114 defines an inverted U-shaped configuration and defines a triangular opening 114 a sized to receive vertical picket 112 shown in FIG. 2A . Alternately, it is envisioned that horizontal member 114 may assume a wide variety of configurations including, but not limited to, square and rectangular configurations.
[0025] FIGS. 3A-3C illustrate the method or steps required to assemble a picket fence assembly constructed in accordance with the principles of the present disclosure. Referring to FIG. 3A , as discussed above, vertical picket 112 is inserted through triangular openings 114 a in first horizontal member 114 to a position in which notches 124 are aligned with the portion of horizontal member 114 defining opening 114 a . As of yet, vertical picket 112 has not be inserted into opening 116 a defined by second horizontal member 116 .
[0026] As illustrated in FIG. 3B , after vertical picket 112 is positioned to align notches 124 within opening 114 a of horizontal member 114 , vertical picket 112 is rotated axially to secure picket 112 within the opening 114 a of first horizontal member 114 at notch 124 . In the present embodiment, vertical picket 112 is rotated about 60° (degrees) to fully position horizontal notches 124 about the portion of first horizontal member 114 defining opening 114 a . In alternate embodiments of the picket fence assembly, the amount of rotation required to fully secure vertical picket 112 to a horizontal support member may be varied and is dictated by the cross sectional profile of the vertical picket, the depth of the notches and the orientation of the opening in the horizontal locking member as will be discussed below. Preferably, the rotation of the picket required to effect securement to the horizontal support member does not exceed 90°. It is noted that, as of yet, vertical picket 112 has not been inserted into opening 116 a of second horizontal member 116 .
[0027] Referring to FIG. 3C , vertical picket 112 , rotatably secured within horizontal support member 114 as shown in FIG. 3B , is inserted into triangular opening 116 a of horizontal locking member 116 . Triangular opening 116 is sized to receive vertical picket 112 so as to prevent further rotation of vertical picket 112 . As illustrated in FIGS. 3B and 3C , opening 116 a in horizontal member 116 is oriented to receive vertical picket 112 after vertical picket 112 has been rotatably secured to horizontal member 114 . As such, if notches 124 were dimensioned to fixedly secure picket 112 to horizontal member 114 after a 40 degree rotation or 90 degree rotation of picket 112 (rather than a 60 degree rotation), the orientation of opening 116 a of horizontal member 116 would have to be altered, i.e., reoriented to facilitate receipt of the vertical picket. When vertical picket 112 is received in opening 116 a of horizontal member 116 , vertical picket 112 is prevented from further rotation because notches are not provided in vertical picket 112 adjacent opening 116 a of horizontal locking member 116 . As such, vertical picket 112 is prevented from rotating and becoming disengaged from horizontal member 114 i.e., vertical picket is rotationally and axially locked in relation to horizontal members 114 and 116 .
[0028] It is noted that in a preferred embodiment, vertical pickets 112 are first secured to horizontal members 114 and 116 and thereafter, horizontal members 114 and 116 are secured between vertical support members 18 ( FIG. 1 ) in the manner discussed above. Alternately, second horizontal member 116 can be secured between vertical support members 18 and then vertical pickets 112 , which are already secured to first horizontal member 116 , can be positioned within openings 116 a of second horizontal member 116 . It is noted that although the upper horizontal member is shown as the support member and the lower horizontal member is shown as the locking member, the locking member and the support member may form either the upper or lower horizontal members, or intermediate horizontal members.
[0029] FIGS. 4A-4D illustrate various alternate embodiments of the vertical picket and horizontal support member secured together in accordance with the principles of the present disclosure. Referring to FIG. 4A , vertical picket 312 , defining an equilateral triangular cross section, is rotatably engaged within equilateral triangular opening 326 of horizontal member 314 . In one preferred embodiment, 60° rotation of picket 312 is required to secure picket 312 to horizontal support member 314 . Alternately other degrees of rotation to effect securement are envisioned, e.g., 30°, 45°, etc. Referring to FIG. 4B , vertical picket 412 , defining a square cross section, is rotatably engaged within square opening 426 of horizontal member 414 . Referring to FIG. 4C , vertical picket 512 , defining a hexagonal cross section, is rotatably engaged within hexagonal opening 526 of horizontal member 514 . Referring to FIG. 4D , vertical picket 612 , defining a pentagonal cross section, is rotatably engaged within pentagonal opening 626 of horizontal member 614 . Referring to FIG. 4E , vertical picket 712 , defining an oval cross-section, is rotatably engaged within oval opening 726 of horizontal member 714 . Referring to FIG. 4F , vertical picket 812 , defining a star-shaped cross-section is rotatably engaged within star-shaped opening 826 of horizontal member 814 . Although each of the embodiments discussed above is shown and or described as being rotatably fastened to the upper horizontal member, the vertical pickets can just as easily be configured to be rotatably secured to the lower horizontal member in the same manner as discussed above with respect to the upper horizontal member. Accordingly, this disclosure contemplates both of these embodiments.
[0030] In one preferred embodiment, the openings in the horizontal members are oriented such that each of the horizontal members can function as either the support member or the locking member. More specifically, the openings in the horizontal members are oriented such that by rotating the horizontal member 180° about a vertical axis (an axis transverse to the longitudinal axis of the horizontal member), the opening in the horizontal member is reoriented from a support orientation to a locking orientation or vice-versa. For example, note that when horizontal support member 114 in FIG. 2B is rotated 180° about a vertical axis, the orientation of opening 114 a assumes the orientation of opening 116 a of horizontal locking member 116 as shown in FIG. 3A . As such, only a single configuration of the horizontal member need be provided which can be used to form either the horizontal locking member or the horizontal support member.
[0031] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, holes may be formed in each end of the horizontal members such that the horizontal members can be secured directly to a vertical support member and no connector sleeve is required. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims append hereto. | A picket fence assembly is provided which includes uniquely configured pickets which facilitate fast and easy construction of a picket fence without the need for additional mechanical fasteners. In one embodiment, the picket fence includes non-circular pickets, a first horizontal member and a second horizontal member. The first and second horizontal members include openings configured to receive respective pickets. Each picket includes at least one notch positioned to align with a respective opening in one of the first and second horizontal members. The notch facilitates rotation of the picket in relation to the one horizontal member to axially secure the vertical picket to the one horizontal member. The opening in the other horizontal member is oriented to non-rotatably receive the picket member after it has been secured to the one horizontal member. A method of assembling a picket fence assembly is also disclosed. | 4 |
[0001] The present invention relates to a process for the separation and isolation of biologically active substances from dairy by-product or secondary waste flows. Many dairy industrial processes, such as in the manufacture of butter and butter concentrates, caseins and caseinates, cheeses, creams, ultra-fresh dairy products, and the like, generate significant amounts of currently unavoidable by-products or waste products. These products must be handled according to legislation that is becoming ever stricter, which often implies a non-negligible cost. One way of recovering that extra cost that the industrialist has to pay, is by attempting to exploit or to find some value added material within the waste or by-product. Unfortunately, such cases are relatively rare on the whole, since the economics of any extra processing steps necessary to retrieve the material are generally unfavorable with respect to value that can be gained from such material. This is especially true of the food and dairy industry, where industrial costs have to be kept as low as possible, in order to maintain economic viability of the general food production processes. Generally speaking, by and waste products of the food industry are handled in the following manner:
separation from the by-product or waste product of all solid, or soluble, mineral or organic matter using classical effluent treatment technology such as sedimentation tanks or other related techniques; drying to a greater or lesser degree, in order to eliminate the liquid fraction and only retain the solid fractions in one or several steps. This or these step(s) is (are) extremely costly, in view of the overall consumption of energy involved; fractionating the remaining waste, typically via chromatography, an expensive technique used to find several kinds of very specific molecules for which niche markets exist that can support the increased cost of production.
[0005] In many cases, however, little or no value-added exploitation can occur, either because the by-product or waste product has a too low concentration in dry matter, or on the other hand, because the waste or by-product is extremely unstable and perishable, and thus unsuitable for storage for a time sufficient to retreat it.
[0006] An example of a branch of the food industry faced with such difficulties is that relating to cheese product manufacture and treatment. Most dairy products start out from a bulk volume, low cost, starting material, namely milk. This starting material is available in very large quantities and the initial transformation steps, such as protein precipitation, filtration, or heat treatment are considered to form part of the well established economic environment in this field, simply because of the immense volumes involved. However, other products and by-products can also be made starting from milk. One such by-product is whey, which again can be transformed into further value added products. Exemplary value added products obtained from whey would be, for example, whey proteins, whey protein concentrate or hydrolysate, β-lactoglobulin, and α-lactalbumin, phosphopeptides, casein proteins, caseinomacropeptides, immunoglobulins and the like. Unfortunately, these further processing steps are not viable on a large scale, simply because of the high cost of the further technological steps that are currently required to produce these products.
[0007] Typically, the processes used in creating value-added products from milk waste or by-products goes through whey, separated from the curds of the milk. Two major techniques are used today:
filtration, including microfiltration, ultrafiltration, and nanofiltration finer separation techniques such as chromatography or electrophoresis.
[0010] In these cases, chromatography is generally considered by far the best in terms of pure performance, and is used for the recovery of molecules such as lactoferrin, lactoperoxydase, glycomacropeptides ou simple fragments thereof. In view of the expense of such relatively small scale techniques, most of the applications envisaged are niche markets, such as infant nutrition formulas, sport nutrition formulas, body building formulas, and specialized dietary supplements for the aged.
[0011] From the above, one can conclude that there is a long felt need in general to provide a large scale or scalable, cost effective, means of treating industrial dairy waste or by-product flows in order to provide an economic way of dealing with such waste or by-product, whilst at the same time providing a value added substance that has other significant applications.
[0012] One object of the present invention is therefore to provide such a low cost, industrially scalable method for the isolation of biologically active substances from by-product or waste flows. Another object of the invention is to provide for biologically active substances obtained via such a method.
[0013] Still yet another object of the present invention is to provide for a biologically active complex in which a biologically active substance obtained via the method of the present invention is used.
[0014] Other objects may become apparent through the reading of the description and claims.
[0015] In the following specification and claims, the following terms have the meaning assigned to them here below:
“by-product or waste flow” is a substantially liquid fraction that is generated during the different steps of industrial dairy processing of a product, and in particular a cheese product; “substantially liquid” means that the fraction contains at most 30% by weight of dry matter; “biologically active substance” means any chemical entity that has an overall physiological effect on the subject to which it is administered; “biologically active complex” means the association of one or more biologically active substances, as defined above, with a support vehicle, that may or may not have an overall physiological effect on the subject to which it is administered in addition to the biologically active substance; “solid support material” is a natural or synthetic insoluble mineral based solid, that is chemically inert, and having molecular adsorptive capacity. Such a material can be present as a powder, granules, flakes, or chips. Suitable supports can be chosen from kaolins, kaolinic clays, montmorillonites, bentonites, bentonitic clays, attapulgites, and the like.
[0021] Particularly preferred solid support materials can be chosen from the group consisting of:
Kaolin commercially available from Sigma Green clay commercially available from Argiletz; Clarsol STF, Clarsol KC1, Clarsol KC2, Clarsol ATC Na, all available from CECA, France; Kaolin Arvolite SP20, Kaolin 7 ASP20, Kaolin Berrien B SP20, Kaolin Laude SP20, all available from Denain Anzin Minéraux, France; Sialite, Metasial, Sokalite, all available from Soka, France; Kaolin K13 available from Sika, France.
[0028] Accordingly, one object of the invention is a method for the isolation of at least one biologically active substance from an industrial dairy by-product or waste flow, comprising:
selecting at least one industrial dairy waste or by-product flow containing at least one biologically active substance; bringing the at least one industrial dairy waste or by-product flow into contact with at least one solid insoluble support material for sufficient time to cause the at least one biologically active substance to selectively adsorb on said support material; recovering the insoluble solid support material carrying the adsorbed at least one biologically active substance.
[0032] Preferably, the at least one industrial dairy waste or by-product flow is substantially liquid.
[0033] Even more preferably, the at least one industrial dairy waste or by-product flow comprises not more than 30% by weight of dry matter. In accordance with the present invention, the at least one industrial dairy waste or by-product flow is preferably generated or supplied from an industrial process that processes or manufactures a product derived from milk. This means that the method of the present invention can be used for treating waste flows and by-products from a number of dairy industries, and more particularly from the group of industries consisting of butter and butter concentrate manufacture, cream manufacture, ultra fresh dairy products, casein and caseinate manufacture, cheese manufacture, and the like. Such processing plants produce huge volumes of liquid or semi-liquid waste or by-product flows, in which many biologically active substances can be found. Most preferably, however, the at least one industrial dairy waste or by-product flow is milk or derived from milk. The milk industry produces huge amounts of liquid waste or by-products such as whey, that contain very interesting biologically active substances, but which with todays current processing techniques require great efforts to isolate and recover them, at great expense, with the result that the products thereby obtained can only be sold in niche markets with perceived high added value. The method of the present invention manages to solve this problem by producing a workable, industrially scalable alternative, that is also very economic, both in the components used, as in the installation and running requirements. Consequently, in one of the most preferred embodiments, the at least one industrial waste or by-product flow is whey.
[0034] In yet another preferred embodiment, the at least one solid insoluble support material and the at least one industrial dairy waste or by-product flow are agitated together after being brought into contact one with the other. The conditions of operation will depend on the type and molecular weight of active substance being recovered from the waste flow. Such conditions can be determined by one skilled in the art, so as to arrive at a system where one can scan a waste product flow for all possible biologically active molecules of interest, and then adapt the adsorption conditions, in a further cycle for example, to retain only those specific molecules that are desired.
[0035] The method of the present invention can, for example, be made to function as a small plug-in unit that is connected to the main processing flows of the industrial plant and produces a value added secondary or tertiary material with potential applications in human and animal health and nutrition. In addition, the method of the invention reduces the volumes that need to be dried subsequent to isolation of the biologically active substance, thereby causing further economies of scale to be obtained in heating and energy costs.
[0036] The unit can for example comprise a chamber, having a solid support material inlet, and a conduit either for the introduction, or the flow through, of the at least one waste flow or by-product. The chamber can also optionally be provided with agitation means, and temperature regulation means. Naturally, the chamber will also be provided with outlets for both the adsorbed biologically active substance/support material complex, and the remaining waste liquid that is now poorer or depleted in molecules of interest and can either be passed through the chamber once again, or dispatched for disposal. In an industrial plant, one could easily foresee the provision of several cycles through the unit, or the provision of multiple chambers, operating in cascade or parallel, each having a different set of operating conditions to specifically adsorb, and optionally specifically desorb any given biologically active substance from the at least one solid insoluble support material. A final optional step, but one that may be advantageous for the preparation of pharmaceutical, or human or animal health preparations, is the isolation of the at least one biologically active substance from the at least one solid insoluble support material. This can be achieved by the desorption step for example, or could be followed by other refining or purifying techniques that are known to the skilled person such as chromatography.
[0037] The invention also therefore provides for a method of screening industrial dairy waste or by-product flows for new biologically active molecules of interest.
[0038] Preferably, the at least one biologically active substance is selected from the group consisting of hormones, proteins, peptides, polypeptides, antibodies, glycoproteins, glycosaminoglycans, and enzymes. Even more preferably, the at least one biologically active substance has a biological activity selected from the group consisting of antibiotic, probiotic, anti-microbial, anti-fungal, cell growth regulation, neurogenerative, oestrogenic, anti-thrombotic, anti-viral, free radical and metal ions scavengers, immuno-modulatory, anti atherogenic, anti-inflammatory.
[0039] A further object of the invention, is the provision of a complex obtainable from a process as defined previously, wherein the complex comprises at least one solid insoluble support material on which is adsorbed at least one biologically active substance. The complex preferably has a biological activity selected from the group consisting of antibiotic, probiotic, anti-microbial, anti-fungal, cell growth regulation, neurogenerative, oestrogenic, anti-thrombotic, anti-viral, free radical and metal ion scavengers, immuno-modulatory, anti atherogenic, anti-inflammatory.
[0040] Still yet another object is an animal feedstock composition comprising a complex as defined previously. In a most preferred embodiment, the complex has antimicrobial activity. In this way, the complex can be used as a substitute for feedstocks that currently contain antibiotics and which will soon be forbidden for use in agricultural animal nutrition. The antimicrobial activity of the feedstock of the present invention will act as a therapeutic solution to minor infections that some agricultural animals tend to suffer from, e.g. poultry, pigs, sheep and cattle, but is also applicable to domestic animals, and aquaculture, i.e. the farming of molluscs, crustaceans, shell animals, and fish.
[0041] Finally, it is most preferred that the at least one biologically active substance be a substance naturally present in the at least one industrial waste or by-product, i.e. that it not be a substance that has resulted from the addition by man to the mainstream product or to the animal that created the starting materials for the mainstream product. This of course extends to substances that are introduced by genetic manipulation.
BRIEF DESCRIPTION OF THE FIGURES
[0042] FIG. 1 represents Coomassie Blue stained SDS PAGE runs of proteins of interest in whey adsorbed onto and desorbed from a selection of solid support materials in accordance with the method of the present invention;
[0043] FIG. 2 represents Coomassie Blue stained SDS PAGE runs of proteins of interest in whey adsorbed onto and desorbed from a selection of solid support materials different to those of FIG. 1 ;
[0044] Where the following meaning is given to the symbols in the FIGS. 1 and 2 :
[0045] In FIG. 1 , E=the initial sample, M=a molecular weight marker, T=control, adsorption conditions: 1=STF, 2=KC1, 3=KC2, 4=ATC Na; desorption conditions: 5=STF, 6=KC1, and 7=KC2;
[0046] In FIG. 2 , E=initial sample, adsorption conditions : 1=sialite, 2=metasial C, 3=sokalite powder; desorption conditions: 4=sialite, 5=metasial C, 6=sokalite powder;
[0047] FIG. 3 is a schematic representation of the implementation of the process of the invention in an industrial environment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0048] The invention will be further described and explained by the following examples, that are given for the purposes of illustrating some of the preferred embodiments of the present invention, in particular in relation to the recovery of biologically substances of interest from the well known agro-industrial by-product known as whey.
EXAMPLES
Example 1
[0000] Whey Preparation
[0049] The control whey is obtained from fermented milk (Ribot milk™, sold by BRIDEL, France), and simulates whey obtained from cheese manufacturing plants during the manufacture of fresh cheese from cow's milk or certain cow's milk based soft cheeses.
[0050] The fermented milk is centrifuged at 6000 g for 20 minutes. The precipitate obtained, that is made up mainly of caseins and caseinates, was eliminated ; the supernatant was collected and made up the control whey sample.
[0051] Two types of fermented milk were used
[0052] 1. low fat type (low in fats);
[0053] 2. whole fat or creamy (rich in fats).
[0054] The pH of each whey obtained was measured and found to be approximately pH 4.6.
[0055] For some of the examples, the pH was adjusted to pH 6.8, by the addition of 0.5M aqueous sodium hydroxide NaOH, in order to simulate sweet whey, and in order to limit the effects of dilution of the starting material. Other aqueous hydroxides could also be optionally be used instead of NaOH, but the latter is most often used in the milk industry.
[0056] Unless indicated otherwise, 25 millilitres of each whey was taken as the starting material, and the solid support material concentration was 2% (w/v). After addition of the support material to the whey, the mixture was agitated, for example on an agitation table, for an hour.
[0057] The mixture was then filtered on a Büchner filter, using a Whatman #4 filter paper. The solid and liquid fractions obtained after filtration were stored at −20° C. for further analysis.
[0058] The various different solid support materials used were as follows in Table 1:
TABLE 1 Product Name Supplier Number kaolin Sigma 1 Argile verte Argiletz 2 Clarsol STF CECA 3 Clarsol KC1 CECA 4 Clarsol KC2 CECA 5 Clarsol ATC Na CECA 6 Kaolin Arvolite Denain Anzin 7 SP20 Minéraux Kaolin 7 ASP20 Denain Anzin 8 Minéraux Kaolin Berrien B Denain Anzin 9 SP20 Minéraux Kaolin Laude Denain Anzin 10 SP20 Minéraux Sialite SOKA 11 Metasial C SOKA 12 Sokalite poudre SOKA 13 Kaolin K13 SIKA 14
Biochemical Analysis
[0059] The solid support materials that were tested, either with or without prior treatment, are brought into contact with a solution that simulates an agroindustry effluent or by-product that contains one or more biologically active substances of interest.
[0060] Insofar as the experimental parameters are concerned, for example, contact times, type and degree of agitation, etc., these are adjusted to in order to modulate the adsorption and selectivity of the solid insoluble support material for the biologically active substances of interest. After solid-liquid separation, two fractions are obtained
1. a solid fraction comprising the solid support material that is more or less loaded with biologically active substances of interest, and particularly with proteins ; and 2. a liquid fraction that has a lower protein content.
[0063] The obtained fractions are analysed using a gel electrophoresis technique known as SDS-PAGE, which involves separating out proteins based on their respective molecular masses, followed by staining. The SDS-PAGE technique enables identification of all of the proteins present in a given sample and provides a visualisation of their distribution in each fraction, when compared to the starting sample analysed. The liquid fraction can be analysed as it is after the solid-liquid separation step, i.e. directly after adsorption. The solid fraction, on the other hand, is put into solution with what is known to the skilled in the art as a “loading” buffer, and brought to the boil. Such drastic conditions enable all of the adsorbed proteins to be desorbed, but are not representative of the enzymatic or temperature conditions prevalent in the normal digestive tract, rumen or stomach. In the figures, the dotted line delimits two areas, with the proteins of interest being located in the area above the dotted line. In the examples given, these proteins are substantially immunoglobulins and lactoferrin. The area below the dotted line is that in which unwanted residual caseins and low molecular weight proteins such as α-lactalbumin and β-lactoglobulin are to be found, which have molecular weights at about 16 to 18 kDa. These latter kind of molecules are not of interest in the present invention.
[0064] SDS-PAGE method and analysis conditions.
[0065] The following stock solutions were used
[0066] Denaturing buffer 5×(5 mL)
SDS 10% (500 mg) β-mercaptoethanol 25% (1.25 mL) Bromophenol blue 0.1% (2 mg) glycerol 15% 750 mg QSP 5 mL H 2 O
[0072] Separation buffer, or lower buffer, (50 mL)
TRIS 9.075 g SDS 0.2 g QSP H 2 O 50 mL Adjust pH to 8.8 avec Hcl 1M
[0077] Concentration buffer or upper buffer (25 mL)
TRIS 1.5 g SDS 0.1 g QSP H 2 O 25 mL Adjust pH to 6.8 avec HCl 1M
[0082] Migration buffer 10X (200 mL)
TRIS 6 g Glycine 28.8 g SDS 2 g QSP H 2 O 200 mL
[0087] APS 10% (1 mL)
APS (ammonium persulfate powder) 100 mg QSP H 2 O 1 mL
[0090] The polyacrylamide gels were prepared as follows:
Separation Gel 10% Acrylamide 30% 3.3 mL TRIS HCl pH 8.8 2.5 mL H2O 4.1 mL APS 10% 40 L Temed 3 L Concentration Gel 4% Acrylamide 30% 0.67 mL TRIS HCl pH 6.8 0.63 mL H 2 O 3.6 mL APS 10% 50 μL Temed 5 μL
[0091] The samples were adjusted to a total protein concentration of approximately 1 mg/mL, by the addition of a volume of loading buffer i.e. sufficient to obtain a concentration that is ready to load of 1 mg/mL. The volume actually loaded onto the gel was comprised between about 25 μl and about 30 μL per well.
[0092] Electrophoresis was carried out under the following conditions concentration gel at 60V, then separation gel at 190 V, with migration lasting approximately 45 minutes. After migration was stopped, the gels were stained with Coomassie blue and then dried.
Example 2
[0093] The sample used was a low fat whey, the pH of which had been adjusted to between 4.6 to 6.8 by the addition of 0.5 M NaOH. The results for the solid insoluble support materials 3, 4, 5 and 6 are given in FIG. 1A , with lanes 1, 2, 3 and 4 representing adsorption, and lanes 5, 6, 7 and 8 respectively representing desorption.
[0094] The four solid insoluble support materials tested all had high adsorptive capacity, cf. A1, but especially A2, A3 and A4. However, desorption, even under drastic conditions, was low, cf. A5 to A8. Support number 4, a clarsol KC1 did show a slight difference in the desorption profile compared to the others, the uppermost band being separating out slightly higher, which indicated the desorption of a protein of higher molecular mass.
Example 3
[0095] The sample tested was a whole fat whey, the pH of which was adjusted to between 4.6 to 6.8 by the addition 0.5M NaOH. The results of solid insoluble supports numbered 3, 4, 5 and 6 are given in FIG. 1B , with adsorption being represented in lanes 1, 2, 3 and 4, and desorption being represented in lanes 5, 6, 7 and 8 respectively. A few significant differences can be seen depending on the nature of the solid insoluble support material, in particular for KC1 (B2) and KC2 (B3). For KC1 (support n°4), one can see that the bands corresponding to a low molecular weight have disappeared, when compared to the adsorption of this protein on the support in B2. For KC2 (support n°5), this result is also observed, but further included the absorption of a high molecular weight protein, since the band that was visible in B3 also disappeared. Adsorptive capacity is thus generally low under these experimental conditions, with little or few differences between the initial sample in E and lanes B1 to B4. To summarize, adsorptive capacity is low, but despite this, a slight difference in the profiles between clarsols KC1 and KC2 is noticed, with certain bands appearing to be more intense than for the two other supports B6 and B7.
Example 4
[0096] The sample used was a low fat whey, the pH was not adjusted and was naturally close to 4.6. The results of solid support materials 3, 4, 5 and 6 are given in FIG. 1C , with adsorption being represented in lanes 1, 2, 3 and 4, and desorption being represented respectively in lanes 5, 6, 7 and 8. Here one can observe that adsorption differs greatly depending on the solid insoluble support material used. It is low for STF (C1), medium for KC1 and ATC Na (C2 and C4) and strong for KC2, in which there is almost complete disappearance of the bands, as shown in C3. Desorption, on the other hand, is very high for KC2 (C7), with the presence of a single very intense band in the upper area, indicating a very high selectivity upon desorption, and intermediate for KC1(C6) and finally relatively weal for STF and ATC Na (C5 and C8). The difference in behaviour upon desorption appears to be linked to the degree of adsorption that took place beforehand. As has been shown, depending on the final experimental parameters used, adsorption, desorption and corresponding selectivity can be modulated greatly. The four solid insoluble support materials all behave in a generally similar way. However, clarsol KC1 and especially clarsol KC2 show some noticeable differences in behaviour, which are visible both after adsorption (B2, B3 and C3) and desorption (B6, B7 and C7).
Example 5
[0097] The sample used was a low fat whey, the pH of which had been adjusted to about 4.6 to 6.8 by the addition of 0.5 M NaOH.
[0098] The results of support materials numbered 11, 12 and 13 are presented in FIG. 2A , with adsorption being represented by lanes 1, 2 and 3 respectively, and desorption being represented by lanes 4, 5 and 6. The three support materials tested all demonstrated a high adsorptive capacity (A1, A2 and A3). Desorption, even under extreme conditions, was low (A4, A5 and A6). Metasial C (support n°12) displayed a slight difference in its desorption profile (A6), in that the upper band was slightly higher, indicative of the desorption of a protein with higher molecular weight.
Example 6
[0099] The sample tested was a whole fat whey, the pH of which was adjusted to between 4.6 to 6.8 by addition of 0.5M NaOH. The results for support materials 11, 12 and 13 are given in FIG. 2B , whereby adsorption is represented in lanes 1, 2 and 3, respectively, and desorption is represented in lanes 4, 5 and 6. Whichever material was used, no significant difference was observed (B1, B2 and B3). Adsorptive capacity is low under the experimental conditions used, with little difference between the starting sample and lanes B1 to B3. However, the desorptive capacity is good. Despite low adsorption, the desorbed fractions were all enriched (B5, B6 and B7), whereby some bands appeared to be more intense than in the starting material. Here once again, Metasial C (support n°12) showed a slightly different profile (B5), in that some bands appeared to be more intense than for the two other support materials (B4 and B6).
Example 7
[0100] The sample used was a low fat whey, the pH was not adjusted and was naturally close to 4.6. The results of support materials numbered 11, 12 and 13 are shown in FIG. 2C , with adsorption being given in lanes 1, 2 and 3, and desorption in lanes 4, 5 and 6 respectively. Adsorption is intermediate when compared to the conditions used in A and B. Many bands are present in the fractions C1, C2 and C3, but are generally of a lower intensity than the starting sample. Desorption is very high (C4, CS and C6), with the presence of a very intense band in the upper area (very high selectivity for the corresponding protein). Under these conditions, no significant difference was observed between the three support materials (C4, Cs and C6). It can thus be concluded that depending on the final experimental parameters used, adsorption, desorption and selectivity can be modulated in an important way. The three support materials behave in a virtually identical manner. However, Metasial C shows some differences in behaviour, that are especially noticeable upon desorption (AS and B5).
Example 8
[0000] Microbiology
[0000] Sample Selection
[0101] The samples of example 7 were those that showed the most interesting desorption profile, with high desorption of proteins having a molecular weight within the target area being searched for. An in vitro test was carried out on these samples to show that the complex obtained had antimicrobial activity.
[0000] Mother Culture Preparation
[0102] The bacterial strain used was a strain of E. Coli. This strain was maintained in culture in a Luria-Bertani medium having the following composition: bactopeptone 10 g/L, yeast extract 5 g/L, sodium chloride 5 g/L, prepared in purified water. The culture conditions were as follows: temperature 37° C., agitation 250 rpm on an agitating table, period between reseeding: 24 hours.
[0103] At T=0 (where T equals time), an aliquot was thawed. Reseeding was carried out at 2% (v/v) in Luria-Bertani medium. At T=24 hours and 48 hours, a further reseeding at 2% was carried out. The culture at T=48 hours was taken for the experiments, since by this time, the culture had reached the exponential growth phase.
[0000] Preliminary Tests
[0104] The analytical method used was reading from a spectrophotometer at a wavelength of 565 nm. In a non-inoculated medium, one of either whey n°1 or whey n°2 was added, in order to test whether the endogenous bacteria would not develop in these experimental conditions, and thereby lead to inaccurate results. Under the conditions given, no bacterial growth was observed.
[0000] Control Experiments
[0105] Several control experiments were carried out in addition to the main experiment involving the complex comprising the solid support material and biologically active substance plus seeded medium (A):
B) whey+seeded medium : check for antimicrobial activity of whey on its own; C) seeded medium: bacterial growth control D) seeded medium+solid insoluble support material alone effect of the solid support material on its own on bacterial growth; E) solid insoluble support material alone+LB medium: test for an eventual effect of a non-sterile support material; F) complex+LB medium: test for an eventual effect of a non-sterile complex.
[0111] In a glass tube with a diameter of 1.7 mm, 0.1 mL (i.e. 2% v/v) of culture was added to 5 mL of LB media placed within the tube. The culture had reached its exponential growth phase (T=0 h). 10 mg of product was added, whereby the product was the complex, or a whey powder, to give a weight of 0.2% (w/v). A collection of tubes prepared in the same way with different solid insoluble support materials was agitated at 250 rpm and maintained at at temperature of 37° C. Optical density measurements were taken at regular intervals, for example after 1, 3, 5, and 22 hours respectively via spectrophotometry, using a wavelength of 565 nm, in order to check for bacterial growth.
[0000] Calculation Method
[0112] The results given in Table 2 were obtained after subtraction of the optical density of the supports (D-E) or of complex (A-F), in the LB medium and then compared to the control set up (C) and a whey control (B). Only the values for T=5 hours and T=22 hours are shown in the table. The optical densities read at T=1 hour and T=3 hours did not show any significant differences, since they correspond essentially to the beginning of bacterial growth.
[0113] Subtraction of the values is necessary, since bacterial concentration is linked to the turbidity of the seeded medium, and in parallel, the addition of the solid insoluble support material also generates some turbidity that needs to be deducted in order to have the optical density that is directly linked to bacterial growth.
TABLE 2 Samples OD (T = 5 h) OD (T = 22 h) Growth Control (C) 0.93 1.30 Sialite Support (D-E) 0.11 0.41 Complex (A-F) 0.03 0.08 Metasial C Support (D-E) 0.28 0.61 Complex (A-F) 0.08 0.72 Sokalite powder Support (D-E) 0.05 0.59 Complex (A-F) NA 0.11 Whey control (B) 1.06 1.58
Discussion
[0114] Control C shows that in the culture conditions used, a strong rate of bacterial growth was observed.
[0115] Control B, obtained by the addition of lyophilized whey powder, shows that, on its own, whey has no inhibiting effect on bacterial growth. On the contrary, the addition of powdered whey seems to have the opposite effect, i.e. stimulate bacterial growth, probably because it is very rich in lactose.
[0116] The solid insoluble support materials on their limit microbial growth. At T=5 hours, the results obtained for sialite, metasial C and sokalite powder are respectively 11.8%, 30.1% and 5.4%, compared to the control growth (100%). At T=22 hours, the same measurements gave values of 31.5%, 46.9% and 45.8%. Thus the solid support material on its own has an inhibiting effect on bacterial growth particularly at the beginning of microbial cell growth.
[0117] For the complexes formed according to the invention, growth was in general slowed, with an amplified effect. At T=5 hours, the results for the complexes containing sialite and metasial C were respectively 3.2% and 8.6% compared to the growth control (100%). At T=22 hours, these values had reached 6.1%, 55.4% and 8.5% respectively. Although the complex containing metasial C seems to be quite a good inhibitor at the beginning of bacterial growth, the value obtained at T=22 hours would lead one to believe that its inhibitory capacity is in fact similar to that measured for the insoluble solid support alone, and that therefore adsorption of proteins from whey does not lead to increased anti-microbial activity.
[0118] However, for sialite and powdered sokalite, strong anti-microbial activity is observed at both T=5 hours and T=22 hours, with an inhibition greater than 90% . Thus the adsorption of proteins from whey, as a waste effluent of the milk industry enables not only amplification of the antimicrobial activity, but also enables this activity to be present for longer, as had been already observed with the solid support materials on their own.
[0119] It is thus likely that the complexes formed according to the present invention have bacteriostatic properties.
[0000] Further Studies
[0000] Selection of the Bacterial Strain
[0120] The first set of tests were carried out on a strain known as E. Coli. (gram −). In order to validate the theory behind the invention, other strains were tested. These strains were Staphylococcus Epidermidis (gram +) and Listeria Innocua, the latter often being used to emulate the behaviour of Listeria monocytogenes, but without the precautions necessary to manipulate the monocytogenes strain.
[0121] Other tests were carried out to discover the mechanism of action of the complexes according to the present invention, to determine whether the complexes were “concentration dependent” or “time dependent”.
[0000] Analytical Method
[0122] The results were confirmed through the use of another analytical method, in order to demonstrate that they were not biased by the experimental conditions. Tests were thus carried out on a gelose media, and visible colony counting.
[0123] In the same manner, the initial analytical method used was challenged by adopting a different method. The addition of the solid support, or the formation of a particular complex leads to the risk biasing the values obtained. For the concentration of solid support material used and tested, approximately 0.2%, the samples were homogenized by centrifugation at low speed for 5 seconds. For other concentrations, however, for example at 1% concentration, i.e. 50 mg, this simple step was insufficient to obtain a homogeneous sample in which the OD could be said to be representative. The inventors therefore resorted to a visual observation of the turbidity of the samples.
[0000] Pilot Scale
[0124] As has been mentioned above, the process or method of the present invention is designed to solve the problem of waste, effluent or by-product flows of organic material that are generated in the dairy industry through a industrially economically viable method of recovering biologically active substances from said waste or by-product flows. FIG. 3 shows a schematic representation of how the process according to the present invention can be implemented into an existing industrial food production unit, and more specifically into a cheese manufacture production line. During cheese production, whey is produced as a by-product, generally indicated on FIG. 3 by the reference numeral 1 . The whey is pumped and collected into a storage vessel 3 . The tank 3 also includes agitation means, such as a stirrer 4 , to keep the whey homogenized. The homogenized whey is then pumped through an automatic rotary valve 5 via a centrifugal pump 6 and into a reactor vessel 7 that will enable the selective absorption and desorption of required biologically active substances in accordance with the present invention, and equipped with agitation means, for example, a stirrer 8 . The reactor vessel 7 is connected to a hopper 9 and a metering pump 10 . The hopper 9 is loaded with solid insoluble support material that is added to the reactor vessel 7 via the metering pump 10 . Other means of transporting and feeding the solid insoluble support material, could be for example, by using a conveyor system. The mixture of whey and insoluble solid support material is stirred continuously and at the necessary optimal conditions and length of time required for the desired biologically active substance or substances to be adsorbed onto the solid support material. Once adsorption is complete or has been maximized, the mixture of whey and solid insoluble support material is fed via a centrifugal pump 16 and a automatic rotary valve 17 through an accumulator vessel 18 into a solid/liquid separation system 20 . The accumulator vessel 18 recirculates the mixture, and enables the system to be operated until optimal filtration conditions are reached, thereby ensuring consistency in the results obtained. In the separation system 20 , the solid and liquid phases are separated one from the other, leaving a solid phase that is as dry as possible. It is noted that the solid support material now contains the biologically active substances absorbed onto it. The solid thus produced is then dried using more conventional techniques, such as via a concentrator, evaporator, flash dryer, spray dryer, atomizer and the like.
[0000] Pilot Scale Production
[0125] The production of several kilograms of active complex was carried out starting from whey originating from a cheese manufacture. Kaolin, available under the tradename Sialite (Soka, France) at 2% w/v, was added to a total volume of approximately 8m 3 whey identical to that mentioned in example 7. Solid-liquid separation was carried out using a press filter. Approximately 160 kg of active complex were recovered for analysis and animal nutrition testing. The whey was tested upon entry into, and exit from, the production process, and the following results obtained:
Whey Entry Exit Whey Dry matter (%) 100% 96.7% Fats (%) 100% 50.0% Lactose (%) 100% 100% Total Nitrogen Content (MAT) (%) 100% 84% Casein nitrogen (%) 100% 0% Serum Proteins (%) 100% 90.3%
[0126] MAT: total nitrogen content=N*6.38 (where 6.38 is a correction factor specific to milk proteins)
[0127] NPN: non-protiein nitrogen (N*6.38*0.97)
[0128] NCN non-casein nitrogen (N*6.38*0.98)
[0129] MAT−NCN=quantity of casein present, and enables determination of the amount of casein degradation
[0130] MAT−NPN=quantity of caseins+serum proteins
[0131] NCN−NPN=quantity of serum proteins
[0132] An SDS-PAGE analysis of the nature of the proteins retained on the solid support confirmed the result described in example 7. Only high molecular weight serine proteins are adsorbed onto the solid support used.
[0000] Animal Studies
[0133] A random test on 14 day old Ross breed chickens was carried out for 14 days over a population of 229 individuals, separated into a first group of 114 chickens on a standard dietary regime, and 115 chickens whose standard dietary regime was supplemented with 2% by weight of the active complex obtained above. The diet, which mainly comprised maize (52%), soybean (34%) and wheat (7%), was given to the animals as crumbs ad libitum. Observations and weighings of the chickens were carried out at the start (day 1), and then at days 7 and 14, to determine the general state of health of each group, but also to ascertain the average daily weight gain and a feed efficiency index.
[0134] These two parameters are usually considered to be the most important parameters for an industrial evaluation of an animal feed test. The average daily weight gain indicates how much weight the animal puts on and the feed efficiency index indicates how much the animal has put on weight compared to the quantity of food ingested. For a farmer, the idea is to have a minimum quantity of feed to distribute for a maximal weight gain. The product described and produced according to the present invention does just that. Physico-chemical and microbiological analyses of the excreta were also undertaken.
[0135] In comparison to the standard dietary regime test group, the tests on the supplemented group of animals showed that during the first week, known as the growth stage, an average daily weight gain increase of +4.2% and a 5.3% reduction of the feed efficiency index were observed. No statistically significant difference was observed for mortality and morbidity rates. The analysis of the excreta showed a reduction in coliform bacteria of −0.5Log CFU/batch of standard food, an increase in dry matter of +12.9%, as well as a reduction in organic matter of −7.9%.
[0136] A random test in an industrial pork farm on piglets that were 28 days old was carried out over 14 days and on 74 specimens, split into two groups of 36 and 38 piglets respectively. The group of 36 piglets was put on a standard dietary regime, and the group containing 38 piglets were fed with an active complex 1% by weight supplement to the standard diet. The standard diet for piglets post-weaning was given as granules ad libitum. Observations and weighings were carried out at day 1 and day 14 to determine the general state of health of each group, but also the average daily weight gain and feed efficiency index. Physico-chemical and microbiological analyses of the excreta were also carried out. In comparison to the chickens on the standard diet, the tests showed that over a period of 14 days, an increase in the average daily weight gain of +23.2% and a reduction of the feed efficiency index of −4.0% was observed. No significant statistical difference was observed for the mortality and morbidity rates. Analysis of the excreta showed an increase in dry matter of +53.9%, a reduction in organic matter of −12.9%, as well as a reduction in the total quantity of phosphorus of −33.3%. | The present invention relates to method for the isolation of at least one biologically active substance from an industrial dairy by-product or waste flow, comprising—selecting at least one industrial dairy waste or by-product flow containing at least one biologically active substance;—bringing the at least one industrial dairy waste or by-product flow into contact with at least one solid insoluble support material for sufficient time to cause the at least one biologically active substance to selectively adsorb on said support material;—recovering the insoluble solid support material carrying the adsorbed at least one biologically active substance. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 97-74207 filed on Dec. 26, 1997, the entire contents of which are hereby incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to integrated circuit semiconductor memory devices and associated methods. In particular, the present invention relates to a column select line (CSL) control for which the same signal controls the enable timing and the disable timing signals for synchronous random access memory devices.
2. Description of Related Art
Speed improvements in semiconductor memory devices, such as Dynamic RAMs and Static RAMs, have historically come from process and photolithography advances. More recent memory speed improvements, however, have resulted mainly from making changes to the base architecture. An example of fast RAM architecture is the synchronous architecture. One key advancement of the synchronous memories is their ability to synchronously burst data at a high-speed data rate. Additionally, in a system with a synchronous RAM, since data, addresses and control signals are latched into the memory in synchronism with the system's clock signal, the system's processor is able to perform other tasks freely until data is available after a known number of clock cycles. This architecture provides substantial advantages in memory operating performance.
In a typical semiconductor memory device, in order to write/read data into/from a specific memory cell in a memory device, the specific memory cell should be designated by a row address and a column address. When the specific memory cell is designated in a read/write operation, a charge distribution operation is performed with respect to data read out from the designated memory cell to a bit line, and the readout data is amplified by a sense amplifier. The amplified data is transmitted to an input/output line through an I/O gate circuit, and then is output from the memory chip via associated output circuits. The read operation of one-bit data stored in the specific memory cell is completed by the above-described process. The column decoder turns on the selected I/O gate by receiving and decoding the column address.
To simplify the complexity of the decoding operation in highly integrated memories, a column pre-decoder is typically provided to pre-decode the column address prior to the main decoding operation therefor. This column decoding scheme has been adopted in most high density memory devices.
FIG. 1 is a block diagram illustrating a conventional exemplary synchronous memory device. Referring to FIG. 1, an array 100 of memory cells is provided to store data. Word lines WL0-WLm and bit lines BL0-BLn coupled with the cells run along the rows and columns of the memory cell array 100, respectively. In the vicinity of the cell array 100, a row decoder 120 is provided for selectively driving the word lines WL0-WLm, and an input/output (I/O) gate circuit 140 for supporting the selective transmission of data from the bit lines BL0-BLn to a data I/O buffer 280, and vice versa. The I/O gate circuit 140 is controlled by column select lines CSL0-CSLn. Externally applied address signals A0-Ax including both column and row address signals are fed to an address buffer 160. The column address signals CA0-CAi among the address inputs are applied to a column pre-decoder 180.
A clock buffer 230 is suppled with an external clock signal XCLK and provides an internal PCLK synchronized with the external clock signal XCLK. A CSL enable control circuit 240 generates a CSL enable control clock signal PCSLE by the logical combination of the internal clock signal PCLK and a column address setting signal PYE from a timing control logic (not seen). The column pre-decoder 180 pre-decodes the column address signals CA0-CAi and generates pre-decoded address signals DCA0-DCAj.
The column pre-decoder 180 outputs the DCA0-DCAj signals under the control of the PCSLE signal from the CSL enable control circuit 240. Main decoding operation of the column address signals are then carried out by a column main-decoder 200. This decoder 200 generates decoded signals DCAB0-DCABk by decoding the DCA0-DCAj. The DCAB0-DCABk signals are provided to a column driver 220 which drives the column select lines CSL0-CSLn selectively in response to the DCAB0-DCABk signals. A CSL disable control circuit 260 generates a CSL disable control clock signal PCSLD by the logical combination of the internal clock signal PCLK and a normally logic-high signal PVCCH. The column driver 220 is disabled by the PCSLD signal from the CSL disable control circuit 260, and hence stops driving the column select lines CSL0-CSLn.
FIGS. 2A and 2B illustrate the constructions of the CSL enable and disable control circuits 240 and 260, respectively, in detail. Referring first to FIG. 2A, the CSL enable control circuit 240 includes a delay circuit formed by inverters IV1-IV4 ("first" delay circuit), a NAND gate G1, and an inverter IV5. The internal clock signal PCLK is provided to the delay circuit. The NAND gate G1 has one input applied with the delayed signal of the clock signal PCLK and the other input applied with the column address setting signal PYE. The output signal of the NAND gate G1 is output through the inverter IV5 as the CSL enable control clock signal PCSLE.
Referring to FIG. 2B, the CSL disable control circuit 260 includes a delay circuit formed by inverters IV6-IV8 ("second" delay circuit) and a NAND gate G2. The second delay circuit is also fed with the clock signal PCLK. This delay circuit has a smaller delay time than the first delay circuit. The output of the second delay circuit is supplied to one input of the NAND gate G2. The normally logic-high signals PVCCH is provide to the other input of the NAND gate G2. This gate G2 outputs the CSL disable control clock signal PCSLD.
FIG. 3 shows the detailed configuration of a unit circuit of the column pre-decoder 180. As shown in FIG. 3, the unit pre-decoder circuit 180' includes inverters IV31-IV49 and NAND gates G34-G49. The unit column pre-decoder circuit 180' is provided with three column address signals CA0-CA2 from the address buffer 160, and generates eight pre-decoded column address signals DCA0-DCA7. The CSL enable control clock signal PCSLE is commonly applied to the first inputs of the NAND gates G42-G49. The second inputs of the NAND gates G42-G49 are provided with the substantial pre-decoded column address signals, i.e., the output signals of the inverters IV34-IV41, respectively. When the PCSLE signal becomes high, the output signals of the inverter IV34-IV41 can be propagated to the inverters IV42-IV49 via the NAND gates G42-G49, respectively, and they are output as the pre-decoded column address signals DCA0-DCA7. The PCSLE signal should go high only after the completion of the pre-decoding operation with the inverters IV31-IV41 and the NAND gates G34-G41 in order to prevent pre-decoding errors.
FIG. 4 illustrates the detailed construction of unit circuits of the column main-decoder 200 and column driver 220, respectively. Referring to FIG. 4, the unit column main-decoder circuit 200' includes NAND gates G50-G57, and inverters IV50-IV57 corresponding to the NAND gates G50-G57, respectively. Each of the NAND gates G50-G57 has one input provided with a corresponding pre-decoded column address signal DCAy (where, y=0, 1, . . . , or 7) and the other input with a gate control signal GCS from a timing control logic (not shown). Each output signal of the NAND gates G50-G57 is provided as a finally decoded signal DCABy (where, y=0, 1, . . . , or 7) through the corresponding inverter IV50, IV51, . . . , or IV57.
The unit column driver circuit 220' includes inverters IV60-IV67, cascode inverters (sometimes called "dual gate inverters") 40-47, and inverting latches 60-67. Each of the cascode inverters 40-47 consists of two PMOS transistors (e.g., MP40a and MP40b) and one NMOS transistor (e.g., MN40), and each inverting latch (e.g., 60) is formed of two cross-coupled inverters (IV60a and IV60b). For each cascode inverter (e.g., 40), three transistors (MP40a, MP40b and MN40) have their source-drain paths coupled in series between a boosted supply voltage terminal VEXT and a ground voltage terminal GND. Each decoded column address signal (e.g., DCAB0) is applied to the gates of the corresponding pull-up and pull-down transistors (MP40a and MN40). The PCSLD signal from the CSL disable control circuit 260 is commonly fed to the gates of the switching transistors MP40b-MP47b of the respective cascode inverters 40-47 via the inverters IV60-IV67. Each inverting latch (e.g., 60) is coupled to the drain junction of the corresponding switching and pull-down transistors (MP60a and MN60).
The pre-decoding operation begins with the CSL disable control clock signal PCSLD of a high level. A pre-decoded column address signal of a high level (e.g., DCA0) can be transferred to the gate of the PMOS transistor MP40a as a decoded column address signal DCABO only when the gate control signal GCS remains at a high level. Namely, the GCS signal determines whether to propagate the DCA0-DCA7 signals through the unit column main-decoder circuit 200' or not. The decoded signal DCAB0 goes high when both DCA0 and GCS signals are high, so PMOS pull-up transistor MP40a turns off and NMOS pull-down transistor MN40 on. The high-level DCAB signal is latched by the inverting latch 60, so that a corresponding column select line CSL0 is driven high. After the PCSLD signal has gone low, the GCS signal also goes low. Accordingly, the pull-up transistor MP40a turns on and the pull-down transistor MN40 off, but the column select line CSL0 still remains high owing to the inverting latch 60. In this situation, when the PCSLD signal goes high again, the switching transistor MP40b turns on, so the CSL0 line is driven low.
As described above, the column select lines CSL0-CSLn are selectively activated by the column pre-decoder 180, but deactivated by separately controlling the column driver 220.
FIG. 5 is a timing diagram illustrating read/write operations of the conventional synchronous memory device of FIG. 1. With reference to FIG. 5, after a column address strobe signal CAS is activated low, in clock cycle T0, the CSL disable control clock signal PCSLD goes high in synchronism with the external clock signal XCLK (or the internal clock signal PCLK). After a predetermined time (i.e., Tm1) has elapsed, during which the first column address signals CA#0 (i.e., CA0-CAi) have reached the column pre-decoder 180, the CSL enable control clock signal PCSLE goes high in response to the activation of the column address setting signal PYE (see FIG. 2A). Of course, the PCSLE signal is also synchronized with the clock signal XCLK (or PCLK). A unit column pre-decoder circuit 180' pre-decodes the column address signals CA#0 (CA0-CA2) and generates the pre-decoded column address signals DCA#0 (DCA0-DCA7) of which only one is active and the others inactive. Here, assuming DCA0 signal is activated high, then a corresponding column select line CSL0 will be driven high by a unit column driver circuit 220'.
In the next clock cycle T1, the PCSLD signal becomes high before the low-to-high transition of the PCSLE signal, so that the line CSL0 is deactivated. Next, after the second column address signals CA#1 (CA0-CA2) had reached the unit column pre-decoder circuit 180' and the time Tm1 has elapsed, when the CSL enable control clock signal PCSLE goes high again in response to the activation of the column address setting signal PYE. The unit column pre-decoder circuit 180' generates the second decoded column address signals DCA#1 (DCA0-DCA7). Here, assuming DCA1 signal is activated high, then a corresponding line CSL1 will be driven high by a unit column driver circuit 220'.
The other column select lines (such as CSL2 and CSL3) also will become activated and deactivated during next clock cycles (T2 and T3) in response to the other column address signals (such as CA#2 and CA#3) in the same manner as the above-mentioned.
In the above conventional memory device, the CSL enable control clock PCSLE should not go active until valid column address signals arrive at the pre-decoder 180 during each clock cycle Tc (where, c=0, 1, 2, . . . ). However, in the event the PCSLE signal goes high during a clock cycle (e.g., T1) before the valid column address signals CA#1 arrive at the column pre-decoder 180, owing to an insufficient delay time of Tm1, then the invalid column address signal CA#0 for the previous clock cycle T0 may be pre-decoded again by the corresponding column pre-decoder circuit 180' (refer to FIG. 3). Hence, the invalid decoded signal DCAB0 will be latched by the corresponding inverting latch 60 via the cascode inverter 40 (refer to FIG. 4). This leads to the activation of the column select line CSL0. Thereafter, when the valid decoded signal DCAB1 is activated by decoding the valid column address signals CA#1 and latched by a corresponding inverting latch 41 in cycle T1, the column select line CSL1 corresponding to the valid column address signals CA#1 also becomes active along with the invalid CSL0 line, causing an erroneous read/write operation. For the above reason, it is essential to ensure sufficient delay time Tm1 in the conventional memory device. This limits the memory access speed improvements.
In addition, according to the conventional memory device structure, a significant area penalty may result from the large reiterative layout area of the unit column driver circuit 220'.
Furthermore, since the pull-up and switching transistors MP40a-MP47a and MP40b-MP47b within the respective cascode inverters 40-47 provide current leakage paths together with the inverters IV60b-IV67b of the inverting latches 60-67 during power-up, the conventional device has large power-up current dissipation.
SUMMARY OF THE INVENTION
The present invention is therefore directed to providing a synchronous semiconductor memory device and associated methods which substantially overcomes one or more of the problems due to the limitations and disadvantages of the related art.
Accordingly, an object of the present invention is to provide a synchronous semiconductor memory device having an improved column selection circuit structure suitable for performing a data accessing at high speed.
It is another object of the present invention to provide a synchronous semiconductor memory device having less power-up current dissipation than the conventional memory.
It is still another object of the present invention to provide a synchronous semiconductor memory device having a smaller area than the conventional synchronous memory.
These and other objects, advantages and features of the present invention may be realized by providing synchronous semiconductor memory devices which include a column main-decoder circuit that is directly coupled to column select lines and selectively drives the column select lines in response to pre-decoded column address signals, and a preferred CSL timing controller that controls both enable timing and disable timing of the column select lines by controlling the column pre-decoder in synchronism with a reference clock signal. Preferably, an externally applied clock signal serves as the reference signal. The preferred CSL timing controller generates a CSL timing control signal representative of the enable timing and the disable timing of the column select lines in synchronism to the reference clock signal. The column pre-decoder is either enabled or disabled depending upon logic states of the CSL timing control signal.
According to a preferred aspect of the present invention, the CSL timing controller includes a first control circuit which provides a CSL enable control signal representative of the enabling timing of the column select lines in synchronism with the reference clock signal, a CSL disable control circuit which provides a CSL disable control signal representative of the disable timing of the column select lines in synchronism with the reference clock signal, and a flip-flop circuit which has first and second inputs for receiving the CSL enable and disable control signals, respectively, and an output for providing the CSL timing control signal. Preferably, a latch logic with NOR gates is used to build the flip-flop circuit. Alternatively, the latch logic may be constructed from NAND gates.
These and other objects, advantages and features of the present invention may also be realized by providing a method of operating an integrated circuit semiconductor memory device in synchronism with a reference signal. The method includes pre-decoding column address signals, selectively driving column select lines in response to pre-decoded column address signals, and controlling both enable timing and disable timing of the column select lines by controlling the column pre-decoder in synchronism with the reference clock signal. Preferably, an externally applied clock signal serves as the reference signal. The preferred controlling includes generating a CSL timing control signal representative of the enable timing and the disable timing of the column select lines in synchronism to the reference clock signal. The column pre-decoder is either enabled or disabled depending upon logic states of the CSL timing control signal. Preferably, the CSL timing control signal is generated even absent the arrival of a valid column address signal. Preferably, the column select lines and the pre-decoded column address signals when the signals are inactivated when the CSL timing control signals is inactive.
According to the present invention, the conventional column driver occupying a large layout area is unnecessary, so that there is a large area savings as well as reducing total power consumption. In addition, since there is no need to always enable the column predecoder after the arrival of the column address signals thereto, it is possible to give a better access speed.
These and other objects of the present invention will become more readily apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating the preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention, and many of the attendant advantages thereof, will become readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like or similar reference symbols denote like or similar components, wherein:
FIG. 1 is a block diagram illustrating a conventional synchronous memory device;
FIG. 2A is a detailed circuit diagram of the CSL enable control circuit of FIG. 1;
FIG. 2B is a detailed circuit diagram of the CSL disable control circuit of FIG. 1;
FIG. 3 is a detailed circuit diagram of the column pre-decoder of FIG. 1;
FIG. 4 is a detailed circuit diagram of the column main-decoder and the column driver of FIG. 1;
FIG. 5 is a timing diagram for the read/write operations of the memory device of FIG. 1;
FIG. 6 is a block diagram illustrating an embodiment of a synchronous memory device according to the present invention;
FIG. 7 is a detailed circuit diagram of the CSL timing controller of FIG. 6;
FIG. 8 is a detailed circuit diagram of the column pre-decoder of FIG. 6;
FIG. 9 is a detailed circuit diagram of the column main-decoder of FIG. 6; and
FIG. 10 is a timing diagram for the read/write operations of the memory device of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to an improvement in selecting the columns of synchronous semiconductor memory devices. In the following description, specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without these particulars. In other instances, well-known elements have not been shown or described to avoid unnecessarily obscuring the present invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
A preferred embodiment of the present invention will now be described with reference to FIG. 6 through FIG. 10.
Referring first to FIG. 6, a synchronous semiconductor memory device according to an embodiment of the present invention is shown. An array 100 of memory cells (not seen), such as DRAM cells, SRAM cells, non-volatile memory cells, is provided to store data. Word lines WL0-WLm and bit lines BL0-BLn, BL0-BLn, coupled with the cells, run along the rows and columns of the memory cell array 100, respectively. In the vicinity of the cell array 100, a row decoder 120 is provided for selectively driving the word lines WL0-WLm, and an input/output (I/O) gate circuit 140 for supporting the selective transmission of data from the bit lines BL0-BLn, BL0-BLn to a data I/O buffer 280 through I/O data lines IO0-IOn, IO0-IOn, and vice versa. The I/O gate circuit 140 is controlled by column select lines CSL0-CSLn. Externally applied address signals A0-Ax for the selection of specific memory cell(s), including row address signals and column address signals, are fed to an address buffer 160. A column pre-decoder 180a is applied with the column address signals CA0-CAi from the address buffer 160 and generates pre-decoded column address signals DCA0-DCAj. The column main-decoder 200a is directly coupled to the column select lines CSL0-CSLn and selectively drive them in response to the pre-decoded column address signals DCA0-DCAj.
An external clock signal XCLK is also input to a clock buffer 230. This buffer 230 produces an internal PCLK synchronized with the external clock signal XCLK. A CSL timing controller 300 generates a CSL timing control signal PCSLED. This signal PCSLED is used to control enable timing and disable timing of the column pre-decoder 180a. Specifically, the pre-decoder 180a outputs the pre-decoded column address signals DCA0-DCAj when the PCSLED signal becomes active, but not when inactive. In other words, one of the signals DCA0-DCAj becomes active when the PCSLED signal is active, so that one of the CSL0-CSLn lines is driven active by the column-main decoder 200a. But, with inactivation of the PCSLED signal, all of the CSL0-CSLn lines are driven inactive because all the DCA0-DCAj signals are rendered inactive. This unified CSL enable/disable control manner of the invention makes it possible to eliminate the column driver, reducing chip area.
With particular reference to FIG. 7, the CSL timing controller 300 includes a CSL enable control circuit 320, a CSL disable control circuit 340, and a flip-flop circuit 360. The CSL enable control circuit 320 is constructed with a delay circuit 380 consisting of inverters IV16-IV19, NAND gate G5, and an inverter IV20. The internal clock signal PCLK is delayed by the delay circuit 380. One input of the NAND gate G5 is supplied with this delayed clock signal and the other input is supplied with a column address setting signal PYE from another internal timing control logic (not seen). The output signal of the NAND gate G5 is output via the inverter IV20 as an CSL enable control clock signal PCSLE.
The CSL disable control circuit 340 includes a delay circuit 400 formed of inverters IV13-IV15 and a NAND gate G4. The delay circuit 400 is also supplied with the clock signal PCLK. This delay circuit 400 has a smaller delay time than the delay circuit 380 within the CSL enable control circuit 320. One input of the NAND gate G4 is supplied with the output of the delay circuit 400 and the other input is supplied with normally logic-high signals PVCCH. This gate G4 outputs the CSL disable control clock signal PCSLD.
The flip-flop circuit 360 includes an S(set)-R(reset) latch logic 70 with NOR gates G6 and G7. The latch logic 70 maintains a given logic condition until changed by inputs. There are two inputs to the latch logic 70; one is "Set" and the other is "Reset". The CSL enable control clock signal PCSLE is supplied to the Set input of the latch logic 70 and the CSL disable control clock signal PCSLD to the Reset input thereof. The latch logic 70 has an inverting output Q. This Q0 signal is provided through an inverter IV21 as the CSL timing control signal PCSLED. When the PCSLD becomes high ("1"), the Q signal goes high ("1") as long as the PCSLE remains low ("0"). If the PCSLE signal goes high while the PCSLD signal is maintained low, then the Q signal goes low ("0"). When both of the signals PCSLE and PCSLD are low, the Q signal remains low. Conversely, when the PCSLE and PCSLD both are high, the Q signal remains high.
Referring next to FIG. 8, the detailed configuration of a unit circuit of the column pre-decoder 180a is shown. The unit pre-decoder circuit 180a' includes inverters IV71-IV89 and NAND gates G74-G89. The unit column pre-decoder circuit 180a' is provided with three column address signals CA0-CA2 from the address buffer 160, and generates eight pre-decoded column address signals DCA0-DCA7. The CSL timing control clock signal PCSLED is commonly applied to the first inputs of the NAND gates G82-G89. The second inputs of the NAND gates G82-G89 are provided with the substantial pre-decoded column address signals, i.e., the output signals of the inverters IV74-IV81, respectively. When the PCSLED signal becomes high, the output signals of the inverter IV74-IV81 can be propagated to the inverters IV82-IV89 via the NAND gates G82-G89, respectively, and they are output as the pre-decoded column address signals DCA0-DCA7.
FIG. 9 is a detailed construction of a unit circuit of the column main-decoder 200a. The unit column main-decoder circuit 200a' includes NAND gates G90-G97, and inverters IV90-IV97. First inputs of the NAND gates G90-G97 are supplied with gate control signal GCS from a timing control logic (not shown) and the others thereof with the pre-decoded column address signals DCA0-DCA7, respectively. The output signals of the NAND gates G90-G97 are provided to the inverters IV90-IV97, respectively. The output signals of the inverters IV90-IV97 drives the respective column select lines CSL0-GSL7.
FIG. 10 is a timing diagram illustrating read/write operations of the synchronous memory device of FIG. 6. Referring to FIG. 10, after a column address strobe signal CAS is activated low, in clock cycle T0, the CSL disable control clock signal PCSLD goes high in synchronism with the external clock signal XCLK (or the internal clock signal PCLK). So, the CSL timing control clock signal PCSLED remains low. Next, the CSL enable control clock signal PCSLE goes high in response to the activation of the column address setting signal PYE (see FIG. 7), so that the PCSLED signal changes to a high level. The logic condition of the PCSLED signal is maintained by the flip-flop circuit 360 till the low-to-high transition of the PCSLD signal. As a result of this, a unit column pre-decoder circuit 180a' pre-decodes the column address signals CA#0 (CA0-CA2) and outputs the pre-decoded column address signals DCA#0 (DCA0-DCA7) of which only one is active and the others inactive. Here, assuming DCA0 signal is activated high, then a corresponding column select line CSL0 will be driven high by a unit column main decoder circuit 200a'.
In the next clock cycle T1, the PCSLD signal becomes high again before the low-to-high transition of the PCSLE signal. Thus, the PCSLED signal goes low, so that the line CSL0 is deactivated.
The other CSL lines (such as CSL1-CSL3) also will become activated and deactivated during next clock cycles (T1-T3) in response to the other column address signals (such as CA#1-CA#3) in the same manner as the above-mentioned.
The PCSLED signal is able to go high even though valid column address signals do not reach the pre-decoder 180a' (see Tm2 of FIG. 10). This is because, with the removal of the column driver, the invalid decoded signal is not latched. Further, an invalid pre-decoded column address signal is disabled as soon as the valid column signals arrive at the pre-decoder 180a'. Since the CSL enable timing is not limited by the arrival of valid column address signals, this column selection can give a significant improvement in accessing speed.
As described above, according to the present invention, the conventional column driver occupying a large layout area is unnecessary, so that there is a large area saving, as well as a reduced power-up current dissipation. In addition, since there is no need to always enable the column pre-decoder after the arrival of the column address signals thereto, it is possible to give a better access speed.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the present invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the invention would be of significant utility without undue experimentation. | A synchronous memory includes a column main-decoder circuit that is directly coupled to column select lines (CSL), and a timing controller that controls both enable timing and disable timing of the column select lines by controlling the column pre-decoder. The CSL timing controller generates a CSL timing control signal representative of the enable timing and the disable timing of the column select lines. The column pre-decoder is either enabled or disabled depending upon logic states of the CSL timing control signal. The timing controller includes a first control circuit which provides a CSL enable control signal, a CSL disable control circuit which provides a CSL disable control signal, and a flip-flop circuit which receives the CSL enable and disable control signals and provides the CSL timing control signal. | 6 |
The present invention claims the benefit of the PCT/GB2012/000109 filed 2 Feb. May 2012, which claims priority to Ser. PT/105770 filed 24 Jun. 2011.
The present invention is related to a process for the manufacture of a triiodinated contrast agent, such as lopamidol, via a new chemical compound.
BACKGROUND
lopamidol is one of the most used non-ionic iodinated X-ray contrast agents. In the manufacture of lopamidol a multi-step synthesis is involved.
Several methods have been disclosed in the literature for the synthesis of lopamidol. The methods first described for the preparation of lopamidol, as disclosed in GB1472050 and U.S. Pat. No. 4,001,323, introduced the chiral center by reacting 5-amino-2,4,6-triiodoisophthaloyl dichloride with (S)-1-chloro-1-oxopropan-2-yl acetate. One disadvantage appointed (see U.S. Pat. No. 7,282,607) to these methods is the introduction of the chiral center very early in the synthesis, however, it is more economically preferred to introduce the highly expensive reagent 2-amino-1,3-propanediol (serinol) as late as possible in the synthesis. In contrast other methods more recently described introduced the chiral center in the last steps of the synthesis, as disclosed in U.S. Pat. No. 7,282,607 and U.S. Pat. No. 7,368,101, including making esters of 5-amino-N 1 ,N 3 -bis(1,3-dihydroxypropan-2-yl)-2,4,6-triiodoisophthalamide and other protecting strategies, followed by the reaction of the protected derivative with (S)-1-chloro-1-oxopropan-2-ylacetate. The last step of the synthesis removes all the groups introduced to protect the primary alcohols including the acetate from the chiral center thus affording lopamidol. Such methods release a high quantity of by products, making these methods less economically and environmentally friendly, atomically speaking. To overcome this drawback a method that includes less “atom usage”, as did the firstly described methods of GB1472050 and U.S. Pat. No. 4,001,323, is preferred. A method that uses fewer acyl chloride intermediates would also be preferred; as such methods would facilitate industrial operations.
Surprisingly, the method of the present invention meets the above needs and requirements by using 5-amino-2,4-6-triidoisophatalic acid as a starting material and introducing the chiral center in the first stage of the process by reaction with (S)-1-chloro-1-oxopropan-2-yl acetate thus forming the new compound, (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid. Furthermore, the method via the new compound allows the synthetic route to triiodinated contrast agents, such as lopamidol, to proceed without racemization, avoiding the use of protection/deprotection methodologies and introducing the highly expensive reagent serinol, immediately before the chemical step where lopamidol is obtained. Moreover lopamidol, is obtained in high purity, with a very low content of related process impurities such as acetyl and hydroxyacetyl analogs.
DESCRIPTION OF THE INVENTION
According to one aspect of the present invention, there is provided a new compound, (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid, of formula II presented below.
According to a second aspect of the present invention, there is provided a process for the synthesis of lopamidol via the new compound of formula II. Said process comprises reacting the new compound of formula II with a chlorinating agent forming the known compound 5-amino-2,4,6-triiodoisophthaloyl dichloride (formula III), followed by an amidation reaction with serinol, which after acetate hydrolysis provides lopamidol, according to the scheme presented below.
The amidation reaction and the acetate hydrolysis may both be carried out via methods described in the prior art.
According to a third aspect of the present invention, there is provided a process for the synthesis of the new compound of formula II. Said process comprises reacting 5-amino-2,4,6-triiodoisophtalic acid (formula I) with (S)-1-chloro-1-oxopropan-2-yl acetate thus forming the new compound (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid of formula II, according to the scheme presented below.
The acylation reaction is carried out in a suitable solvent such as an aprotic polar solvent, preferably dimethylacetamide (DMA), in which 5-amino-2,4,6-triiodoisophtalic acid may be dissolved. From 1 ml to 5 ml of DMA may be used per 1 gram of 5-amino-2,4,6-triiodoisophtalic acid. To this solution an acyl halide, preferably an acyl chloride such as (S)-1-chloro-1-oxopropan-2-yl acetate (also known as (S)-(−)-2-acetoxypropionyl chloride, which is commercially available) may be added without further purification. Preferably the acyl halide is added at a temperature of from 15° C. to 25° C. The ratio of the acyl halide relative to the amine may be of at least 1.5:1 (equivalents). The resulting reaction mixture may be heated at a temperature of from 40° C. to 60° C., preferably from 48° C. to 52° C., most preferably at about 50° C. The heated reaction mixture may be maintained at the desired temperature for a set period of time from 5 to 9 hours, preferably about 8 hours. After this time, the resulting reaction mixture may be stirred at a temperature of from 15° C. to 25° C. until the desired level of conversion is achieved. After the reaction is considered to be completed, the mixture may be slowly added to water to promote the precipitation of the compound of formula II giving a good dispersion of the solids in the mixture. The ratio of water relative to the polar aprotic solvent may be from 5:1 to 16:1. The suspension formed may be stirred for up to 5 hours at a temperature of from 15° C. to 25° C., preferably at a temperature of about 22° C., after which the solids may be separated by filtration and washed with water. The product may be dried under vacuum, preferably at a temperature of below about 50° C. The process for the synthesis of the new compound of formula II, according to the present invention enables the production of the new compound of formula II in good yield and in high purity (by HPLC, up to 99.9%).
To synthesize lopamidol using the new compound of formula II, the new compound is dissolved in a suitable polar solvent such as acetonitrile, N-methylpyrrolidone or, preferably, DMA. The polar solvent may be used in a ratio of 5:1 relative to the compound of formula II. A suitable chlorinating agent, such as phosphorus pentachloride (which is preferred by comparison with for example the less environmental friendly thionyl chloride) is added portion-wise to the solution to promote the formation of the dichloride of formula III. Alternatively other suitable halidating agents may be used to form the dihalide equivalent of formula III. The thus formed reaction mixture is stirred at a temperature of from 25° C. to 50° C., preferably from 38° C. to 42° C., most preferably at about 40° C., until the desired level of conversion is attained. After the reaction is considered to be complete the mixture is added to water previously cooled to a temperature of from 10° C. to 0° C., preferably 5° C. to 0° C., preferably over a period of time of over one hour with stirring. Preferably the reaction mixture is added to the water in a ratio of 2:1 relative to the quantity of the polar solvent. This enables isolation of the acid dichloride of the compound of formula II (or the equivalent dihalide). The white precipitate formed is separated by filtration and washed with water. The wet solid can be further purified according to procedures known and commonly used by those skilled in the art, for example, by suspension in a mixture of water and isopropyl alcohol. The quantity of water added at this stage is minimized to minimize the undesired hydrolysis reaction thus reducing the yield lost. The suspension of the white solid is stirred at temperature of below 25° C. to promote a more efficient wash of the suspended solids. The acid dichloride is separated from the mixture by filtration and the wet filter cake is rinsed with a suitable solvent, as for example isopropyl alcohol to wash out most of the water. The wet solid can be used directly without drying which constitutes another advantage of the present invention. The wet solid can be dried under vacuum at a temperature of from 25° C. to 45° C., preferably at 40° C. to 45° C. obtaining the known compound of formula III.
The compound of formula III (or the equivalent dihalide) is allowed to react with 2-amino-1,3-propanediol. The reaction with 2-amino-1,3-propanediol may be carried out as per the methods disclosed in the literature, such as after dissolution in DMA and in the presence of a base. After isolation the compound of formula IV is obtained in good yield with a purity of 98% in area by HPLC, which includes about 2% of lopamidol (formula V) that is formed during the process. Finally, the compound of formula IV thus obtained may be converted to lopamidol. Conversion of the compound of formula IV to lopamidol may be carried out as per the methods described in the literature, lopamidol may be obtained after isolation by crystallization from ethanol in high purity and with a very low content of impurities B (formula VI) and C (acetyl analog—formula VII), respectively of 0.002% and 0.004% (area by HPLC, lopamidol concentration of 10 mg/ml).
The preparation of the new compound of formula II and the respective process of the invention following the conversion to lopamidol is illustrated and clarified by the description of the non-limiting examples described hereafter.
EXAMPLE 1
Preparation of (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic Acid
(S)-1-chloro-1-oxopropan-2-yl acetate (0.75 ml, 5.91 mmol) was added drop-wise to a solution of 5-amino-2,4,6-triiodoisophthalic acid (1.0 g, 1.79 mmol) in DMA (5 ml). The resulting mixture was stirred at about 50° C. for 5 hours and 20 minutes. 80 ml of water was added to the reaction mixture at room temperature after which the suspension formed was cooled to a temperature between 0° C. and 5° C. and stirred for 25 minutes at this temperature. The suspension was filtered and the solid washed with water. The product was dried in a vacuum oven at 40° C. to yield (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid (0.695 g, 1.03 mmol). The MS, 1 H-NMR and 13 C-NMR data are consistent with the structure for (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid.
Yield: 57.5%
HPLC Purity: 99.91%
(Column: μ Porasil 125 A 10 μm (300×3.9 mm). Mobile Phase: Hexane: Tetrahydrofuran [(80/20) (v/v)] and 0.05% of trifluoracetic acid. Wavelength: 254 nm;
Column temperature: 40° C.).
MS: ES + [M+H] + found 673.88, C 13 H 11 I 3 NO 7 requires 673.77.
1 H-NMR: δ H (400 MHz, DMSO- d6 ) 10.11 (2H, s, C(O)O—H), 5.22 (1H, m, C—H), 2.12 (3H, s, COCH 3 ), 1.51 (3H, d, J 6.8, CHCH 3 ); 13 C-NMR: δ C (100 MHz, DMSO- d6 ) 169.4 (C═O), 168.2 (C═O), 149.3 (2 Ar—C), 142.4 (1 Ar—C—N), 97.9 (2 Ar—C—I), 87.3 (1 Ar—C—I), 69.4 (C—O), 20.8 (CH 3 ), 17.5 (CH 3 ).
EXAMPLE 2
Preparation of (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic Acid
(S)-1-chloro-1-oxopropan-2-yl acetate (37.4 ml, 295.4 mmol) was added slowly to a suspension of 5-amino-2,4,6-triiodoisophthalic acid (50.0 g, 89.5 mmol) in DMA (100 ml) at a temperature of between 25° C. and 29° C. The resulting mixture was heated to about 50° C. and stirred at this temperature for about 8 hours after which heating was removed and the mixture was stirred for about 14 hours at room temperature. The reaction mixture was added slowly over water (500 ml) with strong stirring at a temperature between 22° C. and 30° C. After addition 300 ml of water were added to the suspension. The suspension was stirred for 5 further hours at about 22° C. after which the white solid was filtered and washed with water previously cooled at about 5° C. twice (30 ml each time). The product was dried in a vacuum oven at about 5.0° C. to yield (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid (48.8 g, 72.5 mmol).
Yield: 81%
[α] 436 20 =−21.69° (99.25 mg/ml, Ethanol)
Purity by HPLC: 99.4% (HPLC conditions as used for example 1)
Melting point: 214.7° C. (with decomposition)
EXAMPLE 3
Preparation of (S)-1-((3,5-bis(chlorocarbonyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate
Phosphorus pentachloride (37.1 g, 178.3 mmol) was added portion-wise to a solution of the (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid obtained in example 2 (40.0 g, 59.4 mmol) in DMA (200 ml). The reaction mixture was stirred at about 40° C. for 6 hours after which it was added drop-wise to water (400 ml) cooled to a temperature of between 0° C. and 5° C. with vigorous stirring over 1 hour. The resulting suspension was stirred one further hour at a temperature of between 0° C. and 5° C. and the white precipitate was filtered. The white solid was washed with water (80 ml) previously cooled to a temperature of between 0° C. and 5° C. The solid was re-suspended in a mixture of water (103 ml) and isopropanol (80 ml) and stirred at this temperature for 15 minutes. The suspension was warmed up to a temperature of between 20° C. and 25° C. and stirred at this temperature for 30 minutes and then cooled again to a temperature of between 0° C. and 5° C. and stirred for 15 minutes. The white precipitate was filtered and dried at a temperature of between 40° C. and 45° C. to yield (S)-1-((3,5-bis(chlorocarbonyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate as a white solid (32.4 g, 45.7 mmol).
Yield: 77.0%
HPLC Purity: 98.4% (HPLC conditions as used for example 1)
EXAMPLE 4
Preparation of (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate
The preparation of (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodo-phenyl)amino)-1-oxopropan-2-yl acetate was carried taking as reference the procedures described in the literature. 20 g (28.2 mmol) of (S)-1-((3,5-bis(chlorocarbonyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate from example 3 was reacted with 2-amino-1,3-propanediol (6.4 g, 70.5 mmol) in DMA (100 ml) in the presence of triethylamine (10.0 ml, 71.4 mmol) at 50° C. for 6 hours. After complete reaction and removal of the salts by filtration, the solvent was distilled under vacuum at below 70° C. until a viscous oil was obtained. While the residue was still hot, alcohol was added (20 ml) to fluidize, followed by the addition of acetone (120 ml) in portions for about 1 hour and reflux for another hour. The resulting suspension was filtered and the product was dried under vacuum at 50° C. for 16 hours to give (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate as a white solid (19.0 g, 23.1 mmol).
Yield: 82.0%
HPLC purity: 98% (including 2% lopamidol)
EXAMPLE 5
Preparation of (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl Acetate Using Wet (S)-1-((3,5-bis(chlorocarbonyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate
9.86 g of wet solid, obtained as per example 3 conditions, corresponding to 8.1 g (11.4 mmol) of (S)-1-((3,5-bis(chlorocarbonyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate, was reacted with 2-amino-1,3-propanediol (2.6 g, 28.8 mmol) in DMA (41 ml) in the presence of triethylamine (4.06 ml, 29.0 mmol) at 50° C. for 6 hours. After complete reaction and removal of the salts, the solvent was distilled under vacuum at below 70° C. until a viscous oil was obtained. While the residue was still hot, alcohol was added (8.1 ml) to fluidize, followed by the addition of acetone (48.8 ml) in portions for about 1 hour and reflux for another hour. The resulting suspension was filtered and the product was dried under vacuum at 50° C. for 16 hours to give (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate as a white solid (6.45 g, 7.84 mmol).
Yield: 69.0%
HPLC purity: 98% (including 2% lopamidol)
EXAMPLE 6
Preparation of Lopamidol
The preparation of lopamidol from the (S)-1-((3,5-bis((1,3-dihydroxypropan-2-yl)carbamoyl)-2,4,6-triiodophenyl)amino)-1-oxopropan-2-yl acetate obtained from the previous examples was carried out following the procedures described in the literature. 18 g (22 mmol) of the compound obtained in example 4, was added to water (36 ml) and allowed to react with sodium hydroxide in aqueous solution (1.4 g in 5 ml of water, mmol) at a temperature of below 40° C. maintaining the pH at about 11 until complete reaction. The solution was desalinated and purified using cationic and anionic exchange resins, and the water evaporated under vacuum at a temperature of below 85° C. until a thick oil was obtained and from which the product was isolated and further purified by crystallization from ethanol (102 ml) to give, after filtration and drying under vacuum at a temperature of below 80° C., high purity lopamidol (13.0 g, 16.8 mmol).
Yield: 76.4%
[α] 436 20 =−5.11°
HPLC: Impurity B=0.002% area; Impurity C=0.004% area and lopamidol 99.76% area.
USP lopamidol Monograph: Impurity B=0.0011% w/w; Sum of impurities I+H=0.11% w/w; Any unspecified impurity=0.029% w/w. JP lopamidol Monograph: Related Substances by HPLC, total impurities 0.0389% w/w. | A new compound, (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid, of formula II (S)-5-(2-acetoxypropanamido)-2,4,6-triiodoisophthalic acid. Said new compound is of use for the production of triiodinated contrast agent, especially lopamidol, with low content of acetyl and hydroxyacetyl analogs. The new compound may be formed from 5-amino-2,4,6-triiodoisophtalic acid by acylating with (S)-1-chloro-1-oxopropan-2-yl acetate. The new compound may then be converted to the respective acid dichloride by reacting with a chlorinating reagent, which is a further object of the present invention, followed by the amidation with 2-amino-1,3-propanediol and acetate hydrolysis. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The disclosure of the present application relates to a method for pairing an AV device connected through a network with a controller linked to the AV device or controlling the AV device. Moreover, the disclosure of the present application relates to a pairing system that can execute a pairing process. The disclosure of the present application relates to a portable terminal included in a pairing system.
[0003] 2. Description of Related Art
[0004] Technology has become widespread, in which AV (audio-visual) devices for home use are connected to each other on a network, with the AV devices sharing content and controlling other AV devices. For example, there is a system, in which content of a digital video recorder (DVR) is reproduced and played on a reproducing device, such as a digital television (DTV), that has a so-called “rendering” function, via a controller. In such a system, title information or the like of the content of the DVR may be displayed on a controller that is operated by a user, where the user may select the content to be reproduced at hand, and the content is reproduced on a DTV, thus realizing the operation of a so-called “hand-held operation”.
[0005] Referring to FIGS. 14 and 15 , the following is an explanation of a technology, in which content on a server device is reproduced on a reproducing device via a controller.
[0006] As shown in FIG. 14 , a controller 102 , a reproducing device 103 , and a server device 104 are connected through a cable 107 . FIG. 15 shows a communication sequence when, in this configuration, the content on the server device 104 is generated on the reproducing device 103 via the controller 102 .
[0007] First of all, the controller 102 sends to the reproducing device 103 a request in order to search reproducing devices 103 connected to the network (S 1401 ). Having received a response from the reproducing device 103 (S 1402 ), the controller 102 sends to the reproducing device 103 a request in order to obtain detailed information on the detected reproducing device 103 (S 1403 ). Having received the detailed information from the reproducing device 103 (S 1404 ), the controller 102 next sends to the server device 104 a search request for searching the server device 104 connected to the network (S 1405 ). Having received a response from the server device 104 (S 1406 ), the controller 102 sends to the detected server device 104 a request in order to obtain detailed information on the server device 104 (S 1407 ), and receives a response from the server device 104 (S 1408 ).
[0008] After the controller 102 has detected the reproducing device 103 and the server device 104 connected to the network, it decides on the server device 104 for requesting and obtaining content information, and the reproducing device 103 for reproducing the content (S 1409 ). Next, the controller 102 sends a request to obtain content information to the server device 104 (S 1410 ). After obtaining content information in response (S 1411 ) to this request from the server device 104 , the controller 102 displays the content information, such as the title, in a display portion (not shown in the drawings) of the controller. The user operating the controller 102 selects the content to be reproduced by operating an operation input portion, not shown in the drawings, based on the content information displayed in the display portion of the controller 102 (S 1412 ). When the content to be reproduced has been selected by the user, the controller 102 sends a content reproducing request indicating a location and an indicator of the content, to the reproducing device 103 (S 1413 ). Having received the content reproducing request, the reproducing device 103 sends back a response (S 1414 ), and sends a request to obtain content to the server device 104 where the content is located, as stated in the request (S 1415 ). The server device 104 sends the content to the reproducing device 103 as a response to the request to obtain content sent from the reproducing device 103 (S 1416 ). Having received the content sent from the server device 104 , the reproducing device 103 displays and reproduces the content (S 1417 ).
[0009] With the configuration shown in FIGS. 14 and 15 it is possible to reproduce the content of a server device detected with a controller with a reproducing device detected by the controller. On the other hand, if the technology shown in FIGS. 14 and 15 is used at home, then it is conceivable that a plurality of digital televisions serving as reproducing devices are set up in the living room, the bedroom, the children's room, and so on. Moreover, there are cases conceivable, in which the controller is a mobile device and can be freely moved around the home and used. Furthermore, it is conceivable that the reproducing device, the server device and the controller in the home are connected to a network either by wire or wirelessly. If the user uses the controller in the living room, then in most cases, the content is reproduced on a reproducing device located in the living room. And if the user uses the controller in the bedroom, then in most cases, the content is reproduced on a reproducing device located in the bedroom. However, with the conventional technology, the controller may detect a plurality of reproducing devices that are connected to the network. Therefore, a user who freely moves a controller around and uses it, must select, in the living room, the reproducing device located in the living room, and in the bedroom, the reproducing device located in the bedroom, by selecting them by manual operation from a plurality of reproducing devices detected by the controller, requiring a troublesome operation.
[0010] To address this problem, JP 2006-115196A realizes pairing with a nearby device without selecting the device by the user, using two communication portions, operating by infrared and by radio (wirelessly). With the configuration disclosed in JP 2006-115196A, in order to realize pairing with a nearby device, two communication portions are necessary, and there was the problem that the devices became large and costly.
[0011] Moreover, to play broadcasting content in the US, ordinarily, a set-top box (STB) for cable television or satellite broadcasts is connected to an external input terminal of the DTV. The tuner of the DTV is not used. Therefore, the DTV may not know the content that is displayed on it. Thus, there is the problem that it cannot notify the controller of that content.
SUMMARY OF THE INVENTION
[0012] In view of the above-described problems, it is an object of the disclosure of the present application to provide a controller and a pairing system, with which, depending on the position of the controller, the device that has the desired capability and is closest, such as a reproducing device, can be automatically selected, and the reproducing device as well as the content information that is played on the device to be paired can be specified.
[0013] A pairing system disclosed in the present application includes a content identification server that outputs content information in response to an input of audio fingerprint information; a plurality of devices capable of sending audio fingerprint information of audio that can be output from the devices; and a portable terminal. The portable terminal includes an audio input portion into which audio can be input from outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been input into the audio input portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and upon receiving audio fingerprint information from each of the plurality of devices, and send the received audio fingerprint information to the content identification server, receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent audio fingerprint information corresponding to content information matching the first content information, out of the received content information.
[0014] A pairing system disclosed in the present application includes a content identification server that outputs content information in response to an input of audio fingerprint information; a plurality of devices capable of sending content information of content that is currently being played; and a portable terminal. The portable terminal includes an audio input portion into which audio can be input from outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been input into the audio input portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent content information matching the first content information, out of the received content information.
[0015] A pairing system disclosed in the present application includes a content identification server; a plurality of devices capable of sending, to the content identification server, audio fingerprint information of audio that can be output from the devices; and a portable terminal. The portable terminal includes an audio input portion into which audio can be input from outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been input into the audio input portion; and a communication portion that sends to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion. The content identification server includes a subordinate communication portion that receives the audio fingerprint information sent by the communication portion; a content identification portion that outputs content information corresponding to the audio fingerprint information received by the subordinate communication portion; and a subordinate pairing device deciding portion that establishes a pairing between the portable terminal and the device that has sent audio fingerprint information corresponding to content information matching the content information corresponding to the audio fingerprint information received from the portable terminal.
[0016] A pairing system disclosed in the present application includes a content identification server that outputs content information in response to an input of audio fingerprint information; a plurality of devices capable of sending audio fingerprint information of audio that can be input into the devices; and a portable terminal. The portable terminal includes an audio output portion capable of outputting audio to the outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been output by the audio output portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and upon receiving audio fingerprint information from each of the plurality of devices and sending the received audio fingerprint information to the content identification server, receives content information corresponding to the respective audio fingerprint information received from the plurality of devices, and a pairing device deciding portion that establishes a pairing with a device that has sent audio fingerprint information corresponding to content information matching the first content information, out of the content information.
[0017] A pairing system disclosed in the present application includes a content identification server that outputs content information in response to an input of audio fingerprint information; a plurality of devices capable of sending content information corresponding to audio that can be input into the devices; and a portable terminal. The portable terminal includes an audio output portion capable of outputting audio to the outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been output by the audio output portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent content information matching the first content information, out of the content information.
[0018] A pairing system disclosed in the present application includes a content identification server; a plurality of devices capable of sending, to the content identification server, audio fingerprint information of audio that can be input into the devices; and a portable terminal. The portable terminal includes an audio output portion capable of outputting audio to the outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been output by the audio output portion; and a communication portion that sends to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion. The content identification server includes a subordinate communication portion that receives the audio fingerprint information; a content identification portion that outputs content information corresponding to the audio fingerprint information received by the subordinate communication portion; and a subordinate pairing device deciding portion that establishes a pairing between the portable terminal and the device that has sent audio fingerprint information corresponding to content information matching the content information corresponding to the audio fingerprint information received from the portable terminal.
[0019] A portable terminal disclosed in the present application can be connected to a content identification server that outputs content information in response to an input of audio fingerprint information and to a plurality of devices that are capable of sending audio fingerprint information of audio that can be output from the devices. The portable terminal includes an audio input portion into which audio can be input from outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been input into the audio input portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and upon receiving audio fingerprint information from each of the plurality of devices and sending the received audio fingerprint information to the content identification server, receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent audio fingerprint information corresponding to content information matching the first content information, out of the received content information.
[0020] A portable terminal disclosed in the present application can be connected to a content identification server that outputs content information in response to an input of audio fingerprint information and to a plurality of devices capable of sending content information of content that is currently being played. The portable terminal includes an audio input portion into which audio can be input from outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been input into the audio input portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent content information matching the first content information, out of the received content information.
[0021] A portable terminal disclosed in the present application can be connected to a content identification server that outputs content information in response to an input of audio fingerprint information and to a plurality of devices that are capable of sending audio fingerprint information of audio that can be input into the devices. The portable terminal includes an audio output portion capable of outputting audio to the outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been output by the audio output portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and upon receiving audio fingerprint information from each of the plurality of devices and sending the received audio fingerprint information to the content identification server, receives content information corresponding to the respective audio fingerprint information received from the plurality of devices, and a pairing device deciding portion that establishes a pairing with a device that has sent audio fingerprint information corresponding to content information matching the first content information, out of the content information.
[0022] A portable terminal disclosed in the present application can be connected to a content identification server that outputs content information in response to an input of audio fingerprint information and to a plurality of devices capable of sending content information corresponding to content that can be input into the devices. The portable terminal includes an audio output portion capable of outputting audio to the outside; an audio fingerprint information generation portion that generates audio fingerprint information of audio that has been output by the audio output portion; a communication portion that, upon sending to the content identification server the audio fingerprint information generated by the audio fingerprint information generation portion, receives first content information, and receives content information corresponding to the respective audio fingerprint information received from the plurality of devices; and a pairing device deciding portion that establishes a pairing with a device that has sent content information matching the first content information, out of the content information.
[0023] With the disclosure of the present application, it is not necessary to select a reproducing device by a manual operation in accordance with the location where the user operates a portable controller, so that the operability can be improved.
[0024] Moreover, with the disclosure of the present application, it is possible to perform pairing with a nearby device by providing one communication portion and without providing two communication portions, so that it is possible make the system smaller and less expensive.
[0025] Moreover, with the disclosure of the present application, simultaneously to the pairing, it is possible to specify content information that is being played on the device to be paired; so that in a combination of a television receiver (one example of a reproducing device) with a tablet terminal (one example of a controller), it becomes possible to display on the tablet terminal information related to the content that is being played on the television receiver.
[0026] Moreover, with the disclosure of the present application, it becomes possible to pair a plurality of nearby portable terminals with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a diagram showing a configuration example of a pairing system according to Embodiment 1;
[0028] FIG. 2 is a block diagram showing a configuration example of a controller or portable terminal according to this embodiment;
[0029] FIG. 3 is a block diagram showing a configuration example of a digital television (DTV) according to this embodiment;
[0030] FIG. 4 is a block diagram showing a configuration example of a server device according to this embodiment;
[0031] FIG. 5 is a diagram showing a communication sequence of a pairing system according to Embodiment 1;
[0032] FIG. 6 is a diagram showing the processing flow of a controller according to Embodiment 1;
[0033] FIG. 7 is a diagram showing a communication sequence of the pairing system of Embodiment 1;
[0034] FIG. 8 is a diagram showing a communication sequence of the pairing system of Embodiment 1;
[0035] FIG. 9 is a diagram showing a configuration example of a pairing system according to Embodiment 2;
[0036] FIG. 10 is a diagram showing a communication sequence of the pairing system of Embodiment 2;
[0037] FIG. 11 is a diagram showing the processing flow of a controller according to Embodiment 2;
[0038] FIG. 12 is a diagram showing a communication sequence of the pairing system of Embodiment 2;
[0039] FIG. 13 is a diagram showing a communication sequence of the pairing system of Embodiment 2;
[0040] FIG. 14 is a diagram showing a configuration example of a conventional server device, reproducing device and controller; and
[0041] FIG. 15 is a diagram showing a communication sequence of a conventional system in which content on a server device is displayed via a controller on a reproducing device.
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1
1. System Configuration
[0042] Referring to FIGS. 1 to 6 , the following is an explanation of Embodiment 1 of the present invention.
[0043] FIG. 1 is a block diagram showing the configuration of a case in which a pairing system according to Embodiment 1 is applied to a home having a plurality of rooms (room A and room B). It should be noted that in FIG. 1 , connections by wiring are drawn with solid lines and wireless connections are drawn with broken lines.
[0044] The pairing system shown in FIG. 1 includes mainly a first digital television 3 A (referred to as “first DTV 3 A” below) and a second digital television 3 B (referred to as “second DTV 3 B” below), which are a plurality of reproducing devices, a controller 2 , and a server device 4 . The server device 4 is connected to the Internet 9 .
[0045] The first DTV 3 A and the second DTV 3 B are capable of receiving digital broadcasts, for example. The first DTV 3 A and the second DTV 3 B can receive broadcast waves of the same channel, but they can also receive broadcast waves of different channels of a digital broadcast. The specific configuration of the first DTV 3 A and the second DTV 3 B is explained further below.
[0046] The controller 2 is a terminal on which various types of application programs can be installed and executed. The controller 2 is provided with a touch panel superimposed over a display panel, and can be realized with a tablet terminal with which it is possible to touch the touch panel with a stylus pen, for example, to perform various inputs. The specific configuration of the controller 2 is explained further below.
[0047] The pairing system shown in FIG. 1 includes a wireless access point 5 and a wireless client 6 . The wireless access point 5 is connected by a network cable 7 A to the first DTV 3 A. The wireless access point 5 is connected by the wireless communication line to the wireless client 6 . The wireless access point 5 is connected by a network cable 7 C to the Internet 9 . The wireless access point 5 has a wireless function as well as a network hub function. The wireless client 6 is connected by a network cable 7 B to the second DTV 3 B. The wireless client 6 is connected by the wireless communication line to the wireless access point 5 . The wireless client 6 can carry out the exchange between a wired network and a wireless network. The wireless access point 5 and the wireless client 6 may also be omitted, if the first DTV 3 A, the second DTV 3 B and the controller 2 have functionality that is equivalent to this.
[0048] Since the controller 2 is a portable device, it can be arranged in either room A or in room B, but in FIG. 1 , it is assumed that it is arranged in room A. The controller 2 arranged in room A is network-connected via a wireless communication line with the wireless access point 5 .
[0049] The controller 2 in room A and the wireless client 6 constitute a wirelessly connected network with the wireless access point 5 . That is to say, the controller 2 is connected to the same network as the first DTV 3 A and the second DTV 3 B and they constitute a LAN (Local Area Network).
[0050] The wireless access point 5 is connected to the Internet 9 , and is in a state in which it can communicate with a server device 4 on the Internet 9 . In this embodiment, the wireless access point 5 and the Internet 9 are wire-connected through a network cable 7 C, but they may also be wirelessly connected using a mobile phone communication line or the like.
[0051] FIG. 2 is a block diagram showing the configuration of the controller 2 . The controller 2 includes a control portion 201 , a video/audio output portion 202 , an operation input portion 203 , a recording portion 204 , a communication portion 205 , an audio input portion 206 , a buffer portion 207 , and a memory portion 208 . The various portions included in the controller 2 are connected so that they can communicate with each other over a bus 209 . The control portion 201 controls the overall device, and is configured by a CPU (Central Processing Unit). The video/audio output portion 202 is configured by a display panel capable of displaying video and a speaker or the like that is capable of outputting audio. The display panel of the video/audio output portion 202 may not only be capable of displaying video, but may also include a touch panel that detects that it has been touched by a user's finer, a stylus pen or the like, and outputs operation signals. In this case, the touch panel is included in the operation input portion 203 . The operation input portion 203 receives user instructions and can be realized by operation buttons or a touch panel, for example. A recording medium 204 A can be attached to and removed from the recording portion 204 . Various kinds of data can be written onto the mounted recording medium 204 A, and those various kinds of data can be read from the recording medium 204 A. The communication portion 205 , which is configured as a wireless communication circuit, can send various kinds of data to the wireless access point 5 (see FIG. 1 ), for example, and can receive various kinds of data that are sent from the wireless access point 5 , for example. The audio input portion 206 , which may be configured by a microphone, for example, can collect audio from the surroundings of the controller 2 . The buffer portion 207 can temporarily store various kinds of data. The memory portion 208 can store programs or the like that are executed by the control portion 201 .
[0052] When the user touches a menu displayed on the display panel of the video/audio output portion 202 with the touch panel of the operation input portion 203 , then the operation input portion 203 sends an operation signal to the control portion 201 . The control portion 201 executes predetermined processing corresponding to the operation signal sent from the operation input portion 203 .
[0053] It should be noted that in the communication portion 205 , a first communication portion that is capable of communicating with the server device 4 and a second communication portion that is capable of communicating with the first DTV 3 A and the second DTV 3 B may be provided independently. For example, the communication portion 205 may be constituted by including a first communication portion that can be connected to a mobile telephone communications network and a second communication portion that is capable of being connected to a wireless LAN. Alternatively, the communication portion 205 may be constituted by including a first communication portion that can be connected to a mobile telephone communication network and a second communication portion that is capable of communicating according to the Bluetooth™ standard.
[0054] FIG. 3 is a block diagram showing the configuration of the first DTV 3 A. It should be noted that FIG. 3 shows the configuration of the first DTV 3 A, but also the second DTV 3 B has the same configuration. The first DTV 3 A includes a control portion 301 , a video output portion 302 , a broadcast receiving portion 303 , an operation input portion 304 , a communication portion 305 , a buffer portion 306 , a memory portion 307 , an audio output portion 308 , a video input portion 311 , and an audio input portion 310 . The various elements included in the first DTV 3 A and the second DTV 3 B are connected such that they can communication with each other over the bus 309 . The control portion 301 controls the overall device, and is configured by a CPU (Central Processing Unit). The video output portion 302 is configured by a display panel capable of displaying video. The broadcast receiving portion 303 can receive broadcast waves of digital broadcasts, for example. The broadcast receiving portion 303 includes an antenna, a tuner; a signal processing portion and so on. The operation input portion 304 receives instructions from the user, and can be realized by operation buttons, for example. The communication portion 305 includes a network terminal to which a network cable 7 A or the like can be connected, and controls an operation of sending or receiving various kinds of data over the connected network cable 7 A. The communication portion 305 can be connected to the Internet 9 via the wireless access point 5 shown in FIG. 1 . The buffer portion 306 can temporarily store various kinds of data. The memory portion 307 can store programs or the like that are executed by the control portion 301 . The audio output portion 308 is constituted by a speaker; for example, which converts audio signals that are output from the control portion 301 into audio and outputs them. The audio output portion 308 can output audio that is demodulated from broadcast waves of digital broadcasts received with the broadcast receiving portion 303 , for example. The video input portion 311 and the audio input portion 310 can receive, for example, video/audio signals of an external device, such as a set-top box (STB) or the like.
[0055] The broadcast receiving portion 303 demodulates video signals and audio signals from the broadcast waves of the received digital broadcast. The video signals and audio signals demodulated with the broadcast receiving portion 303 are temporarily stored in the buffer portion 306 . The control portion 301 performs a control to display, with the video output portion 302 , video based on the video signals stored in the buffer portion 306 . The video output portion 302 displays video based on the control with the control portion 301 . Moreover, the control portion 301 performs a control to output, with the audio output portion 308 , audio based on the audio signals stored in the buffer portion 306 . The audio output portion 308 outputs audio based on the control with the control portion 301 .
[0056] The communication portion 305 carries out communication processing with external devices (for example, the server device 4 ) network-connected over the network cables 7 A and 7 B (see FIG. 1 ). When displaying and reproducing the content sent from an external device (for example, the server device 4 ), the first DTV 3 A and the second DTV 3 B send a request to obtain content to the external device (for example, the server device 4 ) through the communication portion 305 . After the first DTV 3 A and the second DTV 3 B have temporarily stored, in the buffer portion 306 , the content received in response from the server device 4 , it is displayed on the display panel of the video output portion 302 .
[0057] FIG. 4 is a block diagram showing a configuration example of the server device 4 of this embodiment. As shown in FIG. 4 , the server device 4 includes a control portion 401 , a display portion 402 , an operation input portion 403 , a recording portion 404 , a communication portion 405 , and a memory portion 406 . The control portion 401 can be realized by a CPU, for example, and can carry out various types of signal processing within the server device 4 . The display portion 402 can display various kinds of video. The operation input portion 403 can receive input instructions from the user. The recording portion 404 can be realized by a hard disk, for example, and can record various kinds of data and information. The communication portion 405 can be connected to the Internet 9 (see FIG. 1 ).
2. Communication Sequence
[0058] FIG. 5 is a diagram illustrating the communication sequence of the pairing system of Embodiment 1.
[0059] Referring to FIG. 5 , the following is an explanation of the communication sequence when deciding on a pairing device in accordance with the present embodiment.
[0060] When the controller 2 receives an instruction to start a predetermined application program from a user, then it executes a predetermined application program that is already installed on the controller 2 , and sends to the wireless access point 5 a request for searching a DTV connected to the LAN. The wireless access point 5 sends the search request received from the controller 2 to the first DTV 3 A, and sends it via the wireless client 6 to the second DTV 3 B. The first DTV 3 A and the second DTV 3 B output a response signal as a response to the received search request. The response signal is sent via the wireless access point 5 to the controller 2 . When the controller 2 receives the response signal, a request to obtain detailed information on the DTV detected based on this response signal is sent via the wireless access point 5 to the first DTV 3 A and the second DTV 3 B. In response to the received request to obtain detailed information, the first DTV 3 A and the second DTV 3 B send detailed information on themselves via the wireless access point 5 or the like to the controller 2 . The controller 2 receives the detailed information sent from the first DTV 3 A and the second DTV 3 B. If a plurality of DTVs are connected to the network, then the controller 2 obtains the detailed information concerning each of these DTVs (in the present embodiment this is the first DTV 3 A and the second DTV 3 B).
[0061] Next, the controller 2 puts a microphone in its audio input portion 206 into a state in which it can collect audio. When it is in a state in which it can collect audio, the audio input portion 206 (microphone) obtains audio from the surroundings of the controller 2 . The controller 2 generates audio characteristics information (audio fingerprint information) from the audio obtained by the audio input portion 206 . More specifically, the controller 2 generates audio characteristics information (audio fingerprint information) corresponding to the DTV output audio included in the audio obtained by the audio input portion 206 (S 101 ).
[0062] It should be noted that “audio characteristics information” and “audio fingerprint information” is information formed by extracting only characteristic elements from the audio waveform (frequency characteristics). Audio characteristics information and audio fingerprint information are different in name but are substantially the same information. In the following explanations, these kinds of information are referred to as “audio fingerprint information”.
[0063] The controller 2 sends a request to obtain content information including the generated audio fingerprint information to the server device 4 (S 102 ).
[0064] The server device 4 compares the audio fingerprint information contained in the received request to obtain content information with the audio fingerprint information contained in a content database of the server device itself, and extracts the content information corresponding to the request to obtain content information from the content database. Next, as a response to the request to obtain content information from the controller 2 , the server device 4 sends the content information Con 1 back to the controller 2 (S 103 ).
[0065] Next, the controller 2 sends a request to obtain audio fingerprint information to the first DTV 3 A and the second DTV 3 B connected to the LAN (S 104 , S 106 ).
[0066] When the first DTV 3 A and the second DTV 3 B receive the request to obtain audio fingerprint information, they generate audio fingerprint information from the audio signal that is output from the audio output portions 308 of the DTVs themselves. Next, in response to the request to obtain audio fingerprint information, the first DTV 3 A and the second DTV 3 B send the generated audio fingerprint information to the controller 2 (S 105 , S 107 ).
[0067] When the controller 2 obtains the audio fingerprint information sent from the first DTV 3 A and the second DTV 3 B, it sends the request to obtain content information including the obtained audio fingerprint information to the server device 4 (S 108 , S 110 ).
[0068] The server device 4 compares the audio fingerprint information included in the request to obtain content information with the audio fingerprint information included in the content database of the server device itself, and extracts, from the content database, the content information corresponding to the request to obtain content information. Next, in response to the request to obtain content information, the server device 4 sends the content information Con 2 A and Con 2 B back to the controller 2 (S 109 , S 111 ).
[0069] Next, the controller 2 compares the content information Con 1 with the content information Con 2 A and Con 2 B. The controller 2 carries out a pairing process with the DTV that has sent audio fingerprint information corresponding to the content information Con 2 A or Con 2 B matching the content information Con 1 (S 112 ).
[0070] In the case of this embodiment, the audio input portion 206 of the controller 2 obtains the audio that is output from the audio output portion 308 of the first DTV 3 A, which is in the same room. That is to say, in the case of this embodiment, the controller 2 judges that the content information Con 1 matches the content information Con 2 A. Consequently, the controller 2 is paired with the first DTV 3 A, which has sent audio fingerprint information corresponding to the content information Con 2 A.
3. Process Flow for Deciding the Reproducing Device
[0071] FIG. 6 shows the process flow when the controller 2 decides the pairing with a nearby DTV (for example the first DTV 3 A), from among a plurality of DTVs connected to the network.
[0072] When the controller 2 receives from the user an instruction to activate a predetermined application, it executes a predetermined application program that is preinstalled on the controller, and sends to the wireless access point 5 a request for searching DTVs connected to the LAN. The wireless access point 5 sends the search request, which has been sent from the controller 2 , to the first DTV 3 A, and, via the wireless client 6 , to the second DTV 3 B. The first DTV 3 A and the second DTV 3 B generate a response signal in response to the received search request. The response signal is sent via the wireless access point 5 , for example, to the controller 2 . When the controller 2 receives the response signal, it sends a request for obtaining detailed information on the DTVs detected based on this response signal via the wireless access point 5 , for example, to the first DTV 3 A and the second DTV 3 B. In response to the received request to obtain detailed information, the first DTV 3 A and the second DTV 3 B send detailed information about themselves via the wireless access point 5 to the controller 2 . The controller 2 receives the detailed information sent from the first DTV 3 A and the second DTV 3 B. If a plurality of DTVs are connected to the network, then the controller 2 receives the detailed information from each of the DTVs (in the present embodiment, this is the first DTV 3 A and the second DTV 3 B).
[0073] The controller 2 puts the microphone of the audio input portion 206 into a state in which it can collect audio. When put into a state in which it can collect audio, the audio input portion 206 (microphone) obtains audio from the surroundings of the controller 2 . More specifically, the audio input portion 206 can obtain audio that is output from either one or from both of the first DTV 3 A and the second DTV 3 B (S 501 ).
[0074] The controller 2 generates audio fingerprint information from the audio obtained by the audio input portion 206 . It should be noted that if the audio obtained by the audio input portion 206 includes the audio output from a plurality of DTVs, then the audio with the largest volume is selected to generate the audio fingerprint information (S 502 ).
[0075] Next, the controller 2 sends the request to obtain content information including the generated audio fingerprint information to the server device 4 (S 503 ). The controller 2 receives the response to the request to obtain content information from the server device 4 (S 504 ).
[0076] Next, the controller 2 sends a request to obtain audio fingerprint information to the DTVs connected to the LAN (S 505 ). The controller 2 receives the responses to the request to obtain audio fingerprint information from the DTVs (S 506 ). The controller 2 obtains audio fingerprint information for all detected DTVs (S 507 ).
[0077] After the controller 2 has obtained the audio fingerprint information of the first DTV 3 A and the second DTV 3 B, it sends a request to obtain the content information including the obtained audio fingerprint information to the server device 4 (S 508 ). The controller 2 receives the response to the request to obtain the content information from the server device 4 (S 509 ). The controller 2 obtains the corresponding audio fingerprint information for all DTVs that have obtained audio fingerprint information (S 510 ).
[0078] Next, the controller 2 compares the content information Con 1 corresponding to the audio fingerprint information generated from the audio that has been entered by its own audio input portion 206 with the content information Con 2 A and Con 2 B corresponding to the audio fingerprint information obtained from the first DTV 3 A and the second DTV 3 B connected to the LAN (S 511 ). The controller 2 carries out pairing with the device that has sent audio fingerprint information corresponding to content information (Con 2 A or Con 2 B) matching the content information Con 1 (S 512 ). Thus, the controller 2 carries out pairing with a nearby DTV.
[0079] When the controller 2 has finished the process of comparing the obtained content information of all DTVs, the pairing process is finished (S 513 ).
[0080] Through the above-described series of processes, the controller 2 is able to automatically select the nearest DTV from among the plurality of DTVs connected to the network. Consequently, depending on the position of the operated controller 2 , the user does not need to select by hand the nearby DTV.
[0081] Here, “the nearest DTV” more precisely means the DTV that outputs the audio with the greatest volume among the audio output from the DTVs collected with the audio input portion 206 of the controller 2 . For example, even when the first DTV 3 A is placed in a position that is physically closest to the controller 2 , if the volume of the audio output by the second DTV 3 B, which is placed in another room, is extremely high, then the controller 2 may collect the audio output from the second DTV 3 B. In this case, the controller 2 may judge that the second DTV 3 B is “the closest DTV” However, ordinarily, there will be no large difference in the volume of the audio that is output by DTVs placed in a plurality of different rooms, so that “the closest DTV” is regarded in the present embodiment as the DTV at the position that is physically closest to the controller 2 .
[0082] It should be noted that in the present embodiment, the controller 2 obtains the audio fingerprint information of the first DTV 3 A and the second DTV 3 B, and using the obtained audio fingerprint information, it obtains the content information corresponding to the audio fingerprint information from the server device 4 , but there is no limitation to this.
[0083] For example, as shown in FIG. 7 , it is also possible that the first DTV 3 A and the second DTV 3 B generate audio fingerprint information from the audio that is output from a speaker that is included in their own video output portion 302 , and using this generated audio fingerprint information, inquire the content information from the server device 4 (see S 604 to S 607 in FIG. 7 ). In this case, the controller 2 sends the request to obtain content information to each of the first DTV 3 A and the second DTV 3 B (S 608 , S 610 ), and receives the content information in response (S 609 , S 611 ). It should be noted that in FIG. 7 , the processing content of the steps S 601 , S 602 , S 603 and S 612 is the same as the processing content of the steps S 101 , S 102 , S 103 and S 112 in FIG. 5 .
[0084] As shown in FIG. 8 , it is also possible that the server device 4 that has obtained audio fingerprint information respectively from the controller 2 , the first DTV 3 A and the second DTV 3 B performs pairing between the controller 2 and the DTV (first DTV 3 A) that has sent audio fingerprint information corresponding to the content information matching the content information corresponding to the audio fingerprint information of the controller 2 . In this case, after the pairing device has been decided by the server device 4 (S 708 ), the controller 2 sends a request to obtain pairing device information to the server device 4 (S 709 ). Next, the controller 2 receives a response including pairing device information from the server device 4 (S 710 ). Thus, the controller 2 identifies the device (first DTV 3 A) it is to be paired with. Note that in FIG. 8 , the processing content of the processes S 701 , S 702 and S 703 is equivalent to the processing content of the processes S 101 , S 102 and S 103 shown in FIG. 5 .
[0085] Moreover; the controller 2 , the first DTV 3 A and the second DTV 3 B may send to the server device 4 their audio fingerprint information along with device identification information of the device that has generated the audio fingerprint information, and the server device 4 may hold content information that corresponds to the device identification information and the audio fingerprint information that has been sent. Furthermore, when the device identification information and the audio fingerprint information has been sent from the controller 2 , the first DTV 3 A and the second DTV 3 B, the server device 4 may preferentially carry out the comparison with audio fingerprint information included in the content database that matches the held content information. Thus, it becomes possible to quickly detect whether there is a change in the content information input into the controller 2 or the content information displayed respectively by the first DTV 3 A and the second DTV 3 B. Consequently, in a state in which the controller 2 is paired with the first DTV 3 A, if there is a change in the content that is played on the first DTV 3 A, it is possible to display relevant information tracking this change in content on the tablet terminal, without performing another pairing operation. Moreover, it becomes possible to reduce the server load when detecting whether there is a change in content. More specifically, this becomes possible by letting the controller 2 , the first DTV 3 A and the second DTV 3 B periodically send a request to obtain content information to the server device 4 after the pairing has finished, and upon obtaining the content information carrying out the above-described comparison preference processing.
Embodiment 2
1. System Configuration
[0086] Referring to FIGS. 9 to 13 , the following is an explanation of a second embodiment of the present invention.
[0087] FIGS. 9 and 10 are block diagrams showing a system configuration according to Embodiment 2. In FIG. 10 , structural elements that are equivalent to structural elements of the system configuration shown in FIG. 1 are given the same reference numerals and their further explanation has been omitted. The system shown in FIG. 10 is applied to a network in a plurality of conference rooms (conference room A, conference room B) in an office. A controller 2 , a wireless access point 5 , a first portable terminal 8 A and a second portable terminal 8 B are arranged in the conference room A. A third portable terminal 8 C and a fourth portable terminal 8 D are arranged in the conference mom B. The controller 2 , the first portable terminal 8 A, the second portable terminal 8 B, the third portable terminal 8 C, and the fourth portable terminal 8 D can be moved by the user to any desired location.
[0088] In conference room A, the plurality of portable terminals 8 A and 8 B, and the wireless access point 5 , which has a wireless function as well as a network hub function, are network-connected by a wireless communication line.
[0089] The controller 2 is arranged in the conference room A and is network-connected to the wireless access point 5 by a wireless communication line. Moreover, the controller 2 includes an audio output portion 202 A. The audio output portion 202 A may be configured by a speaker, for example.
[0090] The plurality of portable terminals 8 C and 8 D are arranged in the conference room B. The controller 2 and the portable terminals 8 C and 8 D are wirelessly Connected to the wireless access point 5 , constituting a network. That is to say the controller 2 , the portable terminals 8 A and 8 B, and the portable terminals 8 C and 8 D are connected to the same network, and constitute a IAN (Local Area Network).
[0091] The wireless access point 5 is connected to the Internet 9 , and is in a state in which it can communicate with a server device 4 on the Internet 9 .
[0092] The configuration of the controller 2 , the portable terminals 8 A, 8 B, 8 C and 8 D is the same as the configuration shown in FIG. 2 of Embodiment 1, so that further detailed explanations are omitted.
2. Communication Sequence
[0093] FIG. 10 illustrates a communication sequence of a pairing system of Embodiment 2.
[0094] Referring to FIG. 10 , the following is an explanation of the communication sequence when deciding on a pairing device in accordance with the present embodiment. It should be noted that FIG. 10 shows only the sequence for the first portable terminal 8 A and the second portable terminal 8 B out of all portable devices, but also for the third portable terminal 8 C and the fourth portable terminal 8 D the same sequence as shown in FIG. 10 can be executed.
[0095] When the controller 2 and the portable terminals 8 A to 8 D receive an instruction to start a predetermined application program from a user, then they execute a predetermined application program that is already installed on them. The controller 2 sends to the wireless access point 5 a request for searching portable terminals connected to the LAN. The wireless access point 5 sends the search request received from the controller 2 to the portable terminals 8 A to 8 D. The portable terminals 8 A to 8 D output a response signal as a response to the received search request. The response signal is sent via the wireless access point 5 to the controller 2 . When the controller 2 receives the response signal sent from the portable terminals 8 A to 8 D, a request to obtain detailed information on the portable terminal detected based on this response signal is sent via the wireless access point 5 to the portable terminals 8 A to 8 D. In response to the received request to obtain detailed information, the portable terminals 8 A to 8 D send detailed information on themselves via the wireless access point 5 to the controller 2 . The controller 2 receives the detailed information sent from the portable terminals 8 A to 8 D. If a plurality of portable terminals are connected to the network, then the controller 2 obtains the detailed information concerning each of these portable terminals 8 A to 8 D.
[0096] Next, the controller 2 outputs audio from the audio output portion 202 A. More specifically, the controller 2 outputs suitable audio from a speaker in the audio output portion 202 A (S 800 ).
[0097] The portable terminals 8 A to 8 D put a microphone in their respective audio input portion 206 into a state in which it can collect audio. When the respective audio input portions 206 (microphones) of the portable terminals 8 A to 8 D are in a state in which they can collect audio, they obtain audio from the surroundings of the portable terminals 8 A to 8 D. The portable terminals 8 A to 8 D generate audio fingerprint information from the audio obtained by the audio input portion 206 (S 801 ).
[0098] In the present embodiment, as shown in FIG. 9 , the first portable terminal 8 A and the second portable terminal 8 B are arranged in the conference room A, in which also the controller 2 is arranged, so that the audio input portions 206 of the first portable terminal 8 A and the second portable terminal 8 B can obtain audio that is output from the audio output portion 202 A of the controller 2 . The third portable terminal 8 C and the fourth portable terminal 8 D are arranged in the conference mom B, so that it is difficult for them to obtain audio that is output from the audio output portion 202 A of the controller 2 . Consequently, in the present embodiment, the first portable terminal 8 A and the second portable terminal 8 B generate audio fingerprint information of audio that is output from the audio output portion 202 A of the controller 2 .
[0099] The controller 2 sends a request to obtain content information including the audio fingerprint information generated from the audio that is output from the video/audio output portion 202 to the server device 4 (S 802 ).
[0100] The server device 4 compares the audio fingerprint information contained in the received request to obtain content information with the audio fingerprint information contained in a content database of the server device itself, and extracts the content information corresponding to the request to obtain content information from the content database. Next, as a response to the request to obtain content information sent by the controller 2 , the server device 4 sends the content information Con 3 back to the controller 2 (S 803 ).
[0101] Next, the controller 2 sends a request to obtain audio fingerprint information to the portable terminals 8 A to 8 D connected to the LAN (S 804 , S 806 ).
[0102] After the portable terminals 8 A to 8 D have received the request to obtain audio fingerprint information, the generated audio fingerprint information is sent to the controller 2 in response to the request to obtain audio fingerprint information (S 805 , S 807 ).
[0103] After the controller 2 has obtained the audio fingerprint information from the portable terminals 8 A to 8 D, it sends a request to obtain content information including the obtained audio fingerprint information to the server device 4 (S 808 , S 810 ).
[0104] The server device 4 compares the audio fingerprint information included in the received request to obtain content information with the audio fingerprint information included in the content database of the server device itself, and extracts, from the content database, the content information corresponding to the request to obtain content information. Next, in response to the request to obtain content information, the server device 4 sends the content information Con 4 A and Con 4 B back to the controller 2 (S 809 , S 811 ).
[0105] Next, the controller 2 compares the content information Con 3 with the content information Con 4 A and Con 4 B. The controller 2 carries out pairing with the device that has sent audio fingerprint information corresponding to the content information matching the content information Con 3 (S 812 ). In the case of this embodiment, the audio input portions 206 of the first portable terminal 8 A and the second portable terminal 8 B can obtain the audio that is output from the audio output portion 202 A of the controller 2 , which is in the same conference room. That is to say, the content information Con 3 matches the content information Con 4 A and 4 B. Consequently, the controller 2 is paired with the first portable terminal 8 A, which has sent the content information Con 4 A, and the second portable terminal 8 B, which has sent the content information Con 4 B.
3. Process Flow for Deciding the Reproducing Device
[0106] FIG. 11 shows the process flow when the controller 2 decides the pairing with a nearby portable terminal, from among a plurality of portable terminals connected to a network.
[0107] When the controller 2 receives from the user an instruction to activate a predetermined application, it executes a predetermined application program that is preinstalled on the controller, and sends to the wireless access point 5 a request for searching a portable terminal connected to the LAN. The wireless access point 5 sends the search request from the controller 2 to the portable terminals 8 A to 8 D. The portable terminals 8 A to 8 D output a response signal in response to the received search signal. The response signal is sent via the wireless access point 5 , for example, to the controller 2 . When the controller 2 receives the response signal from the portable terminals 8 A to 8 D, it sends a request for obtaining detailed information on the portable terminals 8 A to 8 D detected based on this response signal to the portable terminals 8 A to 8 D. In response to the received request to obtain detailed information, the portable terminals 8 A to 8 D send detailed information about themselves via the wireless access point 5 to the controller 2 . The controller 2 receives the detailed information sent from the portable terminals 8 A to 8 D. If a plurality of portable terminals are connected to the network, then the controller 2 receives the detailed information from each of the portable terminals 8 A to 8 D.
[0108] The controller 2 outputs audio from the speaker of the audio output portion 202 A (S 1001 ).
[0109] The portable terminals 8 A to 8 D activate the microphones include in their respective audio input portions 206 and collect audio from their surroundings. The portable terminals 8 A to 8 D generate audio fingerprint information from the audio that is output from the audio output portion 202 A of the controller 2 (S 1002 ).
[0110] Next, the controller 2 sends the request to obtain content information including the generated audio fingerprint information to the server device 4 (S 1003 ).
[0111] Having received the request to obtain content information, the server device 4 sends content information to the controller 2 . The controller 2 receives the content information sent from the server device 4 (S 1004 ).
[0112] Next, the controller 2 sends a request to obtain audio fingerprint information to the portable terminals 8 A to 8 D connected to the LAN (S 1005 ).
[0113] Having received the request to obtain audio fingerprint information, the portable terminals 8 A to 8 D send audio fingerprint information to the controller 2 . The controller 2 receives the audio fingerprint information sent from the portable terminals 8 A to 8 D (S 1006 ).
[0114] The controller 2 obtains audio fingerprint information for all detected portable terminals (S 1007 ).
[0115] After the controller 2 has obtained the audio fingerprint information of the portable terminals, it sends a request to obtain content information including the obtained audio fingerprint information to the server device 4 (S 1008 ).
[0116] Having received the request to obtain content information, the server device 4 sends the content information to the controller 2 . The controller 2 receives the content information sent from the server device 4 (S 1009 ).
[0117] The controller 2 obtains the corresponding content information for all portable terminals that have obtained audio fingerprint information (S 1010 ).
[0118] Next, the controller 2 compares the content information Con 3 corresponding to the audio fingerprint information generated from the audio information that has been output by its own video/audio output portion with the content information Con 4 A and Con 4 B corresponding to the audio fingerprint information obtained from the portable terminals connected to the LAN (S 1011 ). As a result of this comparison, the controller 2 carries out pairing with the device that has sent audio fingerprint information corresponding to content information matching the content information Con 3 (S 1012 ). Thus, the controller 2 carries out pairing with a portable terminal nearby.
[0119] When the controller 2 has finished the process of comparing the obtained content information of all DTVs, the pairing process is finished (S 1013 ).
[0120] Through the above-described series of processes, the controller 2 is able to automatically pair itself with a portable terminal, from among a plurality of portable terminals connected to a network, that is within a distance at which it can be reached by audio from the controller 2 . Consequently, depending on the position of the operated controller 2 , the user does not need to select by hand a nearby portable terminal.
[0121] It should be noted that in the present embodiment, the controller 2 obtains audio fingerprint information of the portable terminals, and using the obtained audio fingerprint information, it obtains the content information corresponding to the audio fingerprint information from the server device 4 , but there is no limitation to this.
[0122] For example, as shown in FIG. 12 , it is also possible that the portable terminals 8 A and 8 B each generate audio fingerprint information from the audio that is input from their own audio input portions 206 , and using this generated audio fingerprint information, inquire the content information from the server device 4 (see S 1104 to S 1107 in FIG. 12 ). In this case, the controller 2 sends the request to obtain content information to each of the portable terminals 8 A and 8 B (S 1108 , S 1110 ), and receives the content information in response (S 1109 , S 1111 ). It should be noted that in FIG. 12 , the processes S 1100 , S 1101 , S 1102 and S 1103 are equivalent to the processing content of the processes S 800 , S 801 , S 802 and S 803 in FIG. 10 .
[0123] Moreover, as shown in FIG. 13 , it is also possible that the server device 4 that has obtained audio fingerprint information respectively from the controller 2 , the first portable terminal 8 A and the second portable terminal 8 B performs pairing between the controller 2 and the portable terminals 8 A and 8 B that have sent audio fingerprint information corresponding to the content information matching the content information corresponding to the audio fingerprint information of the controller 2 (S 1208 ). In this case, the controller 2 sends a pairing device information obtaining request to the server device 4 (S 1209 ), and receives a response including pairing device information from the server device 4 (S 1210 ), thus identifying the pairing device. Note that in FIG. 13 , the processes S 1200 , S 1201 , S 1202 and S 1203 are equivalent to the processing content of the processes S 800 , S 801 , S 802 and S 803 shown in FIG. 10 .
[0124] It should be noted that the server device 4 is an example of a content identification server. The first DTV 3 A and the second DTV 3 B are examples of devices. The controller 2 , the first portable terminal 8 A, the second portable terminal 8 B, the third portable terminal 8 C, and the fourth portable terminal 8 D are examples of portable terminals. The audio input portion 206 is an example of an audio input portion. The control portion 201 is an example of an audio fingerprint information generation portion and a pairing device deciding portion. The communication portion 205 is an example of a communication portion. The communication portion 405 is an example of a subordinate communication portion. The control portion 401 is an example of a content identifying portion and a subordinate pairing device deciding portion.
[0125] The disclosure of this application can be used in systems that play content on a server device, such as a digital video recorder (DVR) at home, via a controller on a reproducing device, such as a digital television (DTV) having a so-called “renderer function”, as well as to a portable controller, a portable terminal and a reproducing device, such as a DTV, that constitute a part of this system.
[0126] The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | When pairing an AV device with a controller for linking to and controlling the AV device, it was necessary for the user operating the controller to select an AV device near the user in accordance with the position of the user. A controller 2 specifies a nearby device based on audio characteristic information (an audio fingerprint) generated from audio obtained by an audio input portion (microphone) or content information specified from such audio characteristic information, and audio characteristic information of devices obtained with a communication portion or content information specified from such audio characteristic information, to carry out the pairing. | 7 |
This is a continuation of application Ser. No. 484,360, filed Apr. 12, 1983, which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electric fan device which is used with a cooling radiator for an automotive engine thereby to cool down the radiator. More specifically, the present invention relates to an electric fan device of the type, in which a cooling fan is attached to the output side of a flattened motor having a printed armature built therein.
2. Description of the Prior Art
In an electric fan device for the radiator according to the prior art, a fan is fixed to the output shaft of an ordinary or flattened electric motor, and no special consideration is taken into the radiation of the heat which is generated in the armature of the electric motor.
When the flattened electric motor is to be assembled and attached to the radiator, moreover, two divided motor housings are first assembled as the motor by means of rivets or screws and are then attached to the bracket or the like of the radiator. This requires both fixing means for fixing the motor to the bracket in addition to fastening means such as the screws for assembling the two divided housings and holes or the like which are formed in the housings for the fastening means and the fixing means. As a result, the electric fan device of the prior art has its assembly parts and steps increased to provide an expensive electric fan device.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a radiator cooling electric fan device which makes use of a flattened electric motor so that it can efficiently radiate the heat to be generated in an armature whereby it can be prevented from having its output dropped.
Another object of the present invention is to provide an electric fan device in which the assembly of the electric motor and the attachment to a radiator bracket are simplified so that the cost and the number of assembly steps can be reduced.
According to a feature of the present invention, there is fixed to one of two divided housings a shaft, on which a metal rotor is rotatably supported, wherein a flattened armature plate is fixed to the metal rotor and a radiating member for radiating the heat generated in the armature plate to the outside is also fixed to the metal rotor. According to the construction thus made, the heat generated in the armature plate can be efficiently radiated to prevent the electric motor from having its output dropped.
According to another feature of the present invention, at the joined portions of the two divided housings made of a ferromagnetic substance, one of the housings is formed with holes whereas the other is formed with annular projections to extend through those holes, and the two housings are joined to and held on each other by the magnetic force of the permanent magnet of the electric motor. At the stage of joining the two housings by the magnetic force of that permanent magnet, the assembly of the motor is completed. When the electric fan device is to be attached to the bracket of the radiator, the fastening means such as screws or rivets extend through the aforementioned annular projections to mount the motor on the bracket. As a result, simultaneously as the motor is mounted on the bracket, the two divided housings are fixedly joined at last.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectional view showing an electric fan device according to the present invention;
FIG. 1A is a fragmentary sectional view showing on a larger scale a detail generally depicted at the upper left in FIG. 1;
FIG. 2 is a side view showing the electric fan device; and
FIG. 3 is an enlarged sectional view showing an essential portion of a modification in which terminals are connected with brush holders.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, an armature 1 will be described in the following. A center piece (or rotor) 2 made of die-cast or cold-forged aluminum is formed with steps 2a and 2b on its outer circumference. An armature plate 3 having a flattened shape is made to abut against the step of the center piece 2 such that it is electrically insulated by means of insulators 4 and 5 made of glass cloth. Then, a center ring 6 made of an aluminum or iron plate is made to abut against the lefthand side of the aforementioned insulator 4. Finally, the step 2b of the aforementioned center piece 2 is caulked to fix the aforementioned armature plate 3 to the center piece 2.
In order to enhance the fixedness of the armature plate 3, incidentally, an adhesive may be applied to both the sides of the insulator 5. On the other hand, the cylindrical portion 7b of an oilless bearing 7 having a flange 7a is press-fitted in a step 2d, which is formed in the inner circumference of the center piece 2, such that the flange 7a abuts against the step 2d.
On the other hand, a ball bearing 8 has its outer race 8a abutting against an opposite step 2e also formed in the inner circumference of the center piece 2. That outer race 8a in turn is press-fitted in the inner circumference 2f of the center piece 2 until it abuts against the step 2e. Moreover, the center piece 2 has its end face formed with a plurality of threaded portions 2g into which screws 10 for fixing a load (or fan) 9 are inserted.
Next, one housing 11 will be described in the following. This housing 11 is formed by twice reducing a cold rolled steel plate with a bar ring 11b which is positioned at the center of a reduced portion 11a at the inner peripheral portion and which is directed inwardly. Moreover, the housing 11 is formed with one rectangular hole 11c into which a brush holder 12 can be inserted.
Indicated at reference numeral 13 is a shaft which is formed with a flange 13a, a step 13b and a cylindrical portion 13c and which is fitted in the oilless bearing 7 and the ball bearing 8. The shaft 13 is made as a whole of carbon steel and is press-fitted in the inner wall of the aforementioned bar ring 11b.
Moreover, the flange 13a of the shaft 13 is fixedly welded (as indicated at 13a1) in the form of a ring to the end face of the housing 11 so as to ensure water-tightness.
On the other hand, the shaft 13 is formed at its portion opposite to the flange 13a with a groove 13d in which an E-ring 22 is fitted.
The housing 11 is formed on its outer periphery with a reduced portion 11d which is directed inward likewise the bar ring 11b. Reference numeral 11e indicates an electric fan mounting hole.
The brush holder 12 is molded of a phenol resin or the like and is formed with a rectangular hole 12a, in which a brush 14 and a brush holding spring 15 are inserted such that the brush 14 is urged to slide rightwardly of the drawing by the action of the spring 15. The brush 14 has its pigtail 14a welded and connected to the inner end of a terminal 16.
The terminal 16 is formed with a pair of stopper pawls 16a and 16b and is inserted into a rectuangular slit 12b of the brush holder 12 so that it is prevented from coming out by the action of the pawls 16a and 16b. Moreover, the terminal 16 has its leading end portion formed with a hole 16c to which the core 19a of a lead wire 19 shown in FIG. 2 is connected after it has been inserted thereinto and welded thereto. As shown in FIG. 3, on the other hand, the rectangular slit 12b may have its inner periphery formed with projections 12c corresponding to the pawls 16a and 16b. In this modification, the terminal 16 can be fixed more fixedly to the brush holder 12.
A ring-shaped magnet 20 is fixed by means of an adhesive to the flat portion 11f of the housing 11. This housing is formed at its outer periphery with the reduced portion 11d which is so axially bent as to cover the outer periphery of the other housing 17.
A second housing 17 is made of a cold-rolled steel plate and is formed with a cylindrical portion 17a at its inner periphery. The cylindrical portion 17a has its inner circumference made larger than the external diameter of the step 2a of the center piece 2 of the aforementioned armature 1. Moreover, the cylindrical portion 17a has its leading end portion bent inward to repel water and dust.
On the outer circumference of the cylindrical portion 17a, there is press-fitted a cylindrical portion 18a of a cap 18 which is made of a cold-rolled steel plate for water-tightness. The cap 18 is formed with a drain 18b which extends at a right angle (radially outwardly) with respect to the cylindrical portion 18a.
Indicated at reference numeral 17b is the depth of reduction of the motor housing 17, which is selected to have such a size as to prevent the armature 3 from contacting with the housing 17. This housing 17 has its outer periphery formed with a flat portion 17c and made smaller than the outer periphery 11d of the housing 11.
Moreover, the flat portion 17c is formed with a plurality of positioning and motor fixing bar rings 17d each of which is constituted by a respective annular projection which has its inner circumferential wall formed with internal threading 17e. Numeral 23a designates a radiating member made of a heat-conductive material such as aluminum, iron or the like and fixed to a radiator fan 23 made of a resin, for example. The radiating member 23a is then fixedly secured to the metal rotor 2 by means of the screws 10, so that heat generated at the armature 1 can be transmitted to the radiating member 23a through the rotor 2 and radiated into the air therefrom.
Next, the order of the steps of assembling the embodiment thus constructed will be described in the following.
First of all, the shaft 13 fixed to the housing 11 is inserted into the oilless bearing 7 and the ball bearing 8.
Before this insertion, a clearance adjusting thrust washer 21 is sandwiched in position, if necessary, between the end face of the oilless bearing 7 and the step 13b of the shaft 13 so as to retain the clearance size between the surface of the armature plate 3 and the surface of the magnet 20.
After this insertion, so as to retain the necessary thrusting allowance on the end face of the ball bearing 8, an adjusting thrust washer 21a is fitted, if necessary, and the E-ring 22 is press-fitted in the groove 13d of the shaft 13 so as to provide a stop for the thrusting motion.
After the armature 1 has been assembled, a water-repelling sealing agent is applied to whole the periphery of the flat portion 17c of the housing 17, and the housings 11 and 17 are joined to each other. At this time, the housing 17 is fixed in position by the attracting force of the magnet 20 of the housing 11.
Next, the method of assembling the fan 23 will be described in the following. The radiating member 23a of the fan 23 is applied to the end face of the armature center piece (rotor) 2 and fixedly fastened thereto by means of screws 10, and a sealing agent is applied to the head of the screws 10 so as to ensure the water-tightness.
Next, the mounting structure of the electric fan device will be described in the following. The housing 11 is brought into abutment against the end face of a shroud 25 providing a mounting bracket, and a screw 26 is inserted into and fixedly fastened to the thread 17e of each bar ring 17d of the housing 17, each projection 17d having entered a respective hole 11e in the housing 11 in order to properly locate the housing 11 relative to the housing. Incidentally, although, in the foregoing embodiment, the male and female fitted portions of the locating means are formed of the holes 11e and the bar rings 17d, they may be formed of other portions to prevent the housings 11 and 17 from rotating relative to each other.
Next, other embodiments of the present invention will be described in the following.
The center piece 2 and the armature plate 3 may be integrally molded of a resin. In this case, the insulators 4 and 5 and the center ring 6 may be dispensed with.
As the thrust stopping structure, on the other hand, in place of press-fitting the E-ring 22 into the groove 13d of the shaft 13, a toothed washer having a plurality of teeth on its inner wall may be axially press-fitted in accordance with the thrusting allowance required. In this case, a thrust washer may be inserted, if necessary.
As the adjustment of the air gaps at both sides of the armature plate 3, on the other hand, the inner race of the ball bearing 8 and the cylindrical portion 13c of the shaft 13 are so sized that they can be fixedly press-fitted, in place of inserting the thrust washers 21 and 21a, and the bearing 8 is press-fitted on the shaft 13 so that the necessary air gaps may be retained at both the sides of the armature plate 3. With this construction, the thrust washers 21 and 21a can be dispensed with so that the assembly can be facilitated.
As a counter-measure for preventing water from leaking around the screw 10 for mounting the fan 23, the sealing agent is applied to the head of the screw 10. According to another embodiment, however, a water preventing or repelling sealing agent may be applied to the righthand end face of the armature center piece 2. Moreover, the fan 23 may be assembled with the center piece 2 through a sealing gasket (or packing) or an O-ring.
On the other hand, an insulating paint may be applied either by itself or together with a thin insulating seat to both the sides of the outer periphery of the armature plate 3, thereby to prevent the armature plate 3 from warping due to vibrations or the like and from contacting with the housing 17 and accordingly from being grounded.
Incidentally, either the aforementioned insulating paint or thin insulating sheet may be applied to both the inner periphery of the housing 17 facing the armature plate 3 or the surface of the magnet 20.
On the other hand, the armature center ring 6 for fixing the armature plate may be dispensed with by applying an adhesive to both the sides of the insulator 5 thereby to increase the fixedness.
Although the cap 18 is press-fitted in the housing 17, the cap portion may be integrally molded by reducing the leading end portion 17a of the housing 17.
In the above-described embodiment the fan 23 is attached by fixedly fastening the screw 10. However, the fan 23 may be fixed by forming a projection on the end face of the armature center piece 2, by inserting that projection into the hole of the member 23a of the fan 23 and by press-fitting a toothed washer having a plurality of teeth in the inner wall of the projection inserted.
Incidentally, the housings 11 and 17 have to be made of a ferromagnetic substance such as steel if they are to be temporarily fixed by the magnetic force of the permanent magnet 20. The portions referred to as the bar rings 17d in the present invention are cylindrical projections which is cut out of a metal plate by the pressing operation. Moreover, the fixture 25 may be rivet or a bolt in addition to the screw. On the other hand, the bracket 25 may be an arm-shaped bracket or the like in addition to the shroud.
In the embodiments of the present invention thus far described, by the force acting in the axial direction of the permanent magnet 20 and as a result that each bar ring 17d, for example, providing the male fitted portion is fitted in a respective hole 11e, for example, providing the female fitted portion, there can be attained effects that the housings 11 and 17 can be temporarily fixed to a sufficient extent without coming out in the axial directions and rotating relative to each other, that the housings 11 and 17 can be firmly fixed to each other simultaneously as the flattened electric motor is to be attached to the bracket 25, that the mounting fixture 26 can be commonly used, and that the number of the assembling steps can be reduced.
In the foregoing embodiment of the present invention, moreover, the brush holder acts partly to hold the brush and partly to function as a grommet for extending therethrough the lead wire for leading the electric power into the housings of the electric motor. As a result, there can be attained an effect that the special grommet can be dispensed with so that the number of parts can be reduced together with the production cost. | As a drive source of a blowing fan for a vehicular radiator, there is used a flattened electric motor, wherein there is fixed to one of two divided housings a shaft, on which there is rotatably supported a rotor to which a flattened armature coil is joined and to which the blowing fan is fixed through a radiating member. Thus, the heat, which is generated in the armature coil, is transferred through the rotor and/or the shaft to the radiating member, by which it is efficiently radiated into the air. | 5 |
[0001] This Nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 2003-332470 filed in Japan on Sep. 24, 2003, and is a Division of U.S. application Ser. No. 10/947,311, filed Sep. 23, 2004, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to inkjet recording head, an inkjet recording apparatus and a method for manufacturing an inkjet recording head, and more particularly, to an inkjet recording head, an inkjet recording apparatus, and a method for manufacturing an inkjet recording head, whereby no cross-talk is generated.
[0004] 2. Description of the Related Art
[0005] An inkjet printer used as an image forming apparatus, such as a printer, a facsimile apparatus, a copying apparatus, or the like, forms images on paper by discharging ink from nozzles of pressure chambers, in accordance with image forming data.
[0006] Ink discharging devices based on a piezo-actuator using a piezoelectric element, which deforms in accordance with an electric signal, are known. In a piezo-actuator method, a pressure wave is applied to a pressure chamber by deforming the wall of the pressure chamber by means of a piezoelectric element, thereby causing ink to be discharged from the nozzle of the pressure chamber, and therefore it is possible to generate a strong pressure wave by means of a low drive energy. In recent years, inkjet printers have been required to form images of high precision and resolution, and it has become necessary to eliminate differences in the flight characteristics of ink droplets, when one nozzle is driven and when a plurality of nozzles are driven, and to eliminate the generation of accidental droplets due to cross-talk between one pressure chamber and an adjacent pressure chamber. As a method for resolving these requirements, Japanese Patent Application Publication No. 10-329320 discloses that cross-talk is prevented by forming strain absorbing holes in two or three of the outer edges of the pressure chamber of the piezoelectric element.
[0007] In the recording head disclosed in Japanese Patent Application Publication No. 10-329320, the piezoelectric elements corresponding to respective nozzles are connected partially with the adjacently positioned piezoelectric elements, and hence a problem arises in that cross-talk cannot be completely eliminated. Moreover, the recording head disclosed in Japanese Patent Application Publication No. 10-329320 is formed by stacking green sheets in multilayer on which strain absorbing holes have been formed, and it is difficult to register the small strain absorbing holes in position, and hence productivity declines. Moreover, in an inkjet printer head based on a method wherein ink is discharged by using a bimorph effect between a vibration plate and a piezoelectric body, as in the present example, since the displacement of the piezoelectric body in a lateral direction is utilized, there is a very significant effect on adjacent nozzles if a structure is adopted wherein all of the piezoelectric bodies are connected.
SUMMARY OF THE INVENTION
[0008] The present invention is contrived in view of such circumstances, and an object thereof is to provide an inkjet recording head, an inkjet recording apparatus and a method for manufacturing an inkjet recording head whereby cross-talk is prevented, whilst also achieving excellent productivity.
[0009] In order to attain the above-described object, the present invention is directed to an inkjet recording head, comprising: a plurality of ink chambers aligned, each of the plurality of ink chambers having a nozzle; and a piezoelectric element arranged on an outer side of the plurality of ink chambers, the piezoelectric element using displacement in d 31 direction, piezoelectric strain absorbing holes being formed through the piezoelectric element in regions of outer perimeters of active sections of the piezoelectric element, wherein when voltage is applied to one of the active sections of the piezoelectric element, corresponding one of the plurality of ink chambers is compressed by the piezoelectric element, and ink filled in the one of the plurality of ink chambers is discharged through the nozzle toward a recording medium.
[0010] According to the present invention, since the piezoelectric strain absorbing holes passing through the piezoelectric element are formed in the piezoelectric element in the regions of the outer perimeters of the active sections (i.e., the discrete electrodes, the pressure chambers), then stress generated by piezoelectric strain is eliminated by means of the piezoelectric strain absorbing holes and hence cross-talk can be prevented.
[0011] Preferably, the inkjet recording head further comprises a vibration plate which defines the plurality of ink chambers, grooves being formed on the vibration plate at positions opposing the piezoelectric strain absorbing holes in the piezoelectric element. According to this, it is possible further to alleviate the stress generated in the vibration plate by piezoelectric strain, and hence elimination of cross-talk is promoted.
[0012] Preferably, the vibration plate and the piezoelectric element are bonded by means of adhesive, and the piezoelectric strain absorbing holes form escape regions for surplus adhesive during bonding. According to this, any surplus adhesive enters into the piezoelectric strain absorbing holes, thereby enabling stable bonding of the vibration plate and the piezoelectric element. Moreover, the drying time for the adhesive can also be shortened by means of the piezoelectric strain absorbing holes.
[0013] The present invention is also directed to an inkjet recording apparatus, comprising: a plurality of ink chambers aligned, each of the plurality of ink chambers having a nozzle; and a piezoelectric element arranged on an outer side of the plurality of ink chambers, the piezoelectric element using displacement in d 31 direction, piezoelectric strain absorbing holes being formed through the piezoelectric element in regions of outer perimeters of active sections of the piezoelectric element, wherein when voltage is applied to one of the active sections of the piezoelectric element, corresponding one of the plurality of ink chambers is compressed by the piezoelectric element, and ink filled in the one of the plurality of ink chambers is discharged through the nozzle toward a recording medium.
[0014] The present invention is also directed to a method for manufacturing the inkjet recording head, comprising the steps of: forming a common electrode onto a first surface of a single green sheet by means of a screen printing; then forming discrete electrodes onto a second surface of the green sheet by means of screen printing; then forming the piezoelectric strain absorbing holes in the green sheet in the regions of the outer peripheries of the discrete electrodes by means of a pressing machine; then calcining the green sheet to form the piezoelectric element using displacement in d 31 direction; and then bonding the piezoelectric element to a vibration plate.
[0015] According to the present invention, since the piezoelectric strain absorbing holes are processed after forming the common electrode and the discrete electrodes, whereupon the vibration plate is bonded, it is possible to prevent strain or damage to the vibration plate, which is liable to the vibration plate, during forming and processing, and hence productivity can be increased.
[0016] In the present specification, the term “recording” indicates the concept of forming images in a broad sense, including text. Furthermore, “recording medium” indicates a medium on which an image is formed by means of a recording head (this medium may be called an image forming medium, recording medium, image receiving medium, recording paper, or the like), and this term includes various types of media, irrespective of material and size, such as continuous paper, cut paper, sealed paper, resin sheets, such as OHP sheets, film, cloth, and other materials.
[0017] According to the present invention, cross-talk can be prevented, and productivity can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The nature of this invention, as well as other objects and advantages thereof, will be explained in the following with reference to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures and wherein:
[0019] FIG. 1 is a side view showing an image forming apparatus according to an embodiment of the present invention;
[0020] FIG. 2 is a plan view showing an inkjet recording head according to an embodiment of the present invention;
[0021] FIG. 3 is a partial enlarged cross-sectional view showing the detailed structure the inkjet recording head;
[0022] FIGS. 4A to 4 E are plan views showing other embodiments of piezoelectric strain absorbing holes;
[0023] FIGS. 5A to 5 E are descriptive diagrams showing a method for manufacturing the inkjet recording head;
[0024] FIG. 6 is a detailed cross-sectional diagram showing the inkjet recording head;
[0025] FIG. 7A is a detailed plan view showing an inkjet recording head according to another embodiment of the present invention, and FIG. 7B is a cross-sectional view of FIG. 7A ; and
[0026] FIG. 8 is a detailed plan diagram showing an inkjet recording head relating to a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Below, an embodiment of an inkjet recording head, an inkjet recording apparatus and a method for manufacturing an inkjet recording head are described with reference to the accompanying drawings. FIG. 1 is a side view showing a schematic illustration of the composition of an image forming apparatus 10 to which an inkjet recording head, an inkjet recording apparatus and a method for manufacturing an inkjet recording head according to a first embodiment are applied.
[0028] The image forming apparatus 10 comprises: a recording head 12 ; a belt conveyance unit 18 for conveying recording paper 16 whilst maintaining the recording paper 16 in a flat state, disposed in a position opposing the recording head 12 ; a paper supply unit 20 for supplying recording paper 16 ; and a paper output section 22 for outputting recording paper externally, once an image has been formed thereon.
[0029] The recording head 12 is constituted by a so-called full line type head, wherein a line type head having a length corresponding to the width of the recording paper 16 is disposed in a fixed position, in a direction orthogonal to the paper conveyance direction. Recording heads 12 K, 12 C, 12 M, 12 Y corresponding to respective ink colors are disposed in the order, black (K), cyan (C), magenta (M) and yellow (Y), from the upstream side, following the direction of conveyance of the recording paper 16 (arrow A). Nozzles (not shown) are formed in each of these recording heads, and a color image, or the like, is formed on the recording paper 16 by discharging ink of the colors from the nozzles, onto the recording paper 16 , whilst conveying the recording paper 16 . The details of the recording head 12 are described hereinafter.
[0030] Roll paper 26 is set in place detachably on a paper supply unit 20 . Pickup rollers 21 for picking up the recording paper 16 from the roll paper 26 are provided in the vicinity of the paper supply unit 20 . The force of a motor (not shown) is transmitted to at least one of the pick-up rollers 21 , and the recording paper 16 picked up thereby is conveyed from right to left in FIG. 1 . Reference numeral 24 is a shearing cutter disposed between the rollers 21 , and the recording paper 16 picked up from the roller paper 26 is cut to a prescribed size by means of the cutter 24 .
[0031] The belt conveyance unit 18 has a structure wherein an endless belt 38 is wound about rollers 30 , 32 , 34 and 36 , and is composed in such a manner that at least the portion opposing the recording head 12 is a horizontal surface. This belt 38 has a broader width dimension than the width of the recording paper 16 , and the recording paper 16 can be suctioned onto the surface of the belt. The drive force of a motor (not shown) is transmitted to at least one of the rollers 30 , 32 , 34 , 36 about which the belt 38 is wound, whereby the belt 38 is driven in a counterclockwise direction in FIG. 1 , and hence the recording paper 16 suctioned onto the belt 38 is conveyed from right to left in FIG. 1 .
[0032] Reference numeral 82 denotes a recording determination unit for reading in the position, size, and the like, of the recording paper, reference numeral 84 denotes a recording position determination unit for determining the timing of ink discharge onto the recording paper 16 , and reference numeral 88 denotes a recording paper end detection unit for detecting a stacking of the recording paper 16 and for determining the supply timing of the next sheet. Furthermore, the image forming apparatus 10 has a system controller (not shown) which controls the whole image forming apparatus 10 on the basis of the detection results from these detection units. The system controller is constituted by a central processing unit (CPU) and peripheral circuits, and the like, and it generates, for example, drive signals and control signals for the motors for conveying the recording paper 16 , and image forming signals for the recording head 12 , and the like.
[0033] Next, the structure of the recording head 12 will be described. Since the structure of the recording heads 12 K, 12 C, 12 M and 12 Y provided for the ink colors are similar, each of the recording heads is denoted with the reference numeral 12 hereinafter, as a representative example of the recording heads. FIG. 2 is a plan view of the recording head 12 , and FIG. 3 is a partial enlarged cross-sectional view of the recording head 12 .
[0034] As shown in FIG. 3 , the recording head 12 is composed of a nozzle plate 42 formed in a square plate shape, partitions 43 , a vibration plate 44 , a common electrode 46 , a piezoelectric element 48 , discrete electrodes 50 , and the like. As shown in FIG. 3 , pressure chambers 54 are formed by the empty spaces enclosed by the nozzle plate 42 , the plurality of partitions 43 , and the vibration plate 44 , and the pressure chambers 54 are disposed in a staggered matrix arrangement in the positions indicated by the reference numerals 50 in FIG. 2 . The pressure chambers 54 are connected to an ink supply passage (not shown), whereby ink is supplied to the interior of the pressure chambers 54 .
[0035] A nozzle 56 connected to the lower face of the nozzle plate 42 is formed through the nozzle plate 42 in a position corresponding to the lower portion of each of the pressure chambers 54 . The vibration plate 44 is arranged on the ceiling face of the pressure chambers 54 in such a manner that the vibration plate 44 seals the pressure chambers 54 , and the grounded common electrode 46 is arranged on the upper face of the vibration plate 44 .
[0036] The piezoelectric element 48 is a single plate, and has a rectangular shape similar to the nozzle plate 42 . The piezoelectric element plate 48 is arranged on the upper face of the common electrode 46 . The discrete electrodes 50 are arranged on the upper face of the piezoelectric element 48 , in positions opposing the pressure chambers 54 . When an electric field is applied to the piezoelectric element 48 in the vertical direction in FIG. 3 , by means of the discrete electrode 50 and the common electrode 46 , the piezoelectric element 48 deforms in a lateral direction (mode d 31 ), in other words, in the directions of arrows B in FIG. 3 . The piezoelectric element 48 is connected on the vibration plate 44 through the common electrode 46 and when the piezoelectric element 48 deforms in the lateral direction, both the piezoelectric element 48 and the vibration plate 44 bend downwards as represented with alternate long and two short dashes lines in FIG. 3 , thereby causing the volume of the pressure chamber 54 to change, and thus applying a pressure wave to the pressure chamber 54 .
[0037] In the regions of the four outer edges of the discrete electrodes 50 on the piezoelectric element 48 , a plurality of piezoelectric strain absorbing holes 52 are formed. The piezoelectric strain absorbing holes 52 are formed passing in a direction orthogonal to the sheet of FIG. 2 .
[0038] When a drive voltage is applied to the discrete electrode 50 , the vibration plate 44 deforms due to the deformation of the piezoelectric element 48 as shown with the alternate long and two short dashes lines in FIG. 3 , thereby causing the volume of the pressure chamber 54 to change, and thus applying a pressure wave to the pressure chamber 54 , in response to which ink is discharged from the nozzle 56 . A connection circuit board (not shown) for providing electrical connections to a drive circuit for applying drive voltage to the discrete electrodes 50 provided inside the image forming device 10 , is installed in the recording head 12 .
[0039] Next, the action of the recording head 12 having the composition described above will be explained.
[0040] In order to form an image on the basis of an image forming pattern, drive voltages are applied to the discrete electrodes 50 from the drive circuit, in accordance with a system controller. As shown in FIG. 3 , the piezoelectric element 48 deforms in a lateral direction (the directions of the arrows B in FIG. 3 ), and the vibration plate 44 forming the ceiling face of the pressure chamber 54 bends projectingly towards the pressure chamber 54 as shown with the alternate long and two short dashes lines in FIG. 3 , whereby a pressure wave is applied to the pressure chamber 54 . Upon application of the pressure wave, ink is discharged from the pressure chamber 54 through the nozzle 56 . The ink thus discharged is deposited onto the recording face of the recording paper 16 , whereby an image is formed on the recording paper 16 . When the application of the drive voltage is terminated, the piezoelectric element 48 and the vibration plate 44 which had deformed revert to their state prior to deformation. When they revert in this manner, new ink of approximately the same volume as the ink that has been discharged is supplied to the pressure chamber 54 from the ink supply passage (not shown). This ink discharging operation is performed repeatedly, and an image based on an image forming pattern is formed on the recording paper 16 as it is conveyed.
[0041] Here, when the piezoelectric element 48 is deformed in the lateral direction, internal stress arises in the piezoelectric element 48 to the outer sides of the discrete electrode 50 , but this internal stress is eliminated by means of the piezoelectric strain absorbing holes 52 . More specifically, since the piezoelectric strain absorbing holes 52 are formed in the piezoelectric element 48 , which bends and deforms together with the vibration plate 44 , in the region of the outer perimeter of the discrete electrode (active element) 50 , then it is possible to eliminate cross-talk to the piezoelectric element 48 at other adjacently positioned pressure chambers.
[0042] As shown in FIGS. 4A to 4 E, various shapes and positional configurations may be adopted for the piezoelectric strain absorbing holes 52 . In an example shown in FIG. 4A , piezoelectric strain absorbing holes 52 a are disposed along the four outer edges of each discrete electrode 50 as in the above-described embodiment. In an example shown in FIG. 4B , rectangular shaped piezoelectric strain absorbing holes 52 b are disposed along the four outer edges of each discrete electrode 50 . In an example shown in FIG. 4C , piezoelectric strain absorbing holes 52 c are disposed in a staggered matrix arrangement along the four outer edges of each discrete electrode 50 . In an example shown in FIG. 4D , oval-shaped piezoelectric strain absorbing holes 52 d are disposed along the four outer edges of each discrete electrode 50 . In an example shown in FIG. 4E , piezoelectric strain absorbing holes 52 e of different sizes are disposed along the four outer edges of each discrete electrode 50 .
[0043] The piezoelectric element 48 according to the present embodiment is constituted by a single plate, and hence costs are low and processing is straightforward.
[0044] Next, a method for manufacturing the piezoelectric element 48 used in the recording head 12 according to the present embodiment is described with reference to FIGS. 5A to 5 E. This process advances sequentially from FIG. 5A to FIG. 5E .
[0045] Firstly, in FIG. 5A , a green sheet 60 is laid provisionally on a base plate 62 .
[0046] As shown in FIG. 5B , a common electrode 46 is printed onto the surface of the green sheet 60 , by means of a screen printing technique.
[0047] As shown in FIG. 5C , the green sheet 60 is turned over from the state in FIG. 5B , and discrete electrodes 50 are then printed onto the other surface (i.e., reverse to the surface on which the common electrode 46 has been formed) of the green sheet 60 , by means of a screen printing technique. The positions at which the discrete electrodes 50 are formed are previously set in such a manner that they correspond to nozzles 56 arranged in a matrix configuration.
[0048] As shown in FIG. 5D , piezoelectric strain absorbing holes 52 are then pierced in the green sheet 60 , by means of a pressing machine 64 .
[0049] As shown in FIG. 5E , after degreasing the green sheet 60 , it is calcined, thereby forming a plate of piezoelectric element 48 . Thereupon, the plate of piezoelectric element 48 is bonded to a vibration plate 44 ( FIG. 3 ), whereby the formation process for the piezoelectric element 48 relating to the present embodiment is completed.
[0050] Here, as shown in FIG. 6 , the vibration plate 44 and the piezoelectric element 48 are bonded by means of adhesive 66 . In this case, the piezoelectric strain absorbing holes 52 form escape regions for surplus adhesive 66 a , and as shown in FIG. 6 , stable bonding of the vibration plate 44 and the piezoelectric element 48 is achieved by means of the surplus adhesive 66 a entering into the piezoelectric strain absorbing holes 52 .
[0051] Next, the inkjet recording head relating to a second embodiment of the present invention is described with reference to FIGS. 7A and 7B . Elements which are the same or similar to those of the first embodiment illustrated in FIG. 2 and FIG. 3 are denoted with similar reference numerals and detailed description thereof is omitted here.
[0052] As shown in FIGS. 7A and 7B , in the recording head 100 relating to the present embodiment, grooves 102 for absorbing piezoelectric strain are formed in the vibration plate 44 in positions opposing the piezoelectric strain absorbing holes 52 .
[0053] According to the recording head 100 composed as described above, it is possible further to alleviate any stress generated in the vibration plate 44 by piezoelectric strain, and therefore, the elimination of cross-talk can be promoted.
[0054] The composition of the inkjet recording head, the inkjet recording apparatus and the method for manufacturing an inkjet recording head indicated in the embodiments described above are not limited to the foregoing embodiments. For example, as shown in FIG. 8 , it is also possible to solder electrode lead sections 112 for the discrete electrodes 50 onto the sections where no piezoelectric strain absorbing holes 52 are formed, by means of a ball grid array, or the like, as in the recording head 110 . In this way, the electrodes from the discrete electrodes 50 can be wired in an integrated fashion, by means of these electrode lead sections 112 .
[0055] Moreover, although the discrete electrodes 50 are formed by screen printing before calcining in the above-described embodiments, the invention is not limited to this, and they may also be installed by sputtering, vapor deposition, or the like, after calcining.
[0056] It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the invention is to cover all modifications, alternate constructions and equivalents falling within the spirit and scope of the invention as expressed in the appended claims. | The inkjet recording head comprises: a plurality of ink chambers aligned, each of the plurality of ink chambers having a nozzle; and a piezoelectric element arranged on an outer side of the plurality of ink chambers, the piezoelectric element using displacement in d 31 direction, piezoelectric strain absorbing holes being formed through the piezoelectric element in regions of outer perimeters of active sections of the piezoelectric element, wherein when voltage is applied to one of the active sections of the piezoelectric element, corresponding one of the plurality of ink chambers is compressed by the piezoelectric element, and ink filled in the one of the plurality of ink chambers is discharged through the nozzle toward a recording medium. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. patent application Ser. No. 12/632,411 entitled “DOWNHOLE JARRING TOOL,” filed Dec. 7, 2009, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This disclosure relates to downhole tools in general and, more specifically, to impact jars for freeing stuck tools.
BACKGROUND OF THE INVENTION
Drilling operations have become increasingly expensive as the need to drill in harsher environments, through more difficult materials, and deeper than ever before have become reality. Additionally, more testing and evaluation of completed and partially finished well bores has become a reality in order to make sure the well produces an acceptable return on investment.
In working with more complex and deeper well bores, a greater danger arises that work strings and tools will be stuck within the bore. In addition to the potential to damage equipment in trying to retrieve it, the operation of the well must generally stop while tools are fished from the bore. Moreover, with some fishing techniques, it is possible to damage the well bore itself.
Any tool designed for use in a downhole environment may be subject to heat, pressure, and unclean operating conditions. Internal components may be subject to repeated stresses that must be overcome in order to function reliably, and for a suitable length of time, to warrant inclusion in the work string. Additionally, economies may be realized by constructing a tool that is wear resistant enough to be used for a lengthy periods of time before breakdowns or rebuilds.
What is needed is a device for addressing the above and related concerns.
SUMMARY OF THE INVENTION
The invention of the present disclosure, in one aspect thereof comprising a jarring tool having an extensible joint connecting first and second sub ends. The joint comprises a first inner latch piece connected to the upper sub end, second outer latch piece connected to the lower sub end, and a stationary restraining collar. The joint, in a latched position, has the outer latch piece latched to the inner latch piece and the inner and outer latch piece restrained from unlatching by the restraining collar. Under tensile force, the joint unlatches into an unlatched position by the outer latch piece pulling the inner latch piece through the restraining collar into a position where the inner and outer latch pieces are free to separate. An impact force is generated from the tensile force when the joint unlatches and reaches a maximum extension.
In some embodiments, the joint relatches into a latched position by the outer latch piece pushing the inner latch piece back through the restraining collar into a position where the inner and outer latch pieces are free to relatch.
The outer latch piece may comprises a collet device that may have a plurality of fingers with nubs along distal ends that contact a lip on the inner latch piece when being moved into the latched or unlatch positions through the restraining collar. The collet may be biased toward the inner latch piece by a coil spring.
In some embodiments, the tool includes a lower shaft interconnecting the inner latch piece to the lower sub end, and a lower stop slidably receiving the lower shaft. The impact force at maximum extension results from contact between the lower shaft and the lower stop. The tool may also include an upper sub housing connected to the upper sub end, a lower sub housing, a center connector connecting the upper sub housing and the lower sub housing, an upper shaft slidably received through the center connector and connecting to the upper latch piece, and a plurality of springs biasing the upper shaft away from the center connector. The restraining collar may attached in a fixed relationship to the lower sub housing. The plurality of springs may comprise a plurality of spring washers. A coil spring may abut the plurality of spring washers and a spring cage may partially surround the coil spring.
In some embodiments, a central passage is defined through the extensible joint and through the upper and lower sub ends. An electrical conductor may be carried within the central passage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1D taken together provide a side cutaway view of one embodiment of the jarring tool of the present disclosure.
FIGS. 2A-2E taken together provide a side cutaway view of another embodiment of the jarring tool of the present disclosure.
FIGS. 3A-3D taken together provide a side cutaway view of an embodiment of a jarring tool with reduced wear latch according to aspects of the present disclosure.
FIGS. 4A-4D taken together provide a side cutaway view of another embodiment of a jarring tool with reduced wear latch according to aspects of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1A-1D , a side cutaway view of one embodiment of a downhole jarring tool according to aspects of the present disclosure is shown. These drawings are meant to be understood sequentially as adjoining segments of a jarring tool 100 . FIG. 1A illustrates the uppermost end of the tool 100 , which is to be followed by FIG. 1B , FIG. 1C , and FIG. 1D . In the present embodiment, FIG. 1D illustrates the bottom most portion of the jarring tool 100 . In the present embodiment, the jarring tool 100 includes an upper sub housing 102 having a distal end 104 attached to an upper sub end 106 . A proximal end 108 of the upper sub housing 102 interconnects with a center connector 110 . The center connector 110 joins the upper sub housing 102 with a lower sub housing 112 . A proximal end 114 of the lower housing 112 connects to the center connector 110 .
A distal end 116 of the lower housing 112 is connected to a lower stop 118 . In the present embodiment, the lower stop 118 provides for sliding engagement and limited passage of the lower shaft 120 . The lower shaft 120 may be interconnected to a lower sub end 122 . The range of motion of the lower shaft 120 relative to the lower housing 112 may be limited by both the lower sub end 122 and by an inner shoulder 124 of the lower stop 118 . The lower shaft 120 provides a shoulder 126 , which will be too wide to pass through the lower stop 118 . As will be described in greater detail below, when the jarring tool 100 is activated, the upper sub end 106 will extend away from the lower sub end 122 to the point where inner shoulder 124 of the lower stop 118 contacts the lower shaft shoulder 126 .
The lower shaft 120 connects to an inner latch piece 128 . The inner latch piece 128 interfits with an outer latch piece 130 . In the present embodiment, the outer latch piece 130 is a collet device. In order to secure adequate transmission of tensile forces between the inner latch piece 128 and the outer latch piece 130 , the inner latch piece 128 may have a lip 129 extending substantially around a proximal end of the latch piece 128 . Similarly, outer latch piece 130 may have a lip 131 on one or more of the collet fingers of the latch piece. Additionally, a release sleeve 132 , which restricts the diameter to which the outer latch 130 may open, may be placed in an appropriate fixed location within the lower sub housing 112 .
The upper latch piece 130 may be connected to an upper shaft 134 . In the present embodiment, there may be a number of interposing parts, such as a latch connector 136 , an outer latch connector 138 , and a bias spring 140 . The full function of the additional parts will be explained in greater detail below. However, from the present description, it can be appreciated that the latch connector 136 and outer latch connector 138 serve generally to interconnect the upper shaft 134 to the outer latch piece 130 . The outer latch connector 138 may slide in through the outer latch piece 130 and interfit into the latch connector 136 . The outer latch connector 138 allows a limited degree of sliding to occur with respect to the outer latch piece 130 . In the present embodiment, the bias spring 140 will keep the outer latch piece 130 generally extended away from the upper shaft 134 but will allow a limited degree of movement in the direction of the upper shaft 134 .
The upper shaft 134 may extend generally through the upper sub housing 102 and engage a washer stack 142 or other spring mechanism. The washers of the washer stack 142 may be spring washers, such as Belleville washers. In some embodiments, the entire region between a distal end 135 of the upper shaft 134 and the center connector 110 will be substantially filled with the washer stack 142 . However, in other embodiments, such as the one shown in FIG. 1 , it may not be necessary or desirable to completely fill this region with spring washers. In such case, a slack spring 144 may be provided and may be separated from the washer stack 142 by a washer 146 . The washer 146 may be a flat washer that may or may not be attached to the upper shaft 134 . As will be described in greater detail below, the washer stack 142 will be subject to compressive forces between the distal end 135 of the upper shaft 134 and the center connector 110 . Because the slack spring 144 may have a much lower spring rate than the washer stack 142 , a spring cage 148 may be utilized to limit the amount of compression received by the slack spring 144 .
In some embodiments, the slack spring and/or washer stack 142 may bear directly against the center connector 110 when the device 100 is under tensile stress. However, in the present embodiment, the center connector 110 is provided with an adjustment sleeve 149 on the end connecting to the upper sub housing 102 . Thus, in the present embodiment, the spring cage 148 or the slack spring 144 will bear against the adjustment sleeve 149 . The adjustment sleeve 149 may be threaded or otherwise adjustably attached to the center connector 110 . A set screw 150 may be utilized to prevent the sleeve 149 from coming out of adjustment. In some embodiments, the relative location of the washer stack 142 and the slack spring 144 may be reversed. Additionally, the adjustment sleeve 149 may be located at the distal end 135 of the upper shaft 134 .
In operation, the jarring tool 100 may be used in a well bore or other downhole environment to free stuck tools or other equipment. The present exemplary embodiment is designed primarily for use with a slick line work string, but other embodiments are also contemplated as described below.
In one method of use, the jarring tool 100 will be included with the downhole work string, possibly near the bottom of the string. For example, the upper sub end 106 could connect to the uphole string while the lower sub end connects to a tool on location in the work string where a stickage is likely to result. In some respects, the tool 100 may be considered as a pair of sub ends 106 , 122 having an extensible joint therebetween.
In the configuration shown in FIGS. 1A-1D , the jarring tool 100 is shown in a closed or latched position. At the point the line or tool becomes stuck within a well bore, the tool may be activated by supplying sufficient tensile forces to the sub ends 106 , 122 . As the sub ends 106 , 122 are pulled apart, it will be appreciated that the lower shaft 120 will pull against the inner latch piece 128 . The inner latch piece 128 and/or the lip 129 coming in contact with the outer latch piece 130 and/or lip 131 will pull the distal end 135 of the upper shaft 134 against the washer stack and/or slack spring 134 .
The slack spring 144 may have a limited range of motion before the spring cage 148 will engage the washer 146 and/or the washer stack 142 . It will be appreciated that the washer stack 142 may have an extremely high spring rate such that many hundreds or thousands of pounds of force are required to effectively overcome the force of the springs. In the present embodiment, the outer latch 130 is limited in its ability to disconnect from the inner latch 129 by the fixed release sleeve 132 . However, when sufficient tensile strength has been applied to the tool 100 , so as to displace the inner latch 128 and the outer latch 130 sufficiently through the release sleeve 132 , the outer latch 130 will be free to slip free from the inner latch 128 . The energy stored in the work line will rapidly displace the tool 100 in the direction of the upper sub end 136 . However, the lower sub end 122 , being attached to the stuck tool or line, will remain in place. The lower shaft 122 will then slide axially through the lower stop 118 until the lower shaft shoulder 126 impacts the inner shoulder 124 of the stop 118 . It is this impact resulting from the line tension on the work string suddenly being released that will create a sufficient upward impact on the lower sub end 122 to free the stuck tool, line, or other device.
In some cases, it may be that a single jarring impact will not be sufficient to remove the stuck tool or line. It is also possible that once the tool or line has been freed, it will become stuck again. For this reason, the jarring tool 100 is resettable such that repeated impact jars may be provided in the wellbore. When a compressive force is applied to the tool after it is unlatched, the inner latch piece 128 will encounter the outer latch piece 130 within the release sleeve 132 . However, as described, the release sleeve 132 does not provide sufficient clearance for the inner latch 128 and the outer latch 130 to reconnect. Therefore, in order to reset or relatch the tool 100 , the outer latch piece 130 must be sufficiently displaced through the release sleeve 132 to allow sufficient clearance to relatch to the inner latch piece 128 .
In the present embodiment, the outer latch piece 130 may be slidably attached to the outer latch connector 138 . The bias spring 140 will normally keep the outer latch piece 130 within the release sleeve 132 . However, when the bias spring forces overcome the outer latch piece 130 may displace toward the proximal end 114 of the lower sub housing 112 a sufficient amount to clear the release sleeve 132 and thereby relatch with the inner latch piece 128 . At this point, the tool has been reset and may be activated to produce jarring forces again by reapplication of a tensile force. It will be appreciated that the spring rate of the bias spring 140 may be much lower than the spring rate of the washer stack 142 . In this way, the amount of force necessary to reset or relatch the tool 100 will be very small in comparison to the amount of force required to activate the tool 100 by unlatching.
Referring now to FIGS. 2A-2E , another embodiment of the jarring tool of the present disclosure is shown. As with FIG. 1 , FIGS. 2A-2E comprise a segmented illustration of the entire length of the tool 200 . In the present disclosure, like numbered parts are similar from one drawing to the next, and thus it will be appreciated that the tool 200 bears many similarities to the tool 100 . However, the present embodiment 200 illustrates an e-line version of the jarring tool of the present disclosure
It can be seen that connected to the upper sub end 106 is a conductor housing 204 . The conductor housing 204 may be another sub section that forms a part of the work string. An upper electrical connector 202 may cap off the upper housing 204 and provide for electrical connections to a conductor 206 that runs the length of the tool 200 . The conductor 208 could be a single line or could be a braided or multiplexed line carrying a plurality of signals through the tool 200 . A plug 208 may be provided according to the type of conductor being utilized. As can be seen with reference to FIGS. 2A-2E , a central passage 210 is provided through the entirety of the tool 200 . A lower electrical connector 216 is provided for attachment to work line or tools that are below the jarring tool 200 .
The jarring tool 200 operates in a manner that is similar to the operation of the jarring tool 100 described previously. However, since there may be locations within the passageway 210 that the conductor 206 could be pinched or otherwise damaged, protective sheathing may be provided as needed. In the present embodiment, a stainless steel shaft 214 is provided to prevent the conductor 206 from being damaged by the inner latch 128 and/or the outer latch 130 . It will be appreciated that the length of the conductor 206 may need to change with the length of the tool 200 as the tool is examined for jarring or impacting. In the present embodiment, it can be seen that the conductor 206 may be coiled or otherwise stored within the conductor housing 204 such that the conductor is allowed to expand and contract with the tool 200 .
It will be appreciated that various embodiments of the tools of the present disclosure can be utilized with a wide variety of drilling and downhole technology. Non-limiting examples include drill pipe, e-line, and slick line strings. The sub ends 106 , 122 may be chosen according to the work string. Similarly, the overall size of the tools 100 , 200 may be chosen based on well bore size and other requirements. Both the jarring force and the tension required to activate the tools may be adjusted and fine tuned based upon the number and type of spring washers in the stack 142 and the adjustment of the adjusting sleeve 149 .
Referring now to FIGS. 3A-3D , a side cutaway view of an embodiment of a jarring tool with a reduced wear latch according to aspects of the present disclosure is shown. It will be appreciated that the jarring tool 300 bears some similarity in construction with regard to some components as the tool 100 previously described. However, it can be seen in FIG. 3A that the slack spring 144 and spring cage 148 are now nearer the distal end 104 of the upper housing 102 . As before, a center washer 146 interposes the slack spring 144 and the washer stack 142 . Both the slack spring 148 and the washer stack 142 remain concentrically confined around the upper shaft 134 . In the present embodiment, the spring cage 148 abuts, and may be attached to, the distal end 135 of the upper shaft 134 .
As with previous embodiments, the upper shaft 134 is permitted to slide through the center connector 110 . The upper shaft 134 also connects with a latch piece as in previous embodiments. However, the latch of the jar 300 differs in some respects from those previously described. In the present embodiment, the upper shaft 134 is connected to an inner latch connector 302 . This piece may join the upper shaft 134 to a latch stub 304 . It can be seen that the latch stub 304 has a flare or lip 305 on a distal end. Retained by the latch stub 304 is an inner latch 306 . A flare or lip 307 of the inner latch 306 may abut a flare or lip 305 on the latch stub 304 .
In the present embodiment, the inner latch 306 is restrained by the upper shaft 134 against tensile forces by the inner latch connector 302 connecting to the latch stub 304 . However, a limited degree of movement under compressive force may be allowed from the inner latch 306 sliding along the latch stub 304 toward the inner latch connector 302 . A spring 308 may be provided that interpose the inner latch 306 and a lip 310 on the inner latch connector 302 in order to bias the inner latch 306 away from the upper shaft 134 .
In the view of FIG. 3C , the tool 300 is shown in a latched configuration. In this embodiment, an outer latch 312 connects to the lower shaft 120 . In the present embodiment, the outer latch 312 is a collet having a plurality of fingers with raised nubs 313 .
In operation, as with previous embodiments, the tool 300 may be subject to tensile forces to activate, or unlatch, the tool. In the present embodiment, a tensile force pulling on the lower sub end 122 will translate to a pulling force on the lower shaft 120 . This will cause the outer latch 312 to pull the inner latch 306 . This force will result in the upper shaft 134 compressing the slack spring 144 and the washer stack 142 . It will be appreciated that the slack spring 144 may compress much more easily than the washer stack 142 , owing to differing spring rates. Thus, the amount of force required to activate or unlatch the tool 300 may be varied, based upon the relative amount of compression required of the slack spring 144 and the washer stack 142 . The size of the spring cage 148 , which does not compress, will also be a factor.
When the outer latch 312 has displaced the inner latch 306 a significant degree toward the distal end 116 of the lower housing 112 , the flare or lip 307 and the nubs 313 will be pulled free of the release sleeve 132 . The outer latch 312 will then be free to disengage from the inner latch 306 . It will be appreciated that because the outer latch 312 disengages from the inner latch 306 and does not encounter any internal components of the tool 300 as it is withdrawn toward the distal end 116 of the lower housing 112 , wear to the outer latch 312 will be reduced relative to an embodiment where the outer latch 312 may encounter the release sleeve 132 or another component.
In the present embodiment, the outer latch 312 is a collet and disengages from the inner latch 306 by expanding to become wider than the inner latch 306 . Because the collet fingers will be under strain in this condition, they may be particularly susceptible from wear from impacts and other forces within the tool 300 . Since the inner and outer latch 306 , 312 do not separate until the outer latch 312 is drawn clear of the release sleeve 132 as the lower shaft 120 is drawn toward the distal end 116 of the lower sub housing 112 , reduced wear is achieved. Because the inner latch 306 does not expand or contract in the latching or unlatching process, it may be withdrawn by the force of the slack spring 144 and/or the washer stack 142 through the release sleeve 132 at a high rate of speed without the possibility of damage or excessive wear.
Referring now to FIGS. 4A-4D , another embodiment of a jarring tool with a reduced wear latch according to aspects of the present disclosure is shown. The tool 400 is an e-line tool. As such, it is provided with the conductor 206 and plugs 208 , 212 . This embodiment differs from the previously discussed e-line embodiment in that the coiled conductor 206 is housed directly within the upper sub housing 102 rather than a separate conductor housing. Rather than slick line style sub ends, the tool 400 is provided with an electrical connector type sub end 402 attached to the distal end 104 of the upper sub housing 102 . Similarly, a lower electrical connector 404 is provided attached to the lower shaft 120 . A central passageway 210 is defined through the length of the tool 400 in order to pass the conductor 206 .
In the present embodiment, the lower shaft 134 and the distal end 135 of the lower shaft are formed from separate pieces. The distal end 135 in the present embodiment abuts the concentrically arranged washer stack 142 . In this manner, as in previous embodiments, the tensile forces on the upper shaft 134 will be transmitted to the washer stack 142 via the distal end 135 of the upper shaft. In the present embodiment, the inner latch 306 is concentrically arranged around a portion of the upper shaft 134 . It can be seen that the upper shaft 134 may extend all the way through the center connector 110 , the inner latch piece 306 , the outer latch piece 312 , and into the lower shaft 120 . In this manner, the integrity of the center passageway 210 is maintained throughout the length of the tool 400 , particularly through the area containing the moving latch pieces. As with previous embodiments, the coiled conductor 206 is allowed to expand with the expansion of the tool 400 . However, actual expansion and contraction of the conductor 206 will generally occur in the upper housing 102 .
In the present embodiment, the upper shaft 134 connects directly with the inner latch 306 . Tensile forces may be transferred from the inner latch piece 306 to the upper shaft 134 by pressure between the inner latch piece 306 and a shoulder 406 of the upper shaft. When the lower shaft 120 pulls against the outer latch piece 312 engagement the nubs 313 with the lip 307 , the upper shaft 134 will be forced to press against the washer stack 142 . As before, when the nubs 313 and lip 307 have cleared the release sleeve 132 , the latch piece 306 , 312 will disengage and separate. It will be appreciated that in the present embodiment, as the tool expends to generate an impact force, the lower shaft 120 will slide along the outside of the upper shaft 134 . In this manner, the integrity of the central passage 210 is maintained.
In the present embodiment, the inner latch piece 306 may again be forced through the restraining sleeve 132 by the outer latch piece 312 to accomplish relatching or resetting of the tool 400 . In the present embodiment, the spring 308 interposes the center connector 110 and inner latch piece 306 to bias the inner latch piece 306 toward the distal end 116 of the lower sub housing 112 . As with the embodiment of FIG. 3 , because the outer latch piece 312 is allowed to freely recoil, reduced wear to this component and possibly others will result.
Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims. | A jarring tool having an extensible joint connecting first and second sub ends. A first inner latch piece connects to the upper sub end, and a second outer latch piece connects to the lower sub end. The joint, in a latched position, has the outer latch piece latched to the inner latch piece and the inner and outer latch pieces restrained from unlatching by a stationary restraining collar. Under tensile force the joint unlatches into an unlatched position by the outer latch piece pulling the inner latch piece through the restraining collar into a position where the inner and outer latch pieces are free to separate. An impact force is generated from the tensile force when the joint unlatches and reaches a maximum extension. | 4 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates generally to heat exchangers, and more particularly relates to headers for heat exchangers.
[0003] 2. Background Information
[0004] Typically, automotive vehicles are provided with an engine cooling system with a heat exchanger, such as a radiator. When the engine is running, heat is transferred from the engine to a coolant that flows through the engine, thereby cooling the engine. The coolant then flows from the engine to the heat exchanger through a series of conduits. At the heat exchanger, heat is transferred from the coolant to cooler air that flows over the outside of the heat exchanger. This process repeats itself in a continuous cycle.
[0005] A typical heat exchanger includes a series of tubes supported by two headers. One type of conventional header is a flat header. When these flat headers are joined to a respective tube, for example, by brazing, the joint between the header and the tube lies in a flat plane. These types of header/tube combinations are prone to failure because of the stress concentrations that occur along the header/tube joint. These stresses are typically attributable to the thermal loading (i.e., stresses induced by the rise and fall of the temperature of the heat exchanger components) on the header and tubes during the operation of the engine.
[0006] From the above, it is seen that there exists a need for an improved heat exchanger header that experiences less thermal loading.
BRIEF SUMMARY
[0007] In overcoming the above mention and other drawbacks, the present invention provides a heat exchanger header which when combined with a tube removes the highest stress concentrations in the header/tube joint.
[0008] In one embodiment, a header for a heat exchanger includes a substantially planar base portion and a pair of step portions. The step portions are angled from the plane of the base portion. The step portions are connected by either a straight or a curved section. The header is also provided with a plurality of substantially parallel slots spaced apart along the length of the header. Each slot has an elongate section extending across the width of the base portion and end sections extending from the elongate section into the step portions of the header.
[0009] Various embodiments of the header can have one or more of the following features. The end sections each can have terminal ends spaced apart from the plane of the base portion, defining a separation distance. Each slot can be provided with a tube inserted into the slot. In certain embodiments the tube is brazed to the respective slot. The juncture between each tube and the elongate section of a respective slot defines a transition line of deformation spaced apart from the highest stress concentrations occurring in the brazing joint at or near the location of the juncture between the terminal ends and the tube.
[0010] The foregoing discussion has been provided only by way of introduction. Nothing in this section should be taken as a limitation on the following claims, which define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, incorporated in and forming a part of the specification, illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the views. In the drawings:
[0012] FIG. 1 depicts an automotive radiator;
[0013] FIG. 2A depicts a portion of a conventional heat exchanger header with a flat tube;
[0014] FIG. 2B is a side view of the conventional header with a portion of the flat tube along the line 2 B- 2 B of FIG. 2A ;
[0015] FIG. 3A depicts a portion of a heat exchanger header with several flat tubes in accordance with the invention;
[0016] FIG. 3B depicts the header of FIG. 3A with one of the flat tubes in accordance with the invention;
[0017] FIG. 3C is a view of the header along the line 3 C- 3 C of FIG. 3B ;
[0018] FIG. 4 depicts a conventional flat header without tubes;
[0019] FIG. 5 depicts a trapezoidal header without tubes in accordance with the invention;
[0020] FIG. 6 is a cross-sectional view of an alternative header in accordance with the invention; and
[0021] FIG. 7 is a cross-sectional view of yet another alternative header in accordance with the invention.
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates a typical automotive radiator 2 with a heat exchanger core or matrix 3 . The core 3 includes a number of parallel coolant tubes 4 with heat exchanger fins 5 of concertina form positioned between and in contact with the tubes 4 . The tubes 4 are mounted to a pair of headers 6 . A pair of side walls 7 provide additional structural support to the core 3 . When the radiator 2 is in use, coolant heated by the engine enters an inlet 8 and circulates through the tubes 4 as air moves through the fins 5 . As such, heat in the tubes 4 is exchanged with the air passing through the fins. The cooler coolant exits the radiator 2 through an exit 9 and returns to the engine to repeat the engine cooling process.
[0023] A heat exchanger in an automotive vehicle typical experiences a significant amount of thermal loading, since the heat exchanger is subjected to extreme temperature variations during its lifetime, thereby leading to a failure of the exchanger. For example, referring to FIG. 2A , in a conventional heat exchanger tube 10 , failure, such as a crack, caused by thermal loading usually occurs on the tube at or near the intersection 12 between a flat tube 14 and a header 16 , in particular, at the location 22 where the externally induced stress (or service stress) from the thermal loading overlaps with the highest stress concentrations of the joint between the header 16 and tube 14 , as described below in greater detail.
[0024] Externally induced service stress typically occurs on the tube at or near the boundary between the tube 14 and the header 16 . On one side of this boundary (i.e. the internal or coolant side), the tube 14 does not deform because of the restriction of the header 16 . On the other side, however, the tube 14 deforms under thermal loading. For purposes of illustration, the intersection of the tube 14 and the header 16 define a plane, which in turn defines a “transition line of deformation” 20 , as shown in FIG. 2B , when the tube/header combination is viewed along the line 2 B- 2 B of FIG. 2A .
[0025] The tube 14 and header 16 are in many cases joined together by a suitable process, for example, by brazing. Thus, stresses occur along the brazing between the tube 14 and header 16 . Note that stress concentration is a physical property related to the geometry of the tube-to-header joint configuration. The highest stress concentration generally occurs at or near the narrowest region of the tube 14 that intersects the header 16 , namely, at the locations identified by the reference numerals 22 . When the “transition line of deformation” 20 overlaps the “stress concentration” 22 , as in the case of the tube/header combination of FIGS. 2A and 2B , the externally induced stress intensifies, leading typically to early failure of the heat exchanger.
[0026] Referring now to FIG. 3A , there is shown a heat exchanger 30 with flat tubes (now identified as 32 ), cooling fins 5 positioned between the tubes 32 , and a header 34 in accordance with the invention. Referring also to FIGS. 3B and 3C , the header 34 is configured to separate the externally induced service stress along the aforementioned “transition line of deformation” 20 from the highest stress concentrations occurring at the narrowest regions 36 of the juncture between the tube 32 and the header 34 . This separation (d) effectively reduces the stress intensification at these regions 36 and distributes the stress more evenly over the entire tube-to-header joint, thereby prolonging the tube-to-header joint life. As shown in FIG. 3B , a header with a trapezoidal cross section can achieve such a separation.
[0027] For the sake of comparison, a conventional flat header 40 shown in FIG. 4 was compared with that of a trapezoidal header 50 shown in FIG. 5 in thermal cycling tests. As can be seen in the comparison of FIGS. 4 and 5 , the conventional header 40 has a series of essentially straight tube slots 42 , while the trapezoidal header 50 has tube slots 52 that are not straight. Instead, each slot 52 has an elongate section 54 extending across a planar portion 56 of the header 50 and two end sections 58 that extend from the elongate section 54 into two stepped portions 60 of the header. The stepped portions 60 and hence the end sections 58 of the slots 52 rise at an angle, following a straight segment (or a curved segment as shown in FIGS. 6 and 7 ), from the plane of the planar portion 56 , such that the terminal ends 62 of the end sections 58 are separated from the plane of the planar portion 56 by the separation distance (d). Depending upon the application of the header 50 , the separation distance (d) may be the range from about 2 mm to about 20 mm. Surrounding each slot 52 is a raised region 64 . These regions 64 provide added rigidity to the header 50 and a convenient platform along which the tubes are brazed to the header 50 .
[0028] In certain embodiments, the header 50 is made from a metal such as aluminum or steel, or any other suitable material. Depending on the vehicle, the header 50 can be provided with six to two hundred slots. The slots 52 are spaced apart by about 4 mm to 15 mm, and each slot 52 is about 1 mm to 12 mm wide. The elongate section 54 of each slot is about 3 mm to 85 mm long and the end sections 58 are about 2.5 mm to 28 mm long. As mentioned above, each slot 52 is joined to a respective tube by a suitable method such as brazing, soldering, or mechanically assembling.
[0029] An example of the results of the thermal cycling tests is shown below in Table 1. In these tests, the headers were subjected to a cyclic thermal loading with a high-low temperature differential of about 130° C.
TABLE 1 Crack Initiation Crack Propagation Radiator Failed Flat Header 110 Cycles 119 cycles 119 cycles (two samples) Trapezoidal 854 Cycles No visible crack Tests for two Header propagation samples were suspended after 1572 cycles
[0030] In Table 1, crack initiation cycle is defined as the cycle count at which there is evidence of coolant at the tube/header joint. Crack propagation cycle is defined as the cycle count at which there are several drops of coolant leakage per cycle. And radiator failure cycle is defined as the cycle count at which the test is terminated because of significant amount of leakage of coolant from the heat exchanger. As can be seen in Table 1, crack initiation occurred in the flat header around 110 cycles, and crack propagation was seen around 119 cycles. Thus, the radiator with the flat header was considered to have failed at 119 cycles. This example used a sample size of two for each configuration.
[0031] As for the trapezoidal header, crack initiation was observed around 854 cycles. However, crack propagation was never observed; that is, the radiator did not fail during the test. The test for the trapezoidal header was eventually terminated at 1572 cycles. In view of the above, it is seen that radiators provided with trapezoidal headers have life spans that vastly exceed that of radiators with flat headers.
[0032] It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention. For example, as shown in FIGS. 6 and 7 , the header 34 can be provided with convex segments 70 ( FIG. 6 ) or concave segment 72 ( FIG. 7 ) rather than the straight segments shown in FIG. 3C . | A header for a heat exchanger includes a substantially planar base portion and a pair of step portions. The step portions are angled from the plane of the base portion. The header is also provided with a plurality of substantially parallel slots spaced apart along the length of the header. Each slot has an elongate section extending across the width of the base portion and end sections extending from the elongate section into the step portions of the header. | 5 |
CROSS-REFERENCE TO RELATED DISCLOSURES
Applicant's copending U.S. Pat. No. 4,153,307 is incorporated herein by reference as to the method of operation of the 2/2-way valves described therein.
BACKGROUND OF THE INVENTION
The invention relates to a pressure control valve unit of the type such as is shown in the German Offenlegungsschrift No. 2,625,502. In this known construction, the relay valve monitors only an outside-air connection. It is also known to embody anti-locking protection pressure control valves as complete relay valves, as is shown in the German Auslegeschrift No. 1,630,544. The main advantages in doing so, besides being able to omit the special relay valves or rapid-release valves as well which are often required are as follows:
During normal braking (without anti-locking protection control):
rapid aeration and ventilation in long brake lines;
rapid-release effect when releasing the brake;
movement of the switching elements during each braking occurence; and
load-dependent control devices with small flow-through cross sections when attached to the control circuit.
During regulated braking (when there is anti-locking protection control):
a pressure gradient substantially independent of brake cylinder volume, because of the unitary effect; brake cylinders of different size as well as cylinder volumes which become larger with surface wear have no effect on the regulatory effectiveness;
the inclusion and regulation of several brake cylinders is possible simultaneously, such as in the case of axle regulation.
However, the relatively large structural volume of these valves has a disadvantageous effect on the regulatory function. The long switching times caused thereby result in insufficient pressure modulation values, which do not permit sufficient regulator performance for individual wheel regulation.
Also with respect to cost, relay pressure control valves for individual wheel regulation are too expensive, since, of course, for this type of regulation, a relay pressure control valve is required for each wheel.
Relay pressure control valves therefore are most often utilized as axle regulation valves, that is, for a type of regulation in which several brake cylinders are simultaneously regulated so that they have a common brake pressure level.
In contrast, rapid-switching valves of simple design (without a relay function and without a proportional characteristic), of small structural volume, are inserted for individual wheel regulation; however, because of their functional characteristic, they do not have the advantages, which are in themselves desirable for individual wheel regulation as well, of the relay pressure control valves.
OBJECT AND SUMMARY OF THE INVENTION
The pressure control valve unit of the invention has the advantage over the prior art in that by combining individual switching elements of relay and switching valves, the advantages of these two valve groups are united, without, however, the imposition of their inherent disadvantages.
It is of further advantage that new areas of utilization can be entered with the pressure control valve unit according to the invention, these areas extending beyond the normal anti-locking protection function and being attainable by means of relatively simple additional switching arrangements.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a sectional view of a pressure control valve unit constructed in accordance with the invention;
FIG. 2 is a plan view, partially in section, of a three-channel embodiment of the invention;
FIG. 3 is a sectional view of the embodiment of FIG. 2 rotated by 90°;
FIG. 4 is a plan view of the arrangement of magnetic valves for the embodiment of FIG. 1; and
FIG. 5 is a sectional view of a portion of another embodiment of the pressure control unit of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a reserve supply container 1 is connected at one side to a pedal brake valve 2 and on the other side to a pressure control valve unit 4 through a reserve supply line 3. A control line 5 proceeds from the brake valve 2 which also leads to the pressure control valve unit 4.
The reserve supply line 3 is attached within the pressure control valve unit 4 to a reserve pressure chamber 6, which has a valve seat 7 for a closing body 8 of a relay valve 9. A pressure-relieving rod 10 of the closing body 8 penetrates the valve seat 7 and supports a diaphragm plate 11 at its other end which is intended for cooperation with a switching diaphragm 12.
The rod 10 and the diaphragm plate 11 are located within a pressure exchange chamber 13, which is defined by a valve seat 14 and communicates, when the diaphragm 12 rests on the valve seat 14, with reserve pressure and, when the diaphragm 12 is lifted from the valve seat 14, communicates with outside air through an annular channel 15 as shown also in FIG. 5. The seat 14 and the diaphragm 12 thus form an outlet valve 12/14. A control chamber 12' is disposed beneath the diaphragm 12.
The pressure exchanger chamber 13, in the two-channel embodiment shown in FIG. 1, has further lateral valve seats 16 and 17 for 2/2-way valves 18 and 19, which have diaphragm-closing members 20 and 21 disposed within a chamber 22 and 23 with which the brake cylinder lines 26 and 27 leading to the brake cylinders 24 and 25 respectively, communicate. On the other side of the diaphragm-closing members 20 and 21, there are control chambers 33 and 34, respectively.
Three magnetic valves 29, 30 and 31 in the form of 3/2-way valves are disposed within a lower housing portion 28. These magnetic valves 29, 30, 31 are pre-control valves for the control chambers 12', 33 and 34. The lower housing portion 28 has an outside-air attachment 32 at the bottom which is monitored by a check valve and is covered at the top by an upper housing portion 50, which includes the relay valve 9 and the valve 12/14.
Mode of Operation
The control chamber 12' is subjected to pressure through the control line 5 when the magnetic valve 30 is open, i.e., when there is no current. The switching diaphragm 12 moves upward, contacts the valve seat 14, and thereby blocks the connection between the pressure exchanger chamber 13 and the ventilation as shown best in FIG. 3.
Subsequently the pressure-relieving valve rod 10 is lifted by the diaphragm plate 11 and the closing body 8 is lifted from its seat 7. Reserve air flows from the chamber 6 through the opened 2/2-way valves 18 and 19 to the brake cylinders 24 and 25 and braking occurs.
In the pressure exchange chamber 13, a pressure builds up which rises, as reactive pressure, until the pressure level of the control pressure in the control chamber 12' is reached. By means of the balance of forces thus obtained at the switching diaphragm 12, the spring-loaded valve rod 10 can move toward the valve seat 7 and reach it. In this position, the switching diaphragm 12 rests on the valve seat 14. By this means, reserve pressure, brake cylinder pressure and ventilation are mutually blocked.
If the control pressure below the switching diaphragm 12 is dropped, for example, through the brake valve 2 or through the magnetic valve 30 as well, then the reactive pressure in the chamber 13 immediately predominates and lifts the switching diaphragm 12 from the valve seat 14, so that the reactive pressure and thus, when the 2-way valves 18, 19 are not blocked, the brake pressure in the brake cylinders 24 and 25 as well are decreased until such time as the balance of forces has been reinstated.
In addition to the means of regulating brake cylinder pressure by the control pressure, the brake cylinder pressure in the attached brake cylinders 24 and 25 can also be influenced by the 2-way valves 18 and 19, which can be actuated through the pre-control magnetic valves 29 and 21, in such a manner that the brake pressures in the brake cylinders 24 and 25 can be blocked by the pressure exchange chamber 13. Since this blocking function can occur by way of the 2-way valves 18 and 19 independently of the particular position at that time (pressure decrease or pressure buildup) of the relay valves, the following pressure functions are attainable simultaneously:
pressure decrease in both brake cylinders 24 and 25;
pressure decrease in one brake cylinder and pressure maintenance in the other brake cylinder;
pressure maintenance in one brake cylinder and pressure buildup in the other brake cylinder;
pressure buildup in both brake cylinders 24 and 25, to the same or to different pressure levels.
Thus, either a common or an individual wheel regulation can be performed with only one pressure control valve unit 4, with additional functional advantages, beyond those found in the switching valves conventionally employed in individual wheel regulation, which are derived from the relay function.
As is indicated by broken lines in FIG. 1, the reserve pressure chamber 6 can also be supplied with control line pressure via a control line 51, instead of with reserve pressure.
In the embodiment of FIG. 2, an arrangement for a three-channel brake pressure control means is shown. In FIG. 2, there is shown a T-shaped arrangement of three 2-way valves 35, 36 and 37, which make possible three-channel brake pressure control having only one pressure control valve unit. Four brake cylinders 39, 40, 41 and 42 are attached to the pressure control valve unit 38 through brake cylinder lines 39', 41' and 42'. The 2-way valve 37 has two brake cylinder line attachments, so that all four brake cylinders can be attached, each to its own brake cylinder line attachment.
Regulating a double-axle unit with individual wheel regulation on one vehicle axle and a common brake pressure control on the other axle is also conceivable. Although, in this event, there are widely varying brake cylinder volumes to be aerated and ventilated, since, depending on the requirements of the type of regulation, either individual brake cylinders or all at once must be aerated and ventilated, so that constant pressure gradients are produced by the unitary function.
This unitary function is accomplished in that the given control circuit having a constant control chamber volume is aerated and ventilated through the magnetic valve 30 (FIG. 1) having flow-through cross sections which are likewise constant, yielding a pressure gradient which is shaped accordingly. As a result of the necessary balance between control circuit and reactive circuit, the pressure gradient of the reactive circuit as well is predetermined and is automatically regulated, by means of a corresponding stroke setting at both the relay valve 9 and the outlet valve 12/14, to correspond with the particular brake cylinder volume to be aerated and ventilated.
Since, however, because of the valve hysteresis there is a certain inertia between control pressure and reactive pressure, it would be relatively difficult to control exact brake pressure values in the brake cylinders without the rapid 2-way valves 18, 19 or 35, 36, 37; in particular, insufficient pressure modulations, some of them substantial in extent, would be unavoidable.
Thus, it is advantageous that the rapid-switching, differential-piston-type 2-way valves embodied in a double-diaphragm arrangement are disposed directly in the connection between the reactive circuit and the brake cylinders. In this way, the regulatory effectiveness, which is absolutely necessary for individual wheel regulation, is attainable with assurance even with a multiple-channel relay pressure control valve, such as is shown in FIGS. 1 and 2.
Furthermore, as with the novel arrangement of component parts, functional dependability for the construction of the pressure control valve unit of the invention has been obtained. For example, the disposition of the valves is selected so that water condensation which might appear in air brakes can automatically flow down by force of gravity to the central outside-air connection which is located at the bottom, or can also easily be carried to the outside during ventilation as shown in FIGS. 1 and 3.
In order that the control chambers of the 2-way valves 18, 19 and 35, 36, 37 operate with similar advantages, their diaphragm-closing members were disposed as double diaphragms in a standing position and the magnetic valves 29, 30 and 31 were located at the lowest point of the pressure control valve unit. The connection bores to the brake cylinders 24 and 25, or 39, 40, 41, 42, were also located at the lowest point of the 2-way valve. For reasons of the same considerations, the magnetic valves 29, 30 and 31 were disposed in a suspended position beneath the control chambers 12', 33 and 34.
The disposition of the central outside-air attachment 32, which represents a common outside-air connection for the relay valve and the magnetic valves produces distinct advantages and furthermore protects against the intrusion of water spray from outside.
Measures were also taken to damp the noise generated by the ventilation operations, which take place in sudden bursts. It can be seen by reference to FIG. 1 and FIG. 3, which illustrates the outside-air connection more clearly, that the lower housing portion 28, which has the central outside-air connection 32 at its lowest point and into which an outside-air channel attached to the annular channel 15 discharges, has a relatively large cavity 43. In this cavity 43, the magnetic valves 29, 30, and 31 are held only by strips 44. In this manner, the cavity 43 is effective as a damping chamber, which produces a significant noise damping of the ventilation operations.
Furthermore, the lower housing portion 28 provided with strips 44 permits a simple and cost-effective mounting of the magnetic valves 29, 30 and 31, which are simply pressed into position and are then immovably seated.
FIG. 4 shows in plan view a central magnetic valve plug 47, by means of which all the magnetic valves 29, 30 and 31 are controllable.
The pressure control valve unit 4 according to the invention also permits utilization in other areas with particularly advantageous results. Thus, when building in or attaching a magnetic valve through an internal connecting line, reserve pressure can be directed into the control chamber 12' directly by the magnetic valve 30. As a result, brake pressure can be directed into the attached brake cylinders through the additional magnetic valve as well as through the brake valve 2. Although the pressure control by the brake valve is effective at all axles, the control can intentionally be accomplished at individual brake cylinders through the additional magnetic valve.
With the aid of this one additional magnetic valve and a relatively simple expansion of the anti-locking protection logic circuit, a regulation of drive slippage, for example, can be performed at the driving axle of a railway car. The slipping wheel (rotating without traction), which can be recognized by the anti-locking protection logic circuit through the wheel sensors, is then braked through the additional magnetic valve and simultaneously the buildup of brake pressure for the non-slipping wheel is prevented by blocking the associated 2-way valve. By means of regulating both wheels to the same slippage, that is, to the same rpm, the effect of a mechanical blockage differential can be precisely attained, but with very much less expense.
As has been conventional so far, the state of readiness for slippage regulation can be initiated by the driver, for example, through a switch, or automatically as well by means of the expanded anti-locking protection logic circuit, which recognizes the slipping wheel through a positive slippage shaft and initiates the automatic slippage regulation. Of course, the additional magnetic valve can also be disposed anywhere in the vehicle.
In place of a magnetic valve, the pressure control of individual brake cylinders can also be accomplished with a conventional, mechanically actuated 3/2-way valve, which can, for example, be engaged by a toggle for the duration of the drive slippage regulation at the driver's direction.
If, instead of the toggle, a lockable control with a separate key is provided, then theft protection can also be obtained, which in the simplest manner prevents the unauthorized appropriation of the vehicle by braking the attached brake cylinders.
Beyond the advantages already described, the structure having the additional magnetic valve also has the advantage that all the valve elements, including the magnetic valves, can be tested under pressure. By simultaneously setting all the magnetic valves, pressure is directed into the relay valve, but the further brake pressure buildup in the brake cylinders is prevented by blocking the 2-way valves, so that even during driving, a test cycle can be run.
It is also advantageous that when braking with the brake valve, the control chambers are charged with brake valve pressure. In this manner, it is always possible for the driver to release the brakes, at any time and independently of the valve position or of the magnetic valve position as well--an advantage which in known constructions must be provided by supplementary check valves.
In any event, it is also conceivable that the 2-way valves be actuated by reserve pressure through the magnetic valves 29, 31. Then the advantage is that the 2-way valve can be provided with only one diaphragm. This embodiment is shown in FIG. 5.
It is also advantageous that only small control chambers are aerated or ventilated at a particular time by the magnetic valves or by the mechanically actuatable 3/2-way valve as well. As a result, these valves can be formed with small flow-through cross sections, which is favorable in terms of both effort and cost. This advantage also pertains when there is an automatically load-dependent brake pressure control device attached during initiation of control in the control circuit. Thus, and also as a result of the elimination of the relay valve often required, the utilization of the pressure control valve unit according to the invention offers significant cost advantages.
For example, as compared with conventionally employed anti-locking protection pressure control valves, the following devices can be eliminated, or smaller devices can be used, for the rear axle of a railway car:
1 relay valve;
1 anti-locking protection pressure control valve; and
1 rapid-release valve.
When employing a supplementary 3/2-way valve, a mechanical differential block and an expensive theft protection apparatus may be eliminated. Finally, a load-dependent brake pressure control device can have a small structural volume.
The foregoing relates to preferred embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A pressure control valve unit for an anti-locking apparatus in motor vehicle wheel brakes which is actuatable by a control pressure which controls the brake pressure in at least one wheel brake cylinder, the pressure control valve unit having a pressure exchange chamber, which alternatively has brake cylinder pressure and atmospheric pressure, defined by a switching diaphragm and the switching diaphragm comprising the switching member of a relay valve on one side and on the side--like the closing body of a rapid-release valve--is provided the monitor member of a brake cylinder line leading to the outside air so that the pressure control valve unit combines the advantages of relay and switching valves without their disadvantages and the valve unit can be utilized in other fields, which can be accomplished by simple additional switching arrangements and which extend beyond the normal anti-locking protection function. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The instant application is related to U.S. patent application Ser. No. 11/286,085 filed on Nov. 22, 2005, which is assigned to the same assignee as the instant application and is hereby incorporated by reference.
BACKGROUND
A modern computer system may be divided roughly into three conceptual elements: the hardware, the operating system, and the application programs. The hardware, e.g., the central processing unit (CPU), the memory, the persistent storage devices, and the input/output devices, provides the basic computing resources. The application programs, such as compilers, database systems, software, and business programs, define the ways in which these resources are used to solve the computing problems of the users. The users may include people, machines, and other computers that use the application programs, which in turn, employ the hardware to solve numerous types of problems.
An operating system (“OS”) is a program that acts as an intermediary between a user of a computer system and the computer hardware. The purpose of an operating system is to provide an environment in which a user can execute application programs in a convenient and efficient manner. A computer system has many resources (hardware and software) that may be required to solve a problem, e.g., central processing unit (“CPU”) time, memory space, file storage space, input/output (“I/O”) devices, etc. The operating system acts as a manager of these resources and allocates them to specific programs and users as necessary. Because there may be many, possibly conflicting, requests for resources, the operating system must decide which requests are allocated resources to operate the computer system efficiently and fairly.
Moreover, an operating system may be characterized as a control program. The control program controls the execution of user programs to prevent errors and improper use of the computer. It is especially concerned with the operation of I/O devices. In general, operating systems exist because they are a reasonable way to solve the problem of creating a usable computing system. The fundamental goal of a computer system is to execute user programs and make solving user problems easier. Toward this goal, computer hardware is constructed. Because bare hardware alone is not particularly easy to use, application programs are developed. These various programs require certain common operations, such as those controlling the I/O operations. The common functions of controlling and allocating resources are then brought together into one piece of software: the operating system.
In order to conserve energy, some computer systems incorporate power control mechanisms. For example, Energy Star (“E*”) power requirements require system power consumption to be lowered to 15% of the normal operating power consumption level when the system is idle. In order to conserve power, the operating system turns off (or lowers the operating frequencies of) inactive devices, such as hard disks and monitors. The operating system may also conserve power by adjusting the execution of the CPU.
SUMMARY
In general, in one aspect, the invention relates to a method for conserving power. The method includes determining a first network connection speed for a network interface card (NIC), configuring the NIC to operate at the first network connection speed, processing, after the configuration, packets received by the NIC, obtaining a bandwidth utilization of the NIC, determining, using a power management policy, a second network connection speed for the NIC based on the bandwidth utilization when the bandwidth utilization is outside a threshold range, and configuring the NIC to operate at the second network connection speed.
In general, in one aspect, the invention relates to a system. The system relates to a network interface card (NIC) configured to receive packets from a network, a network statistics module configured to determine bandwidth utilization of the NIC and a policy engine configured to determine a first network connection speed for a network interface card (NIC), obtain the bandwidth utilization of the NIC from the network statistics module, determine, using a power management policy, a second network connection speed for the NIC based on the bandwidth utilization when the bandwidth utilization is outside a threshold range, and initiate the configuration of the NIC to operate at the second network connection speed.
In general, in one aspect, the invention relates to a computer readable medium comprising computer readable program code embodied therein for causing a computer system to determine a first network connection speed for a network interface card (NIC), configure the NIC to operate at the first network connection speed, process, after the configuration, packets received by the NIC, obtain a bandwidth utilization of the NIC, determine, using a power management policy, a second network connection speed for the NIC based on the bandwidth utilization when the bandwidth utilization is outside a threshold range, and configure the NIC to operate at the second network connection speed.
Other aspects of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a system in accordance with one or more embodiments of the invention.
FIG. 2 shows a flow chart in accordance with one or more embodiments of the invention.
FIG. 3 shows a computer system in accordance with one or more embodiments of the invention.
DETAILED DESCRIPTION
Specific embodiments of the invention will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.
In the following detailed description of embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
In general, embodiments of the invention relate to a method and system for conserving power by degrading network connection speed. More specifically, embodiments of the invention relate to method and system for adjusting power consumption of a network interface card (NIC) by adjusting the network connection speed of the NIC. The ability to adjust the power consumption of the NIC allows for power management, which may result in decreased power consumption. Further, the invention provides functionality to monitor the bandwidth utilization of the NIC and adjust the network connection speed appropriately. This allows the NIC to provide the necessary amount of bandwidth while not providing additional excess bandwidth. The minimization of excess bandwidth results in a decrease in power consumption of the NIC.
FIG. 1 shows a system in accordance with one or more embodiments of the invention. The system includes a host ( 101 ) operatively connected to a network interface card (NIC) ( 102 ). The NIC ( 102 ) provides an interface between a network ( 100 ) and the host ( 101 ). In one embodiment of the invention, the network may be a wide area network (WAN), a metropolitan area network (MAN), a local area network (LAN), a public network (such as the Internet or World Wide Web), a wireless network, a telephony network, a mobile telephony network, or any combination thereof. Further, the network ( 100 ) may include one or more networks interconnected by other network types (e.g., distinct LANs connected by one or more WANs).
In one embodiment of the invention, the host ( 101 ) is configured to send packets to the network ( 100 ) and to receive packets from the network ( 100 ). In both cases, the packets are processes by various components within the host ( 101 ). Specifically, the host ( 101 ) includes a NIC driver ( 104 ), a network stack ( 106 ), and processes ( 108 ). The host ( 101 ) further includes a network statistics module ( 112 ) and a policy engine ( 110 ). Each of these components is described below.
In one embodiment of the invention, the NIC driver ( 104 ) provides an interface between the NIC ( 102 ) and the other components on the host ( 101 ). The NIC driver ( 104 ) includes functionality to receive packets from the NIC ( 102 ) (or more specifically, from specific buffers (not shown) in the NIC ( 102 )). Further, the NIC driver ( 104 ) includes functionality to send packets to the NIC ( 102 ) (or more specifically, place packets in specific buffers (not shown) in the NIC ( 102 )). The NIC driver ( 104 ) also includes an interface to allow the host ( 101 ) (or more specifically, a process executing thereon (e.g., processes ( 108 ), processes executing in the policy engine ( 110 )) configured to NIC ( 102 ). Configuring the NIC ( 102 ) may include, but is not limited to, enabling on NIC functionally to record bandwidth utilization characteristics (e.g., packets received, packets dropped) and adjusting the network connection speed (discussed below in FIG. 2 ).
Continuing with the discussion of FIG. 1 , packets received by the NIC driver ( 104 ) from the NIC ( 102 ) are sent to the network stack ( 106 ). In one embodiment of the invention, the network stack ( 106 ) includes functionality to process the packets received from the network ( 100 ) in accordance with one or more protocols. In one embodiment of the invention, the network stack ( 106 ) supports Internet Protocol (IP) processing (including IPv4 and IPv6), Transmission Control Protocol (TCP) processing, and User Datagram Processing (UDP). The network stack ( 106 ) may also support any other network layer, transport layer, and application layer protocols.
Once the packets have been processed by the appropriate protocols in the network stack ( 106 ), the packets are forwarded to the processes ( 108 ). In one embodiment of the invention, the processes ( 108 ) may be operating system processes. Alternatively, the processes ( 108 ) may be user-level application processes.
When a process ( 108 ) sends a packet to the network ( 100 ), the packet must pass through the network stack ( 106 ), NIC driver ( 104 ), and NIC ( 102 ) prior to reaching the network ( 100 ). Each of the above components processes the packet, as necessary, before sending the packet to the next component.
Continuing with the discussion of FIG. 1 , the host includes a network statistics module ( 112 ) and a policy engine ( 110 ). In one embodiment of the invention, the network statistics module ( 112 ) is configured to obtain bandwidth utilization characteristics from the various components in the host ( 101 ) as well as from the NIC ( 102 ) to determine anticipated bandwidth utilization and current bandwidth utilization.
In one embodiment of the invention, the network statistics module ( 112 ), via the NIC driver ( 104 ), may obtain bandwidth utilization characteristics from the NIC ( 102 ). The bandwidth utilization characteristics from the NIC ( 102 ) provide incoming bandwidth utilization (i.e., information about the number of packets received by the NIC ( 102 ), number of packets dropped by the NIC ( 102 ), etc.). In addition, the bandwidth utilization characteristics from the NIC ( 102 ) provide outgoing bandwidth utilization (i.e., the number of packets sent to the network ( 100 ) from the NIC ( 102 )).
In addition, the network statistics module ( 112 ) may also obtain bandwidth utilization characteristics from the network stack ( 106 ). The network stack ( 106 ) may provide outgoing bandwidth information, which specifies the number of packets the network stack receives from the processes ( 108 ). In addition, the network stack ( 106 ) may also include information about the time elapsed between receiving the packets from the processes ( 108 ) to the packets being sent to the NIC driver ( 104 ). The information about the elapsed time may be important in determining whether there is sufficient outgoing bandwidth on the host ( 101 ).
In one embodiment of the invention, the policy engine ( 110 ) is configured to determine the network connection speed of the NIC ( 102 ) (see FIG. 2 ). The policy engine ( 110 ) uses various sources of input to determine the network connection speed of the NIC ( 102 ). For example, the policy engine ( 110 ) may use information about the bandwidth utilization from the network statistics module ( 112 ), a power management policy, and NIC information.
In one embodiment of the invention, the power management policy defines a maximum power consumption of the NIC ( 102 ) and a time of day when the power management policy is in effect. More specifically, the power management policy may specify the number of kilowatt-hours (kWh) the NIC ( 102 ) may consume during a specific portion of the day. For example, the power management policy may indicate that the NIC may consume no more than 0.002 kWh during the hours 6:00 pm-6:00 am and consume no more than 0.004 kWh during the hours of 6:01 am-5:59 pm.
In one embodiment of the invention, the policy engine ( 110 ) may include a number of different power management policies. For example, the policy engine ( 110 ) may include a power management policy that is applied when power conservation is more important than network connection speed. In such cases, the power management policy may specify a maximum power consumption of the NIC (that is less than the power consumption of the NIC at the highest network connection speed the NIC supports), which may not be exceeded regardless of bandwidth utilization requirements. The policy engine ( 110 ) may also include a power management policy that is applied when network connection speed is more important than power conservation. In such cases, the power management policy may not include a maximum power consumption for the NIC (or the maximum power consumption is set at or above the power consumption of the NIC at the highest network connection speed the NIC supports).
In one embodiment of the invention, the NIC information defines the network connection speeds supported by the NIC ( 102 ). For example, the NIC ( 102 ) may be a 10 gigabit network card and support the following network connection speeds: (i) 10 gigabit/s Full Duplex; (ii) 10 gigabit/s Half Duplex; (iii) 1 gigabit/s Full Duplex; (iv) 1 gigabit/s Half Duplex; (v) 100 megabit/s Full Duplex; (vi) 100 megabit/s Half Duplex; (vii) 10 megabit/s Full Duplex; (viii) 10 megabit/s Half Duplex; (ix) 1 megabit/s Full Duplex; and (x) 1 megabit/s Half Duplex. In one embodiment of the invention, the granularity of the network connection speeds supported by the NIC may be larger or smaller than the granularity of the network connection speeds in the above example. In one embodiment of the invention, the NIC information may also define the power consumption of the NIC ( 102 ) at each network connection speed. Alternatively, the NIC information may include a formula (or other information) to enable the policy engine ( 110 ) to determine the power consumption of the NIC ( 102 ) at each network connection speed.
In one embodiment of the invention, the network statistics module ( 112 ) and the policy engine ( 110 ) are located in the same software layer as the NIC driver ( 102 ) (i.e., data link layer in the Open Systems Interconnection Basic Reference Model or the data link layer in the Internet Reference Model). Alternatively, the network statistics module ( 112 ) and the policy engine ( 110 ) may be located at other software layers within the host ( 101 ). For example, the network statistics module ( 112 ) may be located in the data link layer and the policy engine ( 110 ) may be located in the application layer (as defined by the Open Systems Interconnection Basic Reference Model or the Internet Reference Model).
FIG. 2 shows a flow chart in accordance with one or more embodiments of the invention. While the various steps in this flowchart are presented and described sequentially, one of ordinary skill will appreciate that some or all of the steps may be executed in different orders and some or all of the steps may be executed in parallel.
In Step 200 , NIC information is obtained. In embodiment of the invention, the NIC information may be obtained by querying the NIC, querying the NIC driver, or from another source. In Step 202 , the power management policy is obtained. In one embodiment of the invention, Step 202 may include selecting the appropriate power management policy to apply, if more than one power management policy exists. Alternatively, Step 202 may include accessing the power management policy, if only one power management policy exists.
In Step 204 , the anticipated bandwidth utilization is determined. In one embodiment of the invention, the anticipated bandwidth utilization may be determined using historical bandwidth utilization obtained from the network statistics module. Alternatively, the anticipated bandwidth utilization may be a default value.
In Step 206 , the initial network connection speed is determined using the NIC information, the power management policy, and the anticipated bandwidth utilization. In one embodiment of the invention, the anticipated bandwidth and NIC information are used to determined a proposed initial network connection speed. For example, if the anticipated bandwidth is 0.25 gigabits/s and the NIC information indicates that the NIC supports network connection speeds of 1 megabit/s, 10 megabits/s, 100 megabits/s and 1 gigabit/s, then the proposed initial network connection speed may be 1 gigabit/s. The power management policy is subsequently used to determine whether the proposed initial network connection speed satisfies the maximum power consumption for the NIC defined in power management policy. If the power consumption of the NIC at 1 gigabit/s exceeds the maximum power consumption, then the proposed initial network connection speed may be reduced to 100 megabits/s. The power consumption of the NIC at 100 megabits/s is determined using the NIC information and then compared to the maximum power consumption defined in the power management policy. In this example, the power consumption of the NIC at 100 megabits/s is less than the maximum power consumption defined in the power management policy. Thus, 100 megabits/s is set at the initial network connection speed.
If the power consumption of the NIC at 100 megabits/s was not less than the maximum power consumption defined in the power management policy, then the proposed initial network connection speed may be reduced to 10 megabits/s and the above process repeated until the maximum power consumption defined in the power management policy was satisfied.
In Step 208 , the NIC is configured using the network connection speed specified in Step 206 (or Step 216 if the process reaches Step 208 from Step 216 ). In Step 210 , the operating system may also be configured, as necessary, based on the network connection speed used in Step 208 . In one embodiment of the invention, if the NIC ( 102 ) and host ( 101 ) support bandwidth control on a per-connection basis, then various components in the NIC ( 102 ) and host ( 101 ) may be configured (or re-configured) such that the bandwidth allocations to the various connections is proportionally adjusted in view of the network connection speed. U.S. patent application Ser. Nos. 11/112,367, 11/112,322, and 11/480,000 define various methods and systems for enforcing bandwidth control on a per-connection basis. The aforementioned U.S. patent applications are assigned to the same assignee as the instant application and are hereby incorporated by reference.
In Step 212 , the bandwidth utilization of the host ( 101 ) is monitored using the mechanisms discussed above. In Step 214 , a determination is made about whether the bandwidth utilization is outside a threshold range. For example, if the network connection speed is 10 megabits/s with a threshold range of +5 megabits/s and the bandwidth utilization is determined to be 11 megabits/s, then the bandwidth utilization is not outside the threshold range.
In one embodiment of the invention, the threshold range is defined globally for all network connection speeds or defined on a per-network connection speed basis. Further, the threshold ranges may be determined by the host ( 101 ) (or a user using the host ( 101 )).
If the bandwidth utilization is not outside the threshold range, then the process ends or may proceed back to Step 212 . If the bandwidth utilization is outside the threshold range, then in Step 216 the network connection speed is determined using the NIC information, the power management policy, and the bandwidth utilization (obtained in Step 214 ). Step 216 uses the same methodology as Step 206 defined above. Once the network connection speed is determined, the process proceeds to Step 208 .
The invention may be implemented on virtually any type of computer regardless of the platform being used. For example, as shown in FIG. 3 , a computer system ( 300 ) includes a processor ( 302 ), associated memory ( 304 ), a storage device ( 306 ), and numerous other elements and functionalities typical of today's computers (not shown). The computer ( 300 ) may also include input means, such as a keyboard ( 308 ) and a mouse ( 310 ), and output means, such as a monitor ( 312 ). The computer system ( 300 ) is connected to a local area network (LAN) or a wide area network (e.g., the Internet) (not shown) via a network interface connection (not shown). Those skilled in the art will appreciate that these input and output means may take other forms.
Further, those skilled in the art will appreciate that one or more elements of the aforementioned computer system ( 300 ) may be located at a remote location and connected to the other elements over a network. Further, the invention may be implemented on a distributed system having a plurality of nodes, where each portion of the invention (e.g., policy engine, processes) may be located on a different node within the distributed system. In one embodiment of the invention, the node corresponds to a computer system. Alternatively, the node may correspond to a processor with associated physical memory. The node may alternatively correspond to a processor with shared memory and/or resources. Further, software instructions to perform embodiments of the invention may be stored on a computer readable medium such as a compact disc (CD), a diskette, a tape, a file, or any other computer readable storage device.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | In general, in one aspect, the invention relates to a method for conserving power. The method includes determining a first network connection speed for a network interface card (NIC), configuring the NIC to operate at the first network connection speed, processing, after the configuration, packets received by the NIC, obtaining a bandwidth utilization of the NIC, determining, using a power management policy, a second network connection speed for the NIC based on the bandwidth utilization when the bandwidth utilization is outside a threshold range, and configuring the NIC to operate at the second network connection speed. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority benefit under 35 U.S.C. §119(e) of U.S. provisional application No. 60/183,062, filed Feb. 16, 2000.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the production of protective coatings for carbonaceous components of electrolytic cells used in the production of aluminum. The invention more specifically relates to coating compositions which provide carbonaceous components of electrolytic cells with protection from deterioration during electrolysis and components containing the same.
2. Description of Related Art
The manufacture of aluminum is conducted conventionally by the Hall-Heroult electrolytic reduction process, whereby alumina is dissolved in molten cryolite and electrolyzed at temperatures of about 900 to 1000° C. This process is conducted in a reduction cell typically comprising a steel shell provided with an insulating lining of suitable refractory material, which is in turn provided with a lining of carbon which contacts the molten constituents. One or more anodes, typically made of prebaked carbon blocks, are connected to the positive pole of a direct current source, and suspended within the cell. One or more conductor bars connected to the negative pole of the direct current source are embedded in the carbon cathode substrate comprising the floor of the cell, thus causing the cathode substrate to become cathodic upon application of current.
Prebaked anodes used in the production of aluminum are comprised of an aggregate of petroleum coke with pitch as a binder, while the carbon lining is typically constructed from an array of prebaked cathode blocks, rammed together with a mixture typically comprising of anthracite, tar, and coal tar pitch.
Aluminum is produced in a molten form within an electrolysis cell as a result of the following reaction:
2Al 2 O3+3C→4Al+3CO 2
In the conventional design of the Hall-Heroult cell, aluminum collects as a pool of molten aluminum along the base of the cell. In doing so, oxygen becomes liberated and reacts with the available carbon on the surface of the anodes to produce carbon dioxide gas. Theoretically, 0.334 kg of anodic carbon is consumed per kilo of aluminum produced as represented by the above reaction. In reality, however, anodic consumption is 25-35% greater.
Excess consumption of the prebaked anodes is the result of a series of secondary reactions, which can be summarized as follows:
i) Air oxidation: oxidizing reactions result from oxygen in the air contacting the upper part of the anode and, if the anode is left unprotected, reacting to produce carbon dioxide;
ii) Boudouard reaction: carbo-oxidation reactions result from CO 2 at the surface of the anode being immersed in the electrolyte and producing carbon monoxide (known as the Boudouard equilibrium); and
iii) Dusting: the selective oxidation of pitch coke with respect to petroleum coke, results in the release of carbon particles, generating dust, which has negative effects on the operation.
The loss effected by such secondary reactions within the electrolytic cell amounts to approximately 10% of the production cost of aluminum.
The economic inefficiencies of aluminum production can be further attributed to the deterioration of the carbon lining or cathodic material of the electrolytic cell as a result of erosion and penetration of electrolyte and liquid aluminum, as well as intercalation by metallic sodium.
Although the Hall-Heroult process for aluminum production is the most reliable to date, there is a continual need for improvement. In view of the economic impact of the inefficiencies of this process, considerable effort has focused on the development of improved electrolytic cell components which are capable of withstanding the harsh conditions imposed by the electrolysis of aluminum.
For instance, U.S. Pat. No. 3,852,107 to Lorkin et al. teaches of an impermeable protective coating for electrodes comprising a matrix having a melting point under 1000° C. and a refractory filler, dissolved or suspended in a liquid carrier such as water. As an example, the matrix component of this coating was described as a graphite wettable material such as boric acid and/or a glaze forming material such as sodium aluminum fluoride. Suggested refractory fillers include oxides, carbides, nitrides or borides. The use of a suitable surface tension modifying agent such as chrome ore was suggested in certain situations to improve the wetting of the graphite.
U.S. Pat. No. 4,624,766 to Boxall, et al. describes an aluminum wettable, cured, carbonized cathode material for use in aluminum electrolysis cells, comprising a hard refractory material in a carbonaceous matrix which includes a carbonaceous filler and carbon fiber bonded by a non-graphitized amorphous carbon, this matrix having a rate of ablation essentially equal to the rate of wear and dissolution of the refractory hard material in the operating environment of the cell.
Sekhar et al., WO 98/17842 published Apr. 30, 1998, describes a method for applying a refractory boride to components of an aluminum electrolysis cell by forming a slurry of particulate preformed refractory boride in at least two grades of colloidal carriers selected from the group consisting of colloidal alumina, yttria, ceria, thoria, zirconia, magnesia, lithia, monoaluminum phosphate, cerium acetate and mixtures thereof, the two colloidal carriers preferably each being of the same colloid, followed by drying. The two grades of colloidal carrier have mean particle sizes which differ from one another by about 10-50 nanometers.
U.S. Pat. No. 5,486,278 to Manganiello discloses a method of impregnating a carbonaceous cell component with a boron-containing solution to improve resistance to deterioration during cell operation. When water was used as the solvent for the boron-containing solution, a surfactant was required to achieve an acceptable treatment time. Alternatively, the solvent could be chosen from methanol, ethylene glycol, glycerin and mixtures thereof. This method required the intake of the boron-containing solution to a depth of 1-10 cm into the component to be protected. This patent further disclosed that the air oxidation of carbonaceous components treated in this manner was comparable to the net consumption of similar components treated with traditional aluminum protective coatings.
Despite previous efforts, conventional techniques for performing the electrolysis of aluminum are still employed most often. This indicates that a more technically superior or economically profitable method of combating carbonaceous cell component deterioration is not known.
Lignosulfonates, such as ammonium lignosulfonate, have long been used as binders in a variety of different industries but not in aluminum electrolysis cells.
It is an object of the present invention to provide an effective and economical method of treating components of an electrolytic cell, for producing aluminum, to protect them from deterioration during operation of the cell.
BRIEF SUMMARY OF THE INVENTION
The present invention in its broadest aspect relates to a method of treating a carbonaceous cell component of an electrolytic cell for the production of aluminum, to improve the resistance of the component to deterioration during operation of the cell. The method comprises preparing a liquid suspension of refractory material dispersed in a lignosulfonate binder solution and applying the liquid as a protective coating to the carbonaceous cell component, followed by drying the coating. The refractory material may be selected from a wide variety of refractory compounds, such as boron, zirconium, vanadium, hafnium, niobium, tantalum, chromium and molybdenum compounds.
As a by-product of the pulp and paper industry, lignosulfonate is both abundant and relatively inexpensive. It has been found to be surprisingly effective as a binder in the harsh environment of an aluminum electrolysis cell.
According to one embodiment of the invention, lignosulfonate binder is used in the coating of prebaked carbon anodes. For this purpose, a liquid suspension is prepared of a boron compound, e.g. boric acid, boron oxide, hydrated boron oxide or borax, aluminum fluoride and a lignosulfonate binder, e.g. ammonium or calcium lignosulfonate, and the liquid suspension is applied as a protective coating on the anode. Typically, it is applied to the portions of the anode which are exposed to the atmosphere during cell operation. Following application, the coating is dried, e.g. by air drying at room temperature. For greater coating strength, the suspension may also include a phenolic resin binder.
In accordance with a further embodiment of the invention, the lignosulfonate binder is used for coating carbon cathode structures of an aluminum electrolysis cell. For this purpose, a liquid suspension is prepared of a refractory boride, e.g. titanium diboride, a lignosulfonate binder and a phenolic resin binder. This liquid suspension is then applied as a protective coating to the cathode structure, followed by drying.
DETAILED DESCRIPTION OF THE INVENTION
As the formulation base of the liquid suspensions of the present invention, lignosulfonate acts as a dispersant for dispersing the ingredients in the bulk liquid state, a wetting agent for even application of the coating and a binder to create a continuous layer of suspended solids which effectively adheres to the carbonaceous surface.
Oxidation of the upper part of prebaked anodes during cell operation is one of the principal reasons for excess net carbon consumption. In general, prebaked anodes are covered with alumina, crushed bath or a mix thereof to protect them against air oxidation. The practice of applying an aluminum coating to anodic components in Hall-Heroult cell, to reduce the rate of air oxidation is widely used in aluminum production. However, this practice is not optimal with a net carbon consumption of approximately 410-460 kg/t Al. Not to mention, the exorbitant costs associated with aluminum coatings.
One preferred embodiment of the present invention provides a mixture of a boron compound, e.g. boric acid, boron oxide, hydrated boron oxide or borax, and aluminum fluoride dispersed in a lignosulfonate binder as a viscous liquid. In this form, the liquid may be applied to the surface of an anodic surface by pulverization (spraying). Upon drying, a protective coating exists which is capable of combating deterioration of the anode by oxidation. This viscous liquid can be applied to the upper one-half to one-third region of a prebaked anode at ambient temperature with an air gun at 120 psi pressure and allowed to dry at room temperature for approximately 3 hours. The coating is preferably applied over a general thickness range of 0.5 to 2mm. Application of the coating to an approximate thickness of 1 mm is most preferred.
The viscous coating liquid typically contains about 20 to 60% by weight of a 50% lignosulfonate solution, 25 to 60% by weight of boric acid and 0 to 25% by weight of aluminum fluoride. A preferred range is 20 to 40% lignosulfonate (50% solution), 30 to 55% boric acid and 0 to 15% aluminum fluoride. A particularly preferred range is 25-35% lignosulfonate (50% solution), 35-55% boric acid and 0-10% aluminum fluoride. The coating liquid may also contain up to 20% by weight of phenolic resin.
During operation in an aluminum electrolysis cell, the temperature of the top of the anodes in the cell reach approximately 550 to 650° C. When coated with the above viscous coating liquid, and dried, the anodes are protected against oxidation by the formation of a boron and aluminum oxide coating on the anode.
A significant decrease in net carbon consumption is estimated for anodic components, having the protective coating as taught by this invention. It is estimated that the coating composition of this invention provides a savings of approximately $3 per ton of metal produced for each percent decrease in net carbon consumption.
Another preferred embodiment of the invention relates to a process for protecting the exposed surface of cathode blocks in an aluminum electrolysis cell, by applying a coating comprising titanium diboride dispersed in a mixture of lignosulfonate and phenolic resin. Such a coating provides wetting properties and erosion resistance as well as significantly reducing the deterioration of the underlying layers due to sodium and bath penetration. This coating mixture typically contains about 5 to 40% by weight lignosulfonate (50% solution), about 5 to 40% by weight phenolic resin, about 20 to 70% by weight titanium diboride and 0 to 5% anthracite (or graphite). A preferred composition contains about 14 to 20% lignosulfonate (50%), about 14 to 20% by weight phenolic resin and about 50 to 70% by weight titanium diboride and 2% to 5% by weight anthracite (<74 micron). While titanium boride is the preferred material for this purpose, a wide variety of borides may be used, e.g. zirconium, vanadium, hafnium, niobium, tantalum, chromium or molybdenum boride.
This coating mixture is preferably applied to a thickness of about 1-3 mm with a spray gun at 120 psi pressure and the coated cathode is first air dried at room temperature for about 10 hours. Although, it is possible to increase the lifetime of the coating by increasing the thickness to 10-15 mm by applying many layers of the coating. Between each layer, the coating could be dried by a heating system at about 100-150° C. The coated cathode is then preheated as a part of normal cell start-up. In preparation for the preheat, the cathode is covered with a 4 inch layer of coke (no bath) and the anodes are lowered until they rest on the coke layer. A current is then applied and under these conditions the coating will reach a temperature of about 1000° C., in about 25 hours.
The above composition provides a wettable surface for the metal and not only protects the exposed cathode surface from deterioration, but also reduces the absorption of sodium by the cathode lining in general and reduces the oxidation of the side wall blocks, when applied to these areas.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plot showing the cumulative quantity of TiB 2 removed from an aluminum electrolysis over a period of time.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
A liquid suspension was prepared by mixing 30% wt. H 3 BO 3 , 30% wt. AlF 3 and 40% wt. ammonium lignosulfonate. The lignosulfonate was a 50% liquid preparation (NORLIG TSFL™) obtained from Borregaard Lignotech, Bridgewater, N.J. In liquid state, the lignosulfonate has a pH range of 4-5 and comprises 47.5 to 51.5% solids. The H 3 BO 3 , and AlF 3 were in the form of powders.
Using a spray gun at 120 psi pressure, the liquid suspension was sprayed onto the top of prebaked anodes to approximately one-half to one-third the height of the anodes.
Example 2
A series of oxidation tests were conducted using small lab scale samples of anode material coated with various coating formulations having lignosulfonate as the principal binder. NORLIG TSFL™ was again used as in Example 1. The coatings were applied to a thickness of about 2 mm using a spray gun at 120 psi pressure and then air dried at room temperature for about 3 hours.
For the oxidation test, the coated samples were exposed to high temperatures in a furnace measuring 13″×7″×10. The furnace was heated from room temperature to 600° C. over a period of 4 hours and held at 600° C. for 12 hours.
Each sample was weighted before and after exposure and the percentage weight loss was calculated. The compositions of the coatings and the results obtained are shown in Table 1, below:
TABLE 1
Oxidation Test Compositions and Results.
COMPOSITION
OXIDA-
Binders
Solids
TION
SAMPLE
LSA**
Phenolic
B 2 O 3
H 3 BO 3
Additive
(% weight
No.
(%)
Resin
(%)
(%)
(%)
loss)
Control
0
0
0
0
60-90
Test
E-38
40
1
56
3 SiC
24
E-39
40
1
58
1 SiC
E-40
40
1
56
3 AlF 3
38
E-41
40
1
58
1 AlF 3
29
E-42*
40
1
56
3 SiO 2
38
E-44
40
1
56
3 SiC
40
E-45
40
1
58
1 SiC
22
E-46
40
1
56
3 AlF 3
25
E-47
40
1
58
1 AlF 3
29
E-48*
40
1
56
3 SiO 2
15
E-49*
40
1
58
1 SiO 2
18
*measurements include weight of coating
**LSA - ammonium lignosulfonate
Example 3
The procedure of Example 2 was repeated using a further variety of coating compositions. The coating compositions used and the oxidation results obtained are shown in Table 2, below:
TABLE 2
Oxidation Test Compositions and Results.
COMPOSITION
OXIDA-
Binders
Solids
TION
SAMPLE
LSA**
Phenolic
B 2 O 3
H 3 BO 3
Additive
(% weight
No.
(%)
Resin
(%)
(%)
(%)
loss)
Control
0
0
0
0
60-90
Test
E-60
40
1
57
2
SiC
7
E-61
40
1
57
2
SiC
1
E-62*
40
1
57
2
SiO 2
1
E-63*
40
1
57
2
SiO 2
2
E-78
40
—
30
30
AlF 3
0
E-79
40
—
30
30
AlF 3
0
E-80
40
2
28
30
AlF 3
0
E-81
40
2
28
30
AlF 3
0
E-76
40
—
—
60
AlF 3
39
E-77
40
—
—
60
AlF 3
41
*measurements include weight of coating
**LSA - ammonium lignosulfonate
Example 4
For these tests, the coatings were prepared and applied in the same manner as in Example 2. Some of the coatings contained a phenolic resin binder (DURITE Phenolic Resin RL-2360B). For the high temperature oxidation tests, the samples were placed on a bed of alumina powder. This duplicates more closely the actual conditions in the plant since alumina powder, which is the raw material fed to the electrolysis cell to produce metallic aluminum, is used to cover the anodes during cell operation.
The coating compositions and the results obtained are shown in Table 3, below:
TABLE 3
Oxidation Test Compositions and Results.
COMPOSITION
Solids
OXIDA-
Binders
H 3 BO 3
TION
SAMPLE
LSA**
Phenolic
B 2 O 3
(%)
Additive
(% weight
No.
(%)
Resin
(%)
powder
(%)
loss)
Control
0
0
0
0
60-90
Test
E-98
40
—
30
bn fin 30
14
E-100
40
—
20
bn fin 40
23
E-106
40
—
30
bn fin 30
11
E-105
40
—
40
20 AlF 3
4
E-108
40
—
40
20 AlF 3
5
O-160
38
2
30
30 AlF 3
7
O-161
35
5
30
30 AlF 3
5
O-162
35
5
40
20 AlF 3
0
O-163
38
2% CaO
30
30 AlF 3
8
As a control, each oxidation test included an anode sample without any protective coating according to our invention. These unprotected samples showed a weight loss of 60 to 90% by weight.
Example 5
Further tests were conducted using lab scale samples of anodic material as in Example 2, using the same lignosulfonate and phenolic resin as in Examples 2 and 4. As a source of AlF 3 , a finely divided solid bath material recovered from pots was used, containing about 50% AlF 3 and 50% Al 3 O 3 .
The coated samples were subjected to a high temperature oxidation in a furnace as in Example 2 and the results obtained are shown in Table 4. Also a plant test is underway with the composition O-175.
TABLE 4
Oxidation Test Compositions and Results.
Lignosulfonate
Phenolic
%
Sample
(50%)
Resin
H 3 BO 3*
Fine Bath
Weight Loss
Control
0
0
0
0
60-90
O-174
31
18
51
—
0
O-175
29
17
37
17
0
*granular - 100% active.
Example 6
A series of coating compositions were prepared for application to cathode structures. The same lignosulfonate and phenolic resin were used as in the previous example. The compositions contained by weight 60% titanium diboride, 5% anthracite (<74 micron), 17.5% of phenolic resin and 17.5% of ammonium lignosulfonate solution (50% wt.). Some also contained −200 mesh anthracite. They were prepared as viscous dispersions fluid enough to be applied by spraying.
Using a spray gun at 120 psi pressure the compositions were sprayed onto exposed surfaces of cathodes. The coatings were dried, pre-heated and subjected to electrolysis tests at 900° C. for up to 100 hours. After this test, the total surface of the coated cathode sample was wetted by aluminum and no erosion was observed.
Example 7
Plant tests using 6 full scale electrolysis cells have been completed with the following coating composition: 17.5% phenolic resin, 17.5% ammonium lignosulfonate solution (50%), 60% TiB 2 and 5% anthracite (<74 micron). The cathodic surface (bottom blocks, monolithic ramming paste and sidewall block) was covered by about 60 to 70 kg of coating in total for all of the test cells. The thickness of this coating was about 1 mm. The concentration of the Ti and B in the aluminum produced by the 6 test cells was compared with the levels in 6 control cells to determine the coating lifetime during cell operation. Based on these results the lifetime of a coating having a one mm thickness is about 350-400 days. It is know that during cell operation the carbon cathode erosion rate without the coating is about 15 to 30 mm per year. FIG. 1 presents the cumulative quantity of TiB 2 remove from the test cells based on the concentration of Ti and B in the aluminum. The plant test demonstrates that the erosion rate of coated cathode blocks is lower than 1 mm/year, which is much lower than the erosion rate for uncoated blocks. | A method of treating a carbonaceous cell component of an electrolyte cell for the production of aluminum, to impart protection against deterioration during operation of the cell. A liquid suspension of a refractory material dispersed in a lignosulfonate binder solution is prepared and applied as a protective coating to the surface of carbonaceous cell components and allowed to dry. | 2 |
The present application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 2000-66346, filed on Nov. 9, 2000, which is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to semiconductor fabricating equipment. More particularly, the present invention relates to semiconductor fabricating equipment that can minimize the influence of a process deteriorating material, that is generated during a first process, on a second process, whereby the first and second processes are performed step by step. This can significantly reduce the frequency of failures in patterning.
2. Description of the Related Art
In recent years, rapid developments have been made in the industrial fields of computers, information and communication, and aerospace. As a result, semiconductor products used in these various industries have become smaller, but generally perform higher functions.
The recent development trend toward lighter products with higher function in such a variety of industries has primarily resulted from an improvement in the functions of semiconductor products that can process a large quantity of data within a small unit of time, as well as a dramatic increase in the amount of data that can be stored in a given memory area. As a result, there is a continued need to accelerate the development of semiconductor products having these improved functions.
In general, the aforementioned semiconductor products have circuit wires that are precisely manufactured to have thicknesses as small as 0.1 μm or so. As a result, very fine semiconductor fabricating equipment and related methods are required to manufacture such precise semiconductor products.
Such a semiconductor fabricating method generally consists of two steps: a first (or preceding) semiconductor fabricating step, and a second (or following) semiconductor fabricating step. The combination of these two general steps is required to make a circuit pattern having wires with thicknesses as small as 0.1 μm or so.
Specifically, the first semiconductor fabricating step may include, for example, a photolithography process. In such a photolithography process, a thin photo-resistant layer that may remain or may be removed is formed by exposing light rays onto a pure silicon substrate, or wafer. A reticle, having an open part formed in relation to a circuit pattern, is placed over the photo-resistant layer to which the light rays will be exposed, and then the uncovered part of the wafer is exposed to the light rays to form a circuit pattern.
The second semiconductor fabricating step may include, for example, an ionimplantation process to implant ions into the open part; a deposition process to deposit a thin layer having different characteristics; an etching process to repeatedly form etching grooves or contact holes with an etchant or an etching gas; a metal process to electrically connect a circuit pattern; and the like.
The first and second semiconductor fabricating steps as such are generally performed in turn. At the same time, additional processes are performed to complete the fabrication of a semiconductor product. These additional processes may include making a semiconductor chip, a core part of any semiconductor product; packaging the product to make an electric connection with external devices and to protect the semiconductor chip from negative environmental factors; and testing the final semiconductor product.
When a semiconductor product is to be fabricated through a plurality of complex processes, it is preferable that a reduction in the thickness of wire be made by an improvement in the precision of the semiconductor fabricating equipment used to perform the first semiconductor fabricating step, rather than in the second semiconductor fabricating step.
In particular, in-line type photolithography equipment has been developed that sequentially includes a plurality of operational units such as a photo-resistant painting unit for pasting photo-resist to a wafer, a bake unit, an adhesion unit for improving adhesion between the wafer and the photo-resist, a stepper or a ray exposing unit, an interface unit and a developing unit, all of which are connected “in-line.”
When using such in-line photolithography equipment, wafers are in sequential motion and the first semiconductor fabricating step is in process continuously on successive wafers, so as to maximize efficiency of equipment. However, hexamethyldisilane (HMDS), a chemical used at an operational unit, i.e., at the adhesion unit, generates ammonia (NH 4 ), which can result in a process failure at an adjacent process unit, e.g., at the bake unit. The problem of generating ammonia will be described in more detail below.
FIG. 1 illustrates changes in the quantity of ammonia generated from a sheet of wafers from the start to the completion of the operational processes. As shown in the graph in FIG. 1, there is a sudden change in the quantity of ammonia at some intervals, resulting in problems such as the occurrence of a T-top phenomenon, in which the top portion of the photo-resist layer remains as T-shaped, instead of forming a vertical profile after completion of wafer development at the developing unit.
SUMMARY OF THE INVENTION
The present invention is therefore directed to equipment for fabricating semiconductor products, and a method thereof, which substantially overcome one or more of the problems due to the limitations and disadvantages of the related art.
To solve the above and other problems, it is an object of the present invention to provide semiconductor fabricating equipment and a related method, that minimizes the negative influence of a material generated at one operational unit on an adjacent process unit during the course of a sequential in-line type processing.
In order to accomplish the above-noted and other objects of the present invention, a semiconductor fabricating equipment is provided comprising a first semiconductor process unit installed in a production line for performing first semiconductor fabricating processes that generate a process deteriorating gas; and a second semiconductor process unit installed in the production line for performing second semiconductor fabricating processes dependent on the first semiconductor processes, the second semiconductor processes being susceptible to operational failures if exposed to the process deteriorating gas. In this device, the second semiconductor process unit is installed at a higher level than the first semiconductor process unit, and clean air flows downward over the first and second semiconductor process units to carry the process deteriorating gas away from the second semiconductor process unit. The process deteriorating gas may be ammonia (NH 4 ), for example.
The first semiconductor process unit may comprise an adhesion unit having an adhesion chamber that supplies an adhesion enhancing material for reinforcing adhesion between a wafer and a photo-resist layer, when the photo-resist layer is deposited onto the wafer. The second semiconductor process unit may comprise a bake unit that bakes the wafer that has the photo-resist layer formed on it.
Alternatively, a semiconductor fabricating device may be provided that comprises a first semiconductor process unit installed in a production line for performing first semiconductor fabricating processes that generate a process deteriorating gas; and a second semiconductor process unit installed in the production line for performing second semiconductor fabricating processes dependent on the first semiconductor processes, the second semiconductor processes being susceptible to operational failures if exposed to the process deteriorating gas. In this device, the first semiconductor process unit is installed in a first position and the second semiconductor process unit is installed at second position, and clean air flows from the first position to the second position to carry the process deteriorating gas away from the second semiconductor process unit. The process deteriorating gas may be ammonia (NH 4 ), for example.
The first semiconductor process unit may comprise an adhesion unit having an adhesion chamber that supplies an adhesion enhancing material for reinforcing adhesion between a wafer and a photo-resist layer, when the photo-resist layer is deposited onto the wafer. The second semiconductor process unit may comprise a bake unit that bakes the wafer that has the photo-resist layer formed on it.
The above and other problems also may be overcome by a method of fabricating a semiconductor device including performing first semiconductor fabricating processes at a first location, the first semiconductor fabricating processes generating a process deteriorating gas; performing second semiconductor fabricating processes that are dependent upon the first semiconductor fabricating processes at a second location, the second semiconductor fabricating processes being susceptible to operational failures upon exposure to the process deteriorating gas; and flowing clean air from the second location to the first location to carry the process deteriorating gas away from the second location. In a preferred embodiment, the second location is higher than the first location.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a graph illustrating the changes in density of ammonia contained in a bake unit of in-line photolithography equipment of a conventional semiconductor fabricating device;
FIG. 2 is a plan view illustrating a layout of an in-line photolithography device of a semiconductor fabricating facility, according to a preferred embodiment of the present invention;
FIG. 3 is a partial, cross-sectional perspective view illustrating the in-line photolithography device of FIG. 2; and
FIG. 4 is a lateral view illustrating the relationship of position of a bake unit, a cooling unit, an adhesion unit and air flow from FIGS. 2 and 3 .
DETAILED DESCRIPTION OF THE INVENTION
Specific structure and operational characteristics and effects of the present invention will become apparent from the following detailed description of a preferred embodiment with reference to the accompanying drawings. An in-line photolithography device 400 will be described as a preferred embodiment of the present invention.
FIGS. 2 through 4 illustrate an in-line photolithography device according to a preferred embodiment of the present invention. In particular, FIG. 2 is a plan view illustrating a layout of an in-line photolithography device of a semiconductor fabricating facility according to a preferred embodiment of the present invention; FIG. 3 is a partial, cross-sectional perspective view illustrating the in-line photolithography device of FIG. 2; and FIG. 4 is a lateral view illustrating the relationship of position of a bake unit, a cooling unit, an adhesion unit and air flow from FIGS. 2 and 3.
As shown in these drawings, the in-line type photolithography device 400 is constructed to include a photo-resist treating unit 100 , an interface buffer unit 200 , and a ray exposing unit 300 . The photo-resist treating unit 100 includes a plurality of operational units installed on the base body 110 . The operational units specifically include a wafer cassette loading/unloading unit 120 , a wafer transfer unit 130 , one or more adhesion units 140 , one or more cooling units 150 , a plurality of bake units 161 , 162 , 163 (collectively referred to a bake unit 160 ), one or more spin coating units 170 , and one or more developing units 180 .
Among the operational units, the wafer cassette loading/unloading unit 120 makes it possible to load or unload one or more wafer cassettes 121 , which have wafers that have completed the first semiconductor fabricating step. The wafer cassette loading/unloading unit 120 also allows the device 400 to accommodate the wafers in lot units. The wafer cassette loading/unloading unit 120 may be installed along an edge of the top surface of the base body 110 to enable the wafers to be easily loaded or unloaded. In the preferred embodiment of the present invention, four wafer cassettes 121 are accommodated in the wafer cassette loading/unloading unit 120 . However, alternate embodiments may use more or fewer cassettes 121 .
The spin coating unit 170 and developing unit 180 are installed in series on the top surface of the base body 110 , adjacent to the wafer cassette loading/unloading unit 120 . Although in this embodiment one spin coating unit 170 and two developing units 180 are disclosed, the number of these elements may be varied as necessary.
The plurality of adhesion units 140 , cooling units 150 , and bake units 160 are placed over the base body 110 in a deposition structure, across from the spin coating units 170 and developing units 180 . The adhesion units 140 , cooling units 150 and bake units 160 will be described in further detail as follows.
The adhesion units 140 (marked with the label AD in FIG. 4 ), supply hexamethyldisilane (HMDS) to wafers loaded in a chamber of the photolithography device. The chamber has a predetermined size of volumetric capacity. The HMDS is phase-changed into a gaseous state by way of nitrogen gas to enhance adhesion between a wafer and the photo-resist layer prior to the photo-resist painting process.
The bake unit 160 is preferably constructed to include the first bake unit 161 , the second bake unit 162 and the third bake unit 163 . More specifically, the first bake unit 161 is preferably a soft bake unit that first hardens a photo-resist layer after the photo-resist layer is deposited onto the wafer at the spin coating unit 170 described above. In a preferred embodiment, this operation is performed at one of those positions marked HP in FIG. 4 .
The second bake unit 162 is preferably a post exposure bake unit that performs a post-exposure bake on a wafer having the thin photo-resist layer deposited thereon, after the ray exposing process. In a preferred embodiment, this process is performed at one of the positions marked PEB in FIG. 4 .
The third bake unit 163 is a hard bake unit that performs a hard bake on the photo-resist layer pattern, after completion of development in the development unit 180 . In a preferred embodiment, this process is performed at one of the positions marked HP in FIG. 4 .
The reference symbol HHP in FIG. 4 indicates a bake unit provided for use in a wafer baking process that requires a higher baking temperature. In such a case, a slow cooling process is performed by the cooling units 150 (indicated as COL in FIG. 4) to bring a wafer to room temperature after all the previous processes have been performed at the adhesion unit 140 and the first, second, and third bake units 161 , 162 , and 163 .
As shown in FIG. 4, the adhesion unit 140 is positioned under the cooling unit 150 and the first, second, and third bake units 161 , 162 , and 163 . However, the position of the adhesion unit 140 is not fixed, but is determined by the airflow of the production line where the in-line photolithography device 400 is installed, in accordance with a preferred embodiment of the present invention. In other words, positions of the adhesion unit 140 , cooling unit 150 , and bake unit 160 should be considered according to the airflow of a production line. This is because a failure in patterning a photo-resist layer occurs according to the process features of the adhesion unit 140 , i.e., the flow of ammonia gas that is generated during operational processes in the adhesion unit 140 .
More specifically, if air flows downward in a production line, and if the adhesion unit 140 is installed higher than a bake unit 160 or a cooling unit 150 , a small quantity of the ammonia gas generating during operation of the adhesion unit 140 may flow to the bake unit 160 or the cooling unit 150 . This would be undesirable, because if ammonia gas flows into the bake unit 160 , the previously described T-top phenomenon may occur in the photo-resist layer, resulting in an operational failure.
In accordance with a preferred embodiment of the present invention, air flows downward in the production line, from the ceiling to the floor. As a result, the adhesion unit 140 is first installed on the base body 110 , and the cooling unit 150 or bake unit 160 is then installed above the adhesion unit 140 , thereby preventing the occurrence of any operational failure caused by contamination by ammonia gas.
As shown in FIG. 2, the wafer transfer unit 130 is provided in an empty space formed between the bake unit 160 , cooling unit 150 and adhesion unit 140 , and the spin coating unit 170 and developing unit 180 . The wafer transfer unit 130 operates to transfer wafers between units, e.g., from a bake unit 160 to a cooling unit 150 , from an adhesion unit 140 to a cooling unit 150 , from a spin coating unit 170 to a bake unit 160 , and from a developing unit 180 to a bake unit 160 . The wafer transfer unit 130 includes a guide rail 131 , a transfer unit 132 linearly reciprocating along the guide rail 131 , and a robot arm 133 installed at the transfer unit 132 for freely moving in the empty space to load/unload wafers.
Also, exposing unit 300 may be a stepper ray exposing unit or a scan type ray exposing unit, and is installed close to the photo-resist treating unit 100 . Interface buffer unit 200 is installed between the ray exposing unit 300 and the photo-resist treating unit 100 . The interface buffer unit 200 is used to transfer wafers from the photo-resist treating unit 100 to the ray exposing unit 300 , or from the ray exposing unit 300 to the photo-resist treating unit 100 .
Operational effects of the in-line type of photolithography device 400 according to a preferred embodiment of the present invention will be described as follows, with respect to processes of forming a photo-resist layer onto a sheet of wafers.
First, a sheet of wafers is unloaded out of the wafer cassette loading/unloading unit 120 by the robot arm 133 of the wafer transfer unit 130 , and are loaded into one of the adhesion units 140 installed close to the base body 110 . Then, a process is performed for enhancing the adhesion between the wafers and the photo-resist layer using HMDS gas. At this time, ammonia gas generated during the process to reinforce the adhesion between the wafers and photo-resist layer exhausts out without influencing the bake unit 160 or the cooling unit 150 , since the air flows downward at the adhesion units 140 away from the bake and cooling units 160 and 150 .
After the completion of the process at the adhesion unit 140 , the wafer is transferred by the wafer transfer unit 130 into the cooling unit 150 to be slowly cooled down. Then, the cooled wafer is transferred to the spin coating unit 170 to form a photo-resist layer on the wafer. After the formation of the photo-resist layer, the wafer is transferred to the first bake unit 161 for a soft bake process and is then further transferred to the cooling unit 150 to be slowly cooled down.
Then, after the completion of the soft bake process and subsequent cooling, the wafer is transferred to the interface buffer unit 200 and, then to the ray exposing unit 300 where a ray exposing process is performed according to a set pattern. After the completion of the ray exposing process, the wafer is transferred through the interface buffer unit 200 to the second bake unit 162 to perform a post exposure bake process.
After completion of the post exposure bake process, the wafer is transferred by the wafer transfer unit 130 to the cooling unit 150 to be slowly cooled down. Then, the wafer is transferred to one of the developing units 180 to perform the developing process to form a photo-resist layer. After the completion of the developing process, the wafer is transferred by the wafer transfer unit 130 to the third bake unit 163 to perform a hard bake process. Finally, after the completion of the hard bake process, the wafer is transferred to one of the cooling units 150 to be cooled down, and then to the wafer cassette loading/unloading unit 120 .
As described above, there is an advantage in the semiconductor fabricating equipment of the present invention in that, when a variety of operational processes are sequentially performed, a deteriorating material generated or used during a first process does not harmfully influence a later process, and does not cause any operational failure in the course of the semiconductor fabricating processes.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A semiconductor fabricating device and method that minimize the influence of a process deteriorating material that is generated during first processes on second processes, when the plurality of processes are continually performed step by step. Operational failures are prevented during the course of the semiconductor fabricating processes, by directing air flow from a location where the second processes are carried out to a location where the first processes are carried out, to carry the process deteriorating gas away from the second processes. This reduces the frequency of failures during processing. | 8 |
FIELD OF THE INVENTION
The field of the invention is mills for tubulars downhole and more particularly wireline run mills that can produce windows or other openings of desired shape and location in the tubular.
BACKGROUND OF THE INVENTION
Conventional ways to make outlets in tubulars, commonly referred to as windows, involve setting a diverter, known as a whipstock, and properly supporting and orienting it. The whipstock can also be run attached to a bottom hole assembly that can include one or more mills and orientation equipment for the whipstock and even an anchor for the whipstock that can be set when the desired orientation is obtained for the whipstock. Milling windows incorporates possibilities that something could go different from plan. Mills can bore into the whipstock instead of being urged along its ramped surface until the casing wall is penetrated and an exit is made. Mills can become dull or make too early an exit that can result in the window being too short. The mills can become dull during the window forming procedure or the anchor for the whipstock can prematurely release. Typically windows made by the whipstock need to be very long because ramp angles on the whipstock are very small, in the order of about three degrees or less to avoid bogging down the widow mill with extreme lateral forces to get it to go through the wall. Windows are also made in stages with sequential mills that in series make the window wider than the previous mill. Using such systems of ever larger mills requires the system to withstand bending moments as progressively larger mills get onto the whipstock ramp and start widening the already started window. At times, the stress levels become excessive and connection failures are known to occur between mills.
Openings in tubulars are needed for other purposes such as normal production from the surrounding formation. Many times that is accomplished with perforating guns. The problems with perforating guns are the safety concerns of handling explosives and the potential for formation damage from shooting off the guns as well as other subsidiary issues of proper placement and support for the guns and retrieval after they are shot off.
While guns can be run in wireline for fast delivery to the desired location, assuming that the well is not too deviated, milling assemblies are run in on a tubular string that is either rotated from the surface or includes a downhole mud motor to rotate the mills.
The present invention takes a fresh approach to providing openings in tubulars that avoids many of the issues discussed above. In the preferred embodiment, an assembly is delivered on wireline for rapid deployment into the wellbore. The assembly comprises a processor which can selectively actuate a combination guiding and anchoring system that allows the assembly to be initially positioned in the desired spot and moved longitudinally to fashion any shape of opening or openings desired in a predetermined location or locations. One or more cutters can be extended for milling and the cutters can be moved in a predetermined arc while the assembly is moved uphole or downhole. Spare cutters are envisioned to allow a specific job to be finished without bit change or/and to allow the job to be completed faster. The rate of uphole or downhole movement can be controlled. The assembly can even make locating grooves for proper positioning of subsequent equipment after the desired opening or openings are made. These and other advantages of the present invention will be more apparent to those skilled in the art from a review of the drawings and description associated with the preferred embodiment while recognizing that the full scope of the invention is in the associated claims.
SUMMARY OF THE INVENTION
A milling assembly can be delivered downhole on wireline. Once at the desired location, a processor extends centralizing and driving wheels to initially position the assembly. The assembly has a cutter end with one or more mills or cutters that can be selectively radially extended. The entire cutter end can be rotated in an arcuate manner over a predetermined range. One or more cutter can be extended at a time and driven. The wheels are driven either in an uphole or downhole direction at the same time the arcuate motion can take place. Using a processor, different shapes in a surrounding tubular can be made such as windows for laterals, a plurality of openings for production or interior locator surfaces to properly position subsequent equipment with respect to openings already made by the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of a twin cutter assembly with one cutter extended; and
FIG. 2 is a close up view of the downhole end of the tool from FIG. 1 with the other cutter extended.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a body or main housing 10 that is preferably supported by a wireline 12 to power a processor 30 and other equipment, as will be described below. The body 10 has a set up uphole wheels 16 and downhole wheels 18 . Preferably each wheel set comprises three wheels at 120 degree spacing but other arrangements are possible. Instead of wheels other types of devices that can selectively contact the surrounding tubular, shown schematically as 20 are also envisioned. One example is tracks instead of retractable and driven wheels that are shown. It is preferred that all the wheels be retractable for quick run in and when in the proper location downhole that they are extendable to engage the tubular 20 to not only centralize the housing 10 with respect to tubular 20 but also to allow the housing 10 to be driven uphole or downhole with respect to the tubular 20 .
Housing 10 has a rotating component 22 that can be turned with respect to housing 10 when wheels 16 and 18 are extended. This occurs by the turning of a sun gear 24 around a planetary gear 26 (shown only in part and schematically). Thus the rotating component 22 while being coaxial with housing 10 can rotate about its common longitudinal axis with housing 10 . A motor 28 controlled by processor 30 can selectively turn the housing 22 clockwise or counterclockwise.
Housing 22 is illustrated with cutters or mills 32 and 34 . Although two mills are shown, one or more mills can be incorporated into the design. The terms cuter, mill, drill or bit and other synonymous terms are intended to be interchangeable for the purposes of this description. The mills 32 or 34 are selectively extended radially by ramps 36 or 38 by virtue of motors 40 or 42 attached to them for translating them. Thus, when raised surface 44 is under cutter 34 the cutter 34 is extended up to a maximum extension shown in FIG. 2 . The amount of radial extension is controlled by processor 30 regulating motor 42 so that the amount of radial extension can be held constant at a given value or varied with time as the milling progresses at a speed that is dependent on either predetermined patterns or in real time depending on the actual milling progress being made or the resistance experienced by an extended cutter. The ramp assemblies 36 and 38 are mounted to the housing 22 and rotate with it. Similarly, driven shafts 46 and 48 are also supported by the housing 22 and rotate with it. Bevel gears 50 and 52 are mounted respectively on shafts 46 and 48 and they each engage driven gear 54 that is secured to mill 34 . Gear 54 is mounted to housing 22 to move radially when mill 34 is extended by longitudinal movement of ramp assembly 38 , for example. Housing 22 supports gear 54 through a slot (not shown) in ramp assembly 38 so as to allow translation of ramp 38 in opposed longitudinal directions to force mill 34 out or to allow it to back up in the opposed direction, such as for run in or pulling out of the hole. Ramp assembly 38 can be driven in opposed directions by a threaded shaft 56 and the same assembly can be applied to ramp assembly 36 . The shaft such as 56 can act to change the position of either mill between the maximum extended position of either of the mills 32 or 34 and the fully retracted position. Alternatively, motors 40 or 42 can be stepper motors to advance or withdraw an associated ramp in predetermined increments so that the gear 54 and associated mill 34 can be extended or allowed to retract a predetermined amount along ramp 58 , for example. In the preferred embodiment, identical operation is envisioned for mill 32 that is connected to driven bevel gear 60 , which rides on ramp surface 62 . Bevel gears 64 and 66 mounted to shafts 46 and 48 respectively, drive gear 60 . At the uphole end of shafts 44 and 46 are bevel gears 64 and 66 which mesh with gear 68 connected to shaft 70 . Shaft 70 has a gear 72 near its uphole end that is driven by gears 74 and 76 that are respectively driven by motors 78 and 80 that are also controlled by processor 30 .
In operation, the tool is run in the hole with the wheels 16 and 18 retracted so that delivery can be accomplished in the shortest time. The processor 30 has features to determine the orientation of the mills 32 and 34 much in the way an MWD tool determines the orientation of a whipstock downhole before it is anchored. Mills 32 and 34 are also retracted for run in and do not turn for run in. When the proper depth is determined using known techniques, the wheels 16 and 18 are extended to centralize the tool in the tubular 20 as well as to get traction for driving the tool uphole and downhole as determined by processor 30 . If a window is to be milled, it can be produced from downhole moving up or from uphole going down or even from opposed ends toward a middle of the window. A single mill, such as 34 , can be extended, as shown in FIG. 2 . This is done through processor 30 commanding the motor 42 to drive ramp assembly 38 so that ramp 58 can push out gear 54 to extend mill 34 . Processor 30 then can operate motors 78 and 80 to ultimately drive gears 50 and 52 in the manner described before to get mill 34 turning. At this time mill 32 may also be rotating but it is not extended. Processor 30 has the capacity to operate with more than on mill extended at a time. Thus, for example, if a random or ordered hole pattern is required, as a way of avoiding having to perforate, more than one mill can be extended for making round holes. In the embodiment illustrated the rotation of component 22 rotates both mills 32 and 34 a like amount forcing them to be longitudinally aligned at all times. However, a separate drive for each mill is contemplated. Those skilled in the art will appreciate that one portion of housing 22 will need to be rotatable with respect to another and the driving systems from motors 78 and 80 will need to be independently operated. If this is done, even an oblong window can be milled with two mills operating making two different shapes of a typical window at the same time which in the end results in a single window made to the preprogrammed shape specification. As previously stated one mill can simply be a backup for the other mill so that a given opening can be finished if one mill gets dull or breaks without having to trip out of the hole. By preprogrammed regulation of the driving rate for the wheels 16 or/and 18 and the movement of motor 28 that controls the left to right movement of either or both mills 34 or/and 32 while coupled with associated ramp control for mill extension by controlling the associated motor 40 and/or 42 any shaped opening can be produced in any tubular regardless of its wall thickness.
The tool of the present invention can perforate a tubular in an ordered or random pattern, to avoid having to use a perforating gun that can have adverse effects on the formation. It can also be used to make a window in the shame shape as a multi-mill bottom hole assembly currently makes it when used in conjunction with a whipstock. For example the window can be wider at the top to approximate the diameter of the largest mill being used while becoming more slender at the bottom to approximate what happens when the mills make a departure from the whipstock ramp. Alternatively, a totally different window shape can be made. Rather than going clean through the tubular wall, only some material can be removed from its inside wall leaving a thinner wall to be penetrated by a milling bottom hole assembly in conjunction with a whipstock. Independently, the tool of the present invention can strategically produce radial grooves in the inner wall of the tubular to act as locators for packers or other downhole tools that need to be positioned with respect to the hole or holes just produced.
Other features can be provided that have been left off the drawings for greater clarity of the operation of the milling equipment. Passages can be incorporated though the housing 10 or external grooves that will allow flow with cuttings to be circulated or reverse circulated. A downhole pump can aid in such fluid movements. Alternatively the housing 22 can accept and trap cuttings in a screen basket as long as the rotating components are suitably isolated from the captured cuttings. This method is schematically illustrated as 90 . Such cuttings can be retained with magnets or baskets mounted in housing 22 . While the tool is preferably run in on wireline 12 it can also be delivered on coiled tubing or jointed tubing, either of which will greatly facilitate circulation or reverse circulation for the purpose of capturing cuttings.
While longitudinally shifting ramp assemblies 36 and 38 are illustrated, those skilled in the art will appreciate that other equivalent techniques for extending and retracting the mills 32 and 34 can be used. These mills can be operated in tandem or have totally separate controls so that one mill can either back up the other one if there is a problem or both mills can work on a hole or hole pattern at the same time to expedite the job. While two mills are illustrated fewer or additional mills can be used either as backups or at the same time to shorten the operation.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below. | A milling assembly can be delivered downhole on wireline. Once at the desired location, a processor extends centralizing and driving wheels to initially position the assembly. The assembly has a cutter end with one or more mills or cutters that can be selectively radially extended. The entire cutter end can be rotated in an arcuate manner over a predetermined range. One or more cutter can be extended at a time and driven. The wheels are driven either in an uphole or downhole direction at the same time the arcuate motion can take place. Using a processor, different shapes in a surrounding tubular can be made such as windows for laterals, a plurality of openings for production or interior locator surfaces to properly position subsequent equipment with respect to openings already made by the device. | 4 |
BACKGROUND
[0001] The present invention relates to a heating system, and more particularly, to a heating system which has a structure that may form a floating floor and in which a heating means is applied to an inner space between upper and lower panels that define a two-layered floor on the structure.
[0002] In general, an access floor is installed in an office room such as a computer room, an electrical room and an emergency room and is installed in a dual structure such that it is spaced apart from a bottom surface for the purpose of concealment of electric wires and the like, blocking of moisture and interior decoration of a floor.
[0003] That is, because a number of servers and devices are installed in the electrical room or an equipment room of a company, power cables, LAN cables, private lines, telephone lines and the like are required. Thus, the access floor refers to a construction material that allows installation of a dual floor having a space below a floor such that all the wires may be used without obstructing passage.
[0004] However, the access floor is used only for a floating floor structure.
[0005] Meanwhile, in a current heating system for an apartment, a floor is finished by constructing a heat-insulating sound-absorbing member such as expanded polystyrene, foamed urethane and foamed polypropylene that are combustible sound absorbing materials or shock absorbing materials on a slab, forming a lightweight foamed concrete layer thereon, laying a hot water pipe that is a heating member thereon, and constructing a mortar layer thereon again.
[0006] Such cement construction of the floor structure is totally performed by field technicians in a wet scheme.
[0007] Such an existing technology has problems in that construction is difficult, maintenance and repairs when water leaks are generated are difficult because a large amount of pipe connecting members are arranged inside a concrete layer, a large amount of times are consumed for heating because hot water circulating pipes are connected in series to each other, and floor noise is transferred well because mortar for a heating pipe is integrated with the floor as well.
[0008] To solve the problems of such a wet heating system, a hot water pipe is embedded in a panel formed of concrete, synthetic resin or yellow ocher or a dry heating panel having a groove or a fixing member into which the hot water pipe is inserted is developed and provided.
[0009] Such a dry heating panel, which is a prefabricated heating system, is constructed in a scheme in which pre-manufactured dry panels are simply assembled on the spot, so that there are advantages in that a construction period thereof is shortened and maintenance thereof is easy as well. However, because the panel is manufactured such that the interior thereof is dry, there are problems in that solidity thereof deteriorates and there is no heat storage function.
SUMMARY OF THE INVENTION
[0010] The present invention is conceived to solve the above problems, an aspect of the present invention is to provide a heating system in which a dry construction method in which a floating floor is formed by assembling and fixing a heating panel having a heat generating function and a heat storing function on a structure constituting a two-layered floor is used so that construction is simple and convenient, and noise reduction pad are attached to structure legs forming a two-layered structure so that floor noise may be remarkably reduced.
[0011] Further, another aspect of the present invention is to provide a heating system in which to solve the conventional problem that a large amount of times are consumed for heating because pipes extending in series are thickly covered by cement mortar, panels in which heating pipe are installed are connected in parallel to each other so that heating is uniformly and rapidly performed, a high energy saving effect is achieved due to a high heat retaining property, cement mortar or yellow ocher is filled in the panels so that a heat storing property is high, and an upper portion of the heating panel, which constitutes a floor, is formed of aluminum so that a thermal conductivity thereof is high.
[0012] To achieve the above aspects, a heating system according to an embodiment of the present invention includes: a structure supported by legs and constituting a floating floor on a slab; and heating panels, each of which comprises an upper panel having structure seaters protruding downward from portions inside edges of the upper panel, which support loads, such that the corresponding heating panel is fixed on the structure and having outer walls extending downward, and a lower panel having a body bent upward and coupled to a lower portion of the upper panel and having penetration parts which have a heating means installed in the penetration parts and through which the structure seating parts pass, wherein in a state in which the upper panel and the lower panel are coupled to each other, cement mortar or yellow ocher is filled in an empty space between the upper panel and the lower panel and is cured.
[0013] A heating system according to another embodiment of the present invention includes: a structure supported by legs and constituting a floating floor on a slab; and heating panels, each of which comprises an upper panel having structure seaters protruding downward from portions inside edges of the upper panel, which support loads, such that the corresponding heating panel is fixed on the structure and having outer walls extending downward, and a lower panel having a body bent upward and coupled to a lower portion of the upper panel, having penetration parts which have a heating means installed in the penetration parts and through which the structure seating parts pass, having a heating film attached to a lower bottom surface of the lower panel in a dry scheme, and having a ceramic plate or a fireproof insulation plate fixed to a lower side of the heating film through a steel plate, wherein in a state in which the upper panel and the lower panel are coupled to each other, cement mortar or yellow ocher is filled in an empty space between the upper panel and the lower panel and is cured.
[0014] A heating system according to yet another embodiment of the present invention includes: a structure supported by legs and constituting a floating floor on a slab; and heating panels, each of which comprises an upper panel having structure seaters protruding downward from portions inside edges of the upper panel, which support loads, such that the corresponding heating panel is fixed on the structure, having protrusion fasteners for coupling between the upper panel and a lower panel and having outer walls extending downward, the lower panel having a body bent upward and coupled to a lower portion of the upper panel, having penetration parts through which the structure seating parts pass, and having fastening holes formed at locations corresponding to the protrusion fasteners for bolt coupling from below to above, and a pair of intermediate panels formed by vertically stacking ceramic plates, having through-holes through which the protrusion fasteners pass, and formed in a space defined by coupling the upper panel and the lower panel with a heating film interposed between the pair of ceramic plates.
[0015] A heating system according yet another embodiment of the present invention includes: a structure supported by legs and constituting a floating floor on a slab; and heating panels, each of which comprises an upper steel plate not having structure seaters but having structure fasteners for fastening the corresponding heating panel on the structure such that the heating panel is fixed on the structure, and a lower box having a box shape, of which an upper portion is opened, having a flange extending outward, having a heating means installed in the lower box, and having fasteners allowing the lower box to be fastened to the structure, wherein in a state in which edges of the upper steel plate and the flange of the lower box are coupled to each other through welding, cement mortar or yellow ocher is filled in an empty space of the lower box and is cured.
[0016] According to the technical solutions of the above problems, as a heating system is implemented using general panels having a two-layered structure, construction may be simply and conveniently performed in a dry scheme regardless of locations by positioning a heating panel on a structure constituting a dual floating floor, so that construction costs may be reduced, and weight lightening of a building may be helped due to the dual floor structure.
[0017] Further, a heat storage property is high and cement or yellow ocher is filled in the panels, so that a load strength may be increased, footstep sounds are not generated and a noise absorbing effect of reducing floor noise is achieved as well. Further, when heat is supplied to the panels constituting the floor, heat may be uniformly and rapidly transferred.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view illustrating a process of coupling an upper panel and a lower panel to each other according to an embodiment of the present invention.
[0019] FIGS. 2 and 3 are a perspective view illustrating the upper panel of FIG. 1 and a perspective view illustrating a bottom surface (ceiling), respectively.
[0020] FIG. 4 is a perspective view illustrating the lower panel of FIG. 1 .
[0021] FIG. 5 is a side sectional view illustrating a heating panel according to the embodiment of the present invention.
[0022] FIG. 6 is a perspective view illustrating a rubber foam insulation on which the lower panel of FIG. 1 is mounted.
[0023] FIG. 7 is a system diagram illustrating a state in which heating water circulates in heating panels connected to a boiler according to the embodiment of the present invention.
[0024] FIG. 8 is a view illustrating a state in which the heating panel of FIG. 5 is installed on a structure.
[0025] FIGS. 9 and 10 are exploded perspective views illustrating a heating panel according to other embodiments of the present invention.
[0026] FIG. 11 is a perspective view illustrating a heating panel according to yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Hereinafter, configurations and effects of embodiments of the present invention will be described with reference to the accompanying drawings.
[0028] It should be noted that the same elements in the drawings are designated by the same reference numerals as far as possible even though the elements are illustrated in different drawings.
[0029] In the following description of the present invention, when detailed descriptions of related well-known functions or configurations may unnecessarily make the subject matter of the present invention unclear, the detailed descriptions will be omitted.
[0030] Further, when a specific part “includes” a specific element, this means that the specific part does not exclude other elements but may further include other elements as long as there is no specially contrary description.
[0031] FIG. 1 is a perspective view illustrating a process of coupling an upper panel and a lower panel to each other according to an embodiment of the present invention, FIGS. 2 and 3 are a perspective view illustrating the upper panel of FIG. 1 and a perspective view illustrating a ceiling surface, respectively, FIG. 4 is a perspective view illustrating the lower panel of FIG. 1 , and FIG. 5 is a side sectional view illustrating a heating panel according to the embodiment of the present invention.
[0032] Although a heating pipe 27 connected to a boiler will be described below as an example of a heating means installed in a lower panel 20 , the present invention is not limited thereto, and it is apparent that a metal heating element used in an electric pad or the like, a carbon-coated heating element used in a stone bed or the like, an electric heating wire using a resistor, a carbon fiber or the like may be used as the heating means.
[0033] As illustrated, a Korean floor heating system panel 60 includes an upper panel 10 and a lower panel 20 , and may further include a rubber foam insulation 40 herein.
[0034] First, the upper panel 10 for conducting and storing heat, which is formed by molding aluminum to improve balance and preciseness, includes structure seaters 11 , outer walls 12 , protrusions 13 , protrusion fasteners 14 , ribs 15 , catching bosses 16 , catching steps 17 , fastening bosses 18 , through-holes 28 and caps 34 , and has a square shape or a rectangular shape.
[0035] The outer walls 12 are formed on all sides of the upper panel 10 to protrude downward from a flat aluminum plate, and the fastening bosses 18 having fastening grooves 18 a between the fastening bosses 18 and the outer walls 12 are formed by bending predetermined points of the outer walls 12 twice.
[0036] That is, each fastening boss 18 and the corresponding outer wall 12 have an approximately “7” shape when viewed from below as illustrated in FIG. 3 .
[0037] Further, the corresponding catching step 17 and the corresponding catching boss 16 are formed on sides of the fastening boss 18 and the outer wall 12 , which are close to the corresponding fastening groove 18 a , at different heights.
[0038] When viewed from insides of edges in which the outer walls 12 are formed, fastening holes are formed at centers of the structure seaters 11 formed in four locations that may support loads such that the upper panel 10 may be fixed to a structure 50 constituting a floating floor, the upper panel 10 is fastened to the structure 50 through the fastening holes of the structure seaters 11 using pieces 31 such as screws, and finishing caps 32 are inserted into upper portions of the upper panel 10 .
[0039] Further, when there is no leg, the protruding structure seaters 11 do not protrude from a bottom surface of the lower panel, and thus the entire bottom surface of a heating panel 60 is seated on the structure 50 , so that only structure fasteners (not illustrated) may be used for the upper panel.
[0040] Further, when the heating panel 60 is installed in the structure 50 , because loads of the heating panel 60 is focused on legs of the structure seaters 11 , threads are formed and fastening is performed using nuts N from below, so that the heating panel 60 may be supported.
[0041] Here, when the size of the upper panel 10 is enlarged, a structure seater 11 may be additionally formed at a center of the upper panel to support a load at a central portion of the upper panel 10 .
[0042] Further, the upper panel 10 includes the protrusions 13 for enhancing binding between the upper panel 10 and inner filling materials when cement mortar or yellow ocher is filled in the fastening grooves 18 a , the structure seaters 11 and the panel, the protrusion fasteners 14 for coupling with the lower panel 20 , and the ribs 15 for improving solidity between the catching protrusions 16 in the fastening grooves 18 a and the upper panel 10 .
[0043] Here, threads for bolt coupling are formed in the protrusion fasteners 14 so that the upper panel 10 is bolt-fastened to the lower panel 20 .
[0044] Further, as illustrated in FIG. 2 , fitting grooves 33 a and fitting protrusions 33 b may further formed on front, rear, left and right sides of the upper panel 10 .
[0045] Accordingly, the fitting grooves 33 a and the fitting protrusions 33 b are fitted in each other between adjacent heating panels 60 , so that gaps are not generated during operations or after installation.
[0046] Further, the upper panel 10 is opened/closed by covers 34 after upper portions of connectors 29 for connecting the heating pipe 27 and a hot water supply pipe 35 to each other and connecting the heating pipe 27 and a return water pipe 36 to each other is partially opened.
[0047] Further, the through-holes 28 through which the hot water supply pipe 35 and the return water pipe 36 pass so that the pipes may be horizontally installed in the heating panel 60 are formed in the upper panel 10 .
[0048] Next, the lower panel 20 includes a body 21 , bolt fastening holes 22 , fitting bosses 23 , filling holes 24 , through-holes 25 , wire meshes 26 , a heating pipe 27 , through-holes 28 , a hot water supply pipe 35 , a return water pipe 36 and connectors 29 , and has a square shape or rectangular shape to correspond to the upper panel 10 .
[0049] Further, pipe through-holes 37 through which the hot water supply pipe 35 and the return water pipe 36 connected to the through-holes 28 may be connected and assembled are formed inside the lower panel 20 .
[0050] In the lower panel 20 , the body 21 is formed by upward bending a steel plate in a quadrangular shape. The heating pipe 27 is arranged in the lower panel 20 in a zigzag shape, and has one end connected to the hot water supply pipe 35 installed while horizontally passing through one side of a bottom of the lower panel, through one connector 29 , and the other end connected to the return water pipe 36 installed while passing through the lower panel, through the other connector 29 .
[0051] That is, the wire meshes 26 are horizontally or vertically installed inside the lower panel 20 , and the heating pipe 27 is bound to the wire meshes 26 and is connected to the hot water supply pipe 35 and the return water pipe 36 horizontally installed on one side and the other side of the bottom to be parallel to each other while passing through the lower panel 20 , through the T-shaped connectors 29 .
[0052] Bent parts 21 a that are bent inward and downward are formed at ends of upwardly bent portions of the body 21 to be fitted in and fastened to the fastening grooves 18 a of the upper panel 10 , the fitting bosses 23 extending outward are formed at locations corresponding to the catching bosses 16 , and ends of the bent parts 21 a are caught by and are not separated from the catching steps 17 of the fastening bosses 18 in a state in which the bent parts 21 a are fitted in the fastening grooves 18 a.
[0053] Further, the bolt fastening holes 22 are formed at locations corresponding to the protrusion fasteners 14 of the upper panel 10 for bolt fastening from below to above.
[0054] The filling holes 24 are formed on side surfaces of the body 21 , which are upward bent, such that cement mortar or yellow ocher may be filled in an empty space inside the upper and lower panels 10 and 20 , and the through-holes 25 are formed at location corresponding to the structure seaters 11 of the upper panel 10 inside the lower panel 20 so that the heating panel 60 is fixed to the structure 50 through pieces 38 .
[0055] Further, the through-holes 28 through which the hot water supply pipe 35 and the return water pipe 36 pass so that the pipes may be horizontally installed inside the heating panel 60 are formed in the lower panel 20 .
[0056] Here, although a case where the through-holes 28 are formed in both the upper panel 10 and the lower panel 20 is described as an example, the through-holes 28 may be formed only in the lower panel 20 .
[0057] Further, in FIG. 4 , the pipe through-holes 37 are formed and partitioned in advance before cement mortar, yellow ocher or the like is filled in portions of the hot water supply pipe 35 and the return water pipe 36 except for portions of the connectors 29 and the covers 34 .
[0058] Because of this, a space required when the hot water supply pipe 35 and the return water pipe 36 are assembled and installed or are replaced later may be ensured.
[0059] Although such pipe through-holes 37 are not illustrated in the following other embodiments, it is apparent that pipe through-holes are formed in advance even in other embodiments so that a space may be ensured, and partitions or the like is formed so that the pipe through-holes may be partitioned.
[0060] Next, the rubber foam insulation 40 illustrated in FIG. 6 is injection-molded in accordance with an outer appearance of the lower panel 20 (a quadrangular box having an opened upper portion is illustrated in FIG. 6 ), is attached to a lower side of the lower panel 20 and performs insulation such that heat is not transferred downward.
[0061] Here, as illustrated in FIG. 6 , through-holes 41 are also formed at locations corresponding to the structure seaters 11 of the upper panel 10 in the rubber foam insulation (ethylene propylene diene monomer (EPDM)) 40 , an expanded polystyrene insulation or the like, so that the heating panel 60 is fixed to the structure 50 through the pieces 31 .
[0062] Here, an insulation (not illustrated) having no elasticity may be further interposed between the structure 50 and the heating panel 60 such that the heat is not leaked.
[0063] In the above-described Korean floor heating system panel 60 , when the bent parts 21 a of the lower panel 20 are properly pushed and inserted into the fastening grooves 18 a formed at front, rear, left and right edges of the upper panel 10 , the fitting bosses 23 of the lower panel 20 are caught by and coupled to the catching protrusions 16 formed inside the fastening grooves 18 a , and at the same time, while the bent parts 21 a of the lower panel 20 are inserted into the fastening grooves 18 a , ends of the bent parts 21 a are caught by the inner catching steps 17 , so that the upper panel 10 and the lower panel 20 are dually coupled to each other.
[0064] Next, the bolt fastening holes 22 of the lower panel 20 are bolt-fastened to the protrusion fasteners 14 of the upper panel 10 , which have threads on bottom surfaces thereof.
[0065] In this way, cement mortar, yellow ocher or the like is filled in an empty space inside the panel in which the upper panel 10 and the lower panel 20 are coupled to each other, through the filling holes 24 , and is cured. Thereafter, the heating panel 60 is completed.
[0066] FIG. 7 is a system diagram illustrating a state in which heating water circulates in heating panels connected to a boiler according to the embodiment of the present invention.
[0067] As illustrated in FIG. 7 , a hot water supply pipe 71 and a return water pipe 72 connected to a boiler B are connected to a branch port 73 and a reverse branch port 74 , respectively, and an outlet of the branch port 73 and an inlet of the reverse branch port 74 are connected to the hot water supply pipe 35 and the return water pipe 36 , respectively.
[0068] The hot water supply pipe 35 and the return water pipe 36 pass through heating panels 60 that are arranged adjacent to each other, and are connected in parallel to the heating pipe 27 formed in each heating panel 60 through the T-shaped connectors 29 .
[0069] Accordingly, hot water of the boiler B is supplied to the heating pipe 27 of the heating panel 60 through the hot water supply pipe 71 , the branch port 73 , the hot water supply pipe 35 and the connector 29 , is used for heating and is then supplied to the boiler B through the connector 29 , the return water pipe 36 , the reverse branch port 74 and the return water pipe 72 again.
[0070] FIG. 8 is a view illustrating a state in which the heating panel of FIG. 5 is installed on a structure.
[0071] As illustrated in FIG. 8 , heating panels 60 are installed in the structure 50 supported by legs 52 and floating in the air, in an assembling scheme, and the pieces 31 are coupled to the structure 50 through the structure seaters 11 of the upper panel 10 in a state in which the heating panels 60 are located on the structure 50 , so that the heating panels 60 are fixed to and installed in the structure 50 .
[0072] Here, a lower portion of each heating panel 60 may be insulated through the rubber foam insulation 40 , or the structure 50 may be installed after the entire bottom surface is constructed using insulation.
[0073] Further, height adjusting means are provided in the legs 52 in contact with the slab so that a height of the structure may be adjusted.
[0074] Further, ends of the legs 52 are sharpened so that noise transferred to a lower floor through the structure is minimized, noise reduction pads 54 are attached to between upper and lower steel plates 53 as supports 51 of the legs 52 so that a noise absorbing effect of reducing floor noise is achieved, and pads are finished on upper surfaces of the heating panels 60 constituting a floating floor. Then, the construction is completed.
[0075] Although the configuration in which the boiler B is connected to the heating pipe 27 of the heating panel 60 for the purpose of circulation of hot water has been described above as an example of the heating means, it is apparent that when the heating panel is manufactured to include an electric heating wire such as a carbon-coated heating element, a metal heating element and a sheet-type heating element, various kinds of heating panels may be manufactured by variously applying pipes and wires within the panel depending on the kinds of the electric heating wire.
[0076] Further, it is preferred that a bimetal temperature sensor (not illustrated) operated at a temperature of approximately 60-65° C. is provided in the heating means to prevent overheating, so that burns and fires caused by the overheating may be prevented.
[0077] FIGS. 9 and 10 are exploded perspective views illustrating the heating panel according to other embodiments of the present invention.
[0078] As illustrated in FIG. 9 , an upper panel and a lower panel constituting the heating panel have the same structures and shapes as those of the upper panel 10 and the lower panel 20 illustrated in FIGS. 3 and 4 . However, the upper panel 10 does not have the protrusions 13 and the through-holes 29 and the lower panel 20 does not have the heating pipe 27 , the hot water supply pipe 35 , the return water pipe 36 and the connectors 29 that are heating means.
[0079] Instead, a heating film 27 a or a thin sheet-type heating element is installed on a lower bottom surface of the lower panel 20 as the heating means.
[0080] Here, a fireproof insulation plate or a ceramic plate (not illustrated) is further provided below the heating film 27 a and is finished and fixed through a box-shaped steel plate 37 and pieces 38 .
[0081] Here, when the structure seaters 11 of the upper panel 10 do not protrude from a bottom surface of the heating panel 60 and are used only for fastening the structure, the entire bottom surface of the heating panel is seated on the structure 50 .
[0082] Next, as illustrated in FIG. 10 , an upper panel and a lower panel constituting a heating panel have the same shapes as those of the upper panel 10 and the lower panel of FIGS. 2B and 3 . However, the upper panel 10 does not include the protrusions 13 and the through-holes 29 , and the lower panel 20 does not include the heating pipe 27 , the hot water supply pipe 35 , the return water pipe 36 , the connectors 29 and the wire meshes 26 and the filling holes 24 for filling cement mortar or yellow ocher.
[0083] Instead, for heating means and for storing heat, intermediate panels 90 a and 90 b and a heating film 27 a are provided in an inner space defined by coupling the upper panel 10 and the lower panel 20 to each other. The pair of intermediate panels 90 a and 90 b are ceramic plates or fireproof insulation plates and are vertically spaced apart from each other, and the heating film 27 a is interposed therebetween.
[0084] Further, through-holes 93 through which the protrusion fasteners 14 of the upper panel 10 may pass are formed in the intermediate panels 90 a and 90 b.
[0085] Here, the structure seaters 11 of the upper panel 10 are not formed and only structure fasteners may be used.
[0086] FIG. 11 is a perspective view illustrating a heating panel according to yet another embodiment of the present invention.
[0087] As illustrated in FIG. 11 , the heating panel 60 according to yet another embodiment of the present invention includes a quadrangular upper steel plate 70 and a quadrangular lower box 80 , of which a body made of steel is upward bent so that an upper side of the lower box 80 is opened. Further, a flange 82 extending outward is formed at an upper portion of the lower box 80 and edges of the flange 82 and the upper steel plate 70 are spot-welded so that the heating panel 60 is configured.
[0088] Here, a heating panel 87 or the like, which is a heating means, is installed in an inner space of the lower box, which is like FIG. 4 , is bound through wire meshes 86 or the like, and is connected to a hot water supply pipe 85 and a return water pipe 89 through connectors 83 .
[0089] Further, through-holes 88 through which the hot water supply pipe 85 and the return water pipe 89 pass and a pipe connecting space between panels are partitioned and formed in the lower box 80 , and portions of the upper steel plate 70 , which are located above the connectors 83 , are partially opened, so that pipes between panels, that is, the hot water supply pipe 85 and the return water pipe 89 are connected through covers 74 .
[0090] In a state in which the upper steel plate 70 and the lower box are coupled to each other, cement mortar or yellow ocher is filled through filling holes 84 formed on side surfaces of the lower box 80 and is then cured.
[0091] Although the technical spirit of the present invention has been described above together with the accompanying drawings, this description is merely examples of exemplary embodiments of the present invention but does not delimit the present invention. Further, it is apparent that those skilled in the art may derive various modifications and imitations without departing from the scope of the technical spirit. | A heating system comprises: a structure forming an elevated floor above a slab and supported by legs; and heating panels comprising an upper panel having downwardly formed outer walls and downwardly protruding structure-seating parts on parts inside the corners capable of taking the load so that the upper panel can be fixed above the structure, and a lower panel having an upwardly bent body to attach to the bottom of the upper panel, the heating means installed in the interior, and the penetration parts which the structure-seating parts penetrate, wherein when the upper panel and lower panel are attached, the empty space therebetween is filled with cement mortar or red clay and cured. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to an orthopedic trial adaptor for use with both standard and reverse shoulder arthroplasty systems in a cemented, fracture or any similar setting where the final seating height of the head or cup implant is not readily available. The thickness of the orthopedic trial adaptor takes into account the difference in coupling between a trial which sits flush on a humeral stem and an implant which sits proudly on the humeral stem.
BACKGROUND OF THE INVENTION
[0002] Over time and through repeated use, bones and joints can become damaged or worn. For example, repetitive strain on bones and joints (e.g., through athletic activity), traumatic events, and certain diseases (e.g., arthritis) can cause cartilage in joint areas, for example, which normally provides a cushioning effect, to wear down. When the cartilage wears down, fluid can accumulate in the joint areas, resulting in pain, stiffness, and decreased mobility. The same can happen in the case where tendons in a joint become lax or soft tissues in or adjacent the joint tear becomes damaged or worn.
[0003] Arthroplasty procedures can be used to repair damaged joints. During a typical arthroplasty procedure, an arthritic or otherwise dysfunctional joint can be remodeled or realigned, or an implant or implants can be implanted into the damaged region. Arthroplasty procedures may take place in any of a number of different regions of the body, such as a knee, a hip, a shoulder, or an elbow.
[0004] One type of arthroplasty procedure is a shoulder arthroplasty, in which a damaged shoulder joint is replaced with prosthetic implants. The shoulder joint may have been damaged by, for example, arthritis (e.g., severe osteoarthritis or degenerative arthritis), trauma, or a rare destructive joint disease.
[0005] Implants that are implanted into a damaged region may provide support and structure to the damaged region, and may help to restore the damaged region, thereby enhancing its functionality. Prior to implantation of an implant in a damaged region, the damaged region may be prepared to receive the implant. In the case of a shoulder arthroplasty procedure, one or more of the bones in the shoulder area, such as the humerus and/or glenoid, may be treated (e.g., cut, drilled, reamed, and/or resurfaced) to provide one or more surfaces that can align with the implant and thereby accommodate the implant. Standard alignment instrumentation may be used for locating a position and orientation to resect the humeral head for proper humeral stem placement in the humerus.
[0006] Accuracy in implant alignment is an important factor to the success of the procedure. A one to two millimeter translational misalignment, or a few degrees of rotational misalignment, may result in imbalanced ligaments, and may thereby significantly affect the outcome of the procedure. For example, implant misalignment may result in intolerable post-surgery pain, and also may prevent the patient from having proper deltoid tension or range of motion.
[0007] To achieve accurate implant alignment, prior to treating (e.g., cutting, drilling, reaming, and/or resurfacing) any regions of a bone, it is important to correctly determine the location at which the treatment will take place and how the treatment will be oriented. Accordingly, instruments such as trials have been developed to be used in this part of the procedure. Generally, trials are affixed to the bone during joint kinematic evaluation and removed therefrom after a proper position and orientation for the implant has been determined.
[0008] Typically, trials are designed to correspond to an implant in size and shape. In a shoulder arthroplasty procedure, for example, a trial stem may be designed to be temporarily inserted into a prepared medullary canal of the humerus in a manner similar to that of an implant. Known trials may take many forms. For example, an expanding trial stem, such as that described in U.S. Pat. No. 8,216,320, the entire contents of which are hereby incorporated by reference herein, includes a trial stem that may be expanded after insertion into the medullary canal. When using such trial stems, particularly in shoulder replacements, it may be difficult to establish the proper position and orientation for the implant in the humerus. Further, trial cups and heads may be coupled to the trial stem during the trialing procedure. In order to achieve proper deltoid tension in a shoulder arthroplasty procedure, any differences in positioning between the trials and the corresponding implants should be taken into account.
BRIEF SUMMARY OF THE INVENTION
[0009] Humeral trial cups and heads of the present invention have connector or shaft portions for coupling the trial cups and heads to a corresponding humeral stem. While the trials are configured to sit flush with the stem, the implant head or cup sits proudly on the stem to ensure their tapered connection features are always properly engaged. A trial adaptor of the present invention is used to take into account the planar distance by which the implant head or cup sits proudly on the stem. The planar distance is defined by the distance between a base surface of the implant head or cup and a neck or contact surface of the stem.
[0010] A first aspect of the present invention is an orthopedic trialing system comprising a stem, an adaptor and a cup. The stem has a first coupling feature and a shaft portion adapted to be received in a canal of a bone of a patient. The adaptor has top and bottom surfaces and an aperture through the top and bottom surfaces. The cup has a second coupling feature, wherein one of the first and second coupling features extends through the aperture of the adaptor and at least partially into the other of the first and second coupling features for coupling together the cup, the adaptor and the stem.
[0011] In one embodiment of the first aspect, the bottom surface of the adaptor contacts and lies adjacent to a contact surface of the stem when the cup, the adaptor and the stem are coupled together. In another embodiment, when the top surface of the adaptor contacts and lies adjacent to a contact surface of the cup, the adaptor and the stem are coupled together.
[0012] According to the first aspect of the present invention, each of the top and bottom surfaces of the adaptor and the contact surfaces of the cup and stem are planar. In one embodiment, the first coupling feature of the stem is a recess, the stem having a contact surface with the recess therein. The second coupling feature of the cup is a protrusion that extends through the aperture of the adaptor and at least partially into the recess of the stem when the cup, the adaptor and the stem are coupled together.
[0013] In another embodiment, the first coupling feature is a protrusion, the stem having a contact surface with the protrusion extending outwardly therefrom. The second coupling feature of the cup is a recess and the protrusion of the stem extends through the aperture of the adaptor and at least partially into the recess of the cup when the cup, the adaptor and the stem are coupled together.
[0014] In yet another embodiment, the adaptor includes an engagement feature adapted to couple the adaptor to the stem.
[0015] In still yet another embodiment, the stem is selected from the group consisting of a broach, a trial stem or a prosthesis stem.
[0016] A second aspect of the present invention is an orthopedic trialing system comprising a stem, an adaptor and a cup. The stem has a planar surface and a shaft portion adapted to be received in a canal of a bone of a patient. The adaptor has a thickness defined by a linear distance between top and bottom surfaces thereof. The cup has a planar surface, wherein the planar surface of the stem and the planar surface of the cup are separated by the thickness of the adaptor when the cup, the adaptor and the stem are coupled together.
[0017] A third aspect of the present invention is an orthopedic trialing system comprising a stem, an adaptor and a cup. The stem having a shaft portion adapted to be received in a canal of a bone of a patient. The adaptor having top and bottom surfaces and an aperture through the top and bottom surfaces. The cup having a coupling feature for coupling together the cup, the adaptor and the stem.
[0018] In each of the above described aspects of the invention, the orthopedic trial system comprises a stem, an adaptor and a cup. However, in other aspects of the present invention, the cup that is used in reverse shoulder cases can be replaced with a head that is used in a total arthroplasty procedure. In other words, the orthopedic trial system in total arthroplasty cases includes a stem, an adaptor and a head.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A shows the general shoulder joint anatomy of a patient.
[0020] FIG. 1B is a view of a glenoid cavity of the shoulder joint.
[0021] FIG. 2 is a posterior view of a proximal portion of a humerus of the shoulder joint showing a resection line adjacent the anatomical neck of a humerus.
[0022] FIG. 3 is a schematic view of an exemplary proximal humerus broken into a plurality of bone fragments.
[0023] FIG. 4 is a cross-sectional view of one embodiment of a trial stem for use during a shoulder replacement procedure.
[0024] FIG. 5A is a perspective view of one embodiment of a stem implant according to aspects of the disclosure.
[0025] FIG. 5B is a perspective view of a proximal portion of the stem implant of FIG. 5A .
[0026] FIG. 5C is a top view of the stem implant of FIG. 5A .
[0027] FIG. 5D is a side view of a proximal portion of the stem implant of FIG. 5A .
[0028] FIG. 6A is a front view of one embodiment of a humeral head trial coupled to a stem implant of FIG. 5A inserted into a resected humeral bone.
[0029] FIG. 6B is a front view of one embodiment of a humeral head implant coupled to a stem implant of FIG. 5A inserted into a resected humeral bone.
[0030] FIG. 7A is a front view of one embodiment of a humeral cup trial coupled to a stem implant of FIG. 5A inserted into a resected humeral bone.
[0031] FIG. 7B is a front view of one embodiment of a humeral cup implant coupled to a stem implant of FIG. 5A inserted into a resected humeral bone.
[0032] FIG. 8A is a front view of one embodiment of a humeral head trial coupled to a stem implant of FIG. 5A inserted into a fractured humeral bone.
[0033] FIG. 8B is a front view of one embodiment of a humeral head implant coupled to a stem implant of FIG. 5A inserted into a fractured humeral bone.
[0034] FIG. 9A is a perspective view of one embodiment of a humeral trial adaptor of the present invention.
[0035] FIG. 9B is another perspective view of the humeral trial adaptor of FIG. 9A .
[0036] FIG. 10A is a perspective view of a trial assembly including the humeral trial adaptor of FIG. 9A coupled to one embodiment of a humeral trial cup coupled to a humeral trial insert.
[0037] FIG. 10B is a front view of the trial assembly of FIG. 10A coupled to an exemplary trial or implant stem.
[0038] FIG. 11A is a front cross-sectional view of one embodiment of a humeral cup trial, humeral trial adaptor and stem implant coupled to one another.
[0039] FIG. 11B is a front cross-sectional view of one embodiment of a humeral head trial, humeral trial adaptor and stem implant coupled to one another.
[0040] FIG. 12A is a perspective view of another embodiment of a humeral trial adaptor of the present invention.
[0041] FIG. 12B is a perspective view of the humeral trial adaptor of FIG. 12A coupled to one embodiment of a humeral trial cup.
[0042] FIG. 13A is a perspective view of another embodiment of a humeral trial adaptor of the present invention.
[0043] FIG. 13B is a perspective view of the humeral trial adaptor of FIG. 13A coupled to one embodiment of a humeral head trial.
DETAILED DESCRIPTION
[0044] In describing preferred embodiments of the disclosure, reference will be made to the directional nomenclature used in describing the human body. It is noted that this nomenclature is used only for convenience and that it is not intended to be limiting with respect to the scope of the invention. When referring to specific directions in relation to a device, the device is understood to be described only with respect to its orientation and position during an exemplary application to the human body. As used herein when referring to bones or other parts of the body, the term “proximal” means closer to the heart and the term “distal” means more distant from the heart. The term “inferior” means toward the feet and the term “superior” means toward the head. The term “anterior” means toward the front part or the face and the term “posterior” means toward the back of the body. The term “medial” means toward the midline of the body and the term “lateral” means away from the midline of the body. Further, although the devices and methods described herein are generally described in relation to human shoulder replacements, it should be understood that the devices and methods are not intended to be so limited and could be used with other joints, such as other ball and socket joints, including the hip, for example.
[0045] FIGS. 1A-B show the general anatomy of shoulder joint 10 of a patient. As shown in FIG. 1A , humerus 12 of joint 10 includes a neck portion 13 , a head portion 14 and a shaft portion 17 having a greater tuberosity 16 and a lesser tuberosity 18 . Between greater and lesser tuberosities 16 , 18 is bicipital groove 15 . As shown in FIG. 1B , scapula 22 terminates at glenoid 20 having a cavity 21 in which an outer surface 11 of head portion 14 rotates within. Along with humerus 12 and scapula 22 , the acromion 24 , rotator cuff 26 and clavicle 28 all provide support to the range of motion of the shoulder joint 10 of the patient.
[0046] FIG. 2 is a posterior view of a proximal portion of humerus 12 of shoulder joint 10 . Head portion 14 includes outer surface 11 . Also shown is bicipital groove 15 , a substantially straight surgical neck line 25 and a curvy anatomical neck line 27 . Outer surface 11 , biciptal groove 15 , substantially straight surgical neck line 25 and curvy anatomical neck line 27 are all anatomical features of humerus 12 that can be used to aid in determining the proper neck resection line.
[0047] Prior to a total shoulder arthroplasty procedure being conducted, shoulder joint 10 is generally compromised through injury or general wear and tear. A compromised joint generally leads to range of motion difficulty and pain for the patient. In a joint 10 that is compromised, head portion 14 and/or glenoid cavity 21 may be degenerated such that the axis of rotation of the shoulder joint is not in the same location as it was prior to joint 10 being compromised.
[0048] The axis of rotation of the shoulder joint varies based upon the type of motion. For flexion and extension, the axis of rotation is a transverse axis though the center of the humeral head. For abduction and adduction, the axis of rotation is a sagittal axis thought the center of the humeral head. For internal and external rotation, the axis of rotation is a vertical axis though the center of the humeral head.
[0049] During a total shoulder arthroplasty procedure, the humerus is resected in order to receive a humeral stem component. In such a procedure, the humeral head is generally resected and the shaft of the humerus is reamed to receive the humeral stem component prosthesis. It is important that the humeral stem component be positioned in the correct location and orientation in order to restore the axis of rotation of joint 10 . Some humeral stem components may include a flange that is adapted to contact a flat portion of resected bone of the humerus in order to correctly position and stabilize the humeral stem component within shaft 17 of humerus 12 such that the axis of rotation of joint 10 may be restored.
[0050] Also during a total shoulder arthroplasty procedure, the glenoid is resected in order to receive a glenoid component. In a shoulder arthroplasty procedure for implanting a reverse shoulder prosthesis, a cavity of the glenoid may be reamed and a guide hole may be drilled in order to receive a central screw extending outwardly from an outer contact surface of the glenoid component. The location and orientation of the guide hole may be based on the shape of the glenoid component, for example, such that the glenoid component can be implanted in the resected glenoid cavity and the axis of rotation of the joint may be restored. It is important that the glenoid component be positioned in the correct location and orientation in order to restore the axis of rotation of joint 10 . The glenoid component preferably has an articular surface corresponding to an outer surface of a humeral head component which is engaged to the humeral stem component implanted at least partially within the shaft of the humerus. Generally, the glenoid component has a diameter that is approximately 6 mm in diameter larger than the humeral head component.
[0051] As discussed above, humerus 12 must be resected at the correct location and orientation in order for a corresponding humeral stem prosthesis to be accurately implanted in shaft 17 of humerus 12 such that the axis of rotation of the shoulder joint may be restored. Thus, the location and orientation of resection line 30 , as shown in FIG. 2 , is either preoperatively or intraoperatively planned according to a desired result of the arthroplasty procedure.
[0052] Generally, the replacement of a humeral head with a prosthetic implant during shoulder arthroplasty involves gaining access to the shoulder joint through a retracted incision and removing the damaged humeral head. An exemplary damaged proximal humerus 10 ′ is illustrated in FIG. 3 . Although such breaks giving rise to a plurality of bone fragments may occur in any number of ways, this particular humerus 10 ′ is broken such that a first segment 20 ′, a second segment 30 ′, and a third segment 40 ′ including a substantial portion of the humeral head are each detached from the proximal end 12 ′ of the humerus. After removal of the humeral head, the proximal end of the humeral medullary canal may be shaped in order to accept an implant according to known methods. In one exemplary method, a hand reamer, for example, may be used at a proximal humeral bearing surface 14 ′ to remove bone material until an appropriately-shaped opening is formed in the proximal end 12 ′ of humerus 10 ′ for receiving an implant. Typically, successive reamers of increasing size are used in order to form an opening of the desired size. In many cases, bearing surface 14 ′ may not be as flat as shown. Most surfaces at a fracture site are irregularly shaped unless there is a clean break between adjacent fragments. Such a surface may be resected into a generally flat shape to receive a corresponding bearing surface of a trial and/or implant stem as shown in FIG. 3 .
[0053] Once an appropriate bearing surface 14 and opening is formed for receiving an implant, trialing is conducted to determine the proper size and location for the implant prior to implantation thereof. According to one example of the present disclosure, trialing includes inserting a trial stem 100 , as illustrated in FIG. 4 , into the opening in the proximal end 12 of humerus 10 . Trial stem 100 may include a proximal portion 110 connected to a distal portion 120 , for example by welding, with an expansion bolt 130 positioned within the trial stem. Generally, proximal portion 110 is adapted for insertion into the proximal end 12 of a prepared humerus 10 . Proximal portion 110 may include a first catch aperture 112 , a trial recess 114 , two second catch apertures 116 (both not visible in FIG. 4 ) and a driver recess 118 . Catch aperture 112 and driver recess 118 may be configured to mate with a trial cup, for example, as shown in FIG. 7A or as shown in greater detail with respect to the reverse cup humeral trial show in FIG. 11A and described in U.S. Pat. No. 8,545,511, the entire contents of which are hereby incorporated by reference herein. Trial recess 114 may be shaped to receive a corresponding portion of a trial humeral head, for example, as shown in FIG. 11B . Trial recess 114 may have a longitudinal axis that is angled with respect to a longitudinal axis of distal portion 120 so as to substantially replicate the typical geometry of a shaft and neck of the native bone prior to a fracture situation as shown in FIG. 3 .
[0054] The distal portion 120 of trial stem 100 may be structured to fit within a prepared bone canal, preferably the medullary canal of the humerus 10 . Distal portion 120 projects along a longitudinal axis thereof from proximal portion 110 generally in the proximal-to-distal direction. Distal portion 120 may include a first arm 122 and a second arm 124 configured to move away from each other in cooperation with expansion bolt 130 , such as that described in U.S. Pat. No. 8,216,320, the entire contents of which are hereby incorporated by reference herein. Distal portion 120 , or a portion thereof, may define a cavity or configured to accept expansion bolt 130 , the cavity including a mating surface such as threads.
[0055] Expansion bolt 130 may generally include a shaft 132 with a pointed distal tip 134 . A proximal end of expansion bolt 130 may include a head 136 , which may include a recess, such as a hex recess, to cooperate with a correspondingly shaped driving tool (not shown). A proximal end of shaft 132 may include a mating surface, such as threads 138 , configured to mate with a corresponding surface in the cavity of distal portion 120 . Although proximal portion 110 , distal portion 120 , and expansion bolt 130 may each be separate pieces prior to assembly, trial stem 100 is preferably provided to the end user as a single piece with the proximal and distal portions permanently connected, for example by welding, with the expansion bolt contained therein.
[0056] An exemplary embodiment of stem implant 200 is illustrated in FIG. 5A and may be structurally similar to trial stem 100 in certain respects. Stem implant 200 may be monolithic with a proximal portion 210 and a distal portion 220 . Proximal portion 210 of stem implant 200 , shown in greater detail in FIGS. 5B-D , may include a first contact surface 208 having a first catch aperture 212 and an implant recess 214 and a second contact surface 215 having two locking pin apertures 216 and a second catch aperture 218 . The apertures 212 and 218 similar to corresponding features on trial stem 100 , facilitate the connection between features of a trial cup with stem implant 300 . Implant recess 214 may be configured to accept a humeral head trial or implant, reverse cup humeral implant, or other compatible implant. Proximal portion 210 may also include a number of features to facilitate securing portions of humerus 10 , such as first segment 20 and second segment 30 , to stem implant 200 . For example, a first pair of suture holes 217 a may be formed on a lateral-anterior side of proximal portion 210 and a second pair of suture holes 217 b may be formed on a lateral-posterior side of the proximal portion. A third pair of suture holes 217 c may be formed on a medial side of proximal portion 210 . The suture holes 217 a - c may facilitate securing one or more bone fragments to stem implant 200 via sutures (not illustrated). One suture pocket 219 a may be formed on the lateral-anterior side of proximal portion 210 , and may be connected to suture holes 217 a . Another suture pocket (not visible in FIGS. 5A-D ) may be formed on the lateral-posterior side of proximal portion 210 , and may be connected to suture holes 217 b . The suture pockets may, for example, facilitate the insertion of a suture needle.
[0057] FIGS. 6A-B are exemplary embodiments of trial head and implant head assemblies 350 , 350 ′. In FIG. 6A , a trial head 325 is coupled to a stem implant 300 inserted into a resected humeral bone 310 , while in FIG. 6B , an implant head 325 ′ is coupled to stem implant 300 . A base surface 328 , 328 ′ of the respective trial head 325 and implant head 325 ′ lie on resection or neck line 330 of resected humerus 310 . As shown in FIG. 6A , base surface 328 of trial head 325 sits flush against a corresponding first contact surface 308 when trial head 325 is securely coupled to stem implant 300 . In contrast, as shown in FIG. 6B , when implant head 325 ′ is securely coupled to stem implant 300 , base surface 328 ′ of implant head 325 ′ is separated from first contact surface 308 such that implant head 325 ′ sits proudly on stem implant 300 . The gap between base surface 328 ′ and first contact surface 308 ensures that the tapers between the engagement portions of the implant head 325 ′ and stem implant 300 always engage. The gap between generally parallel base surface 328 ′ and first contact surface 308 may be defined as a linear distance D 1 . D 1 is generally 1-2 mm in length. The range of D 1 generally occurs due to the tolerances on the tapers of the implant head 325 ′ and the stem implant 300 . In a total or reverse shoulder case where you have a defined resection line 330 , this gap does not affect the final position of implant head 325 ′ because stem implant 300 will generally subside such that base surface 328 ′ of implant head 325 ′ lies adjacent resection line 330 and articulating surface 327 ′ of implant head 325 ′ will match the position of an articulating surface 327 of trial head 325 that was located during trialing. Implant head 325 ′ may also be impacted until base surface 328 ′ comes in contact with both resection line 330 and first contact surface 308 of stem implant 300 .
[0058] FIGS. 7A-B are exemplary embodiments of humeral cup trial and head assemblies 450 , 450 ′. In FIG. 7A , a trial cup 425 is coupled to a stem implant 400 inserted into a resected humeral bone 410 , while in FIG. 7B , an implant cup 425 ′ is coupled to stem implant 400 . A base surface 428 , 428 ′ of the respective trial cup 425 and implant cup 425 ′ lie on resection or neck line 430 of resected humerus 410 . As shown in FIG. 7A , base surface 428 of trial cup 425 sits flush against a corresponding first contact surface 408 when trial cup 425 is securely coupled to stem implant 400 . In contrast, as shown in FIG. 7B , when implant cup 425 ′ is securely coupled to stem implant 400 , base surface 428 ′ of implant cup 425 ′ is separated from first contact surface 408 such that implant cup 425 ′ sits proudly on stem implant 400 . The gap between base surface 428 ′ and first contact surface 408 ensures that the tapers between the engagement portions of the implant cup 425 ′ and stem implant 400 always engage. The gap between generally parallel base surface 428 ′ and first contact surface 408 may be defined by linear distance D 1 as shown in corresponding FIG. 6B . D 1 therefore does not affect the final position of implant cup 425 ′ because stem implant 400 will generally subside such that base surface 428 ′ of implant cup 425 ′ lies adjacent resection line 430 and articulating surface 427 ′ of implant cup 425 ′ will match the position of an articulating surface 427 of trial cup 425 that was located during trialing.
[0059] FIGS. 8A-B are exemplary embodiments of trial head and implant head assemblies 450 , 450 ′. However, in FIGS. 8A-8B , as opposed to FIGS. 6A-6B , the stem implants are inserted into fractured humeral bone rather than resected humeral bone. In most fracture situations a defined resection line cannot be produced. Therefore, separate instrumentation such as that described in U.S. Pat. Pub. No. 2015/0328015 titled “Guides for Fracture System” which is incorporated by reference herein in its entirety and/or skill of a surgeon is generally used to determine proper stem placement to achieve a desired location and orientation of an implant head. In FIG. 8A , a trial head 525 is coupled to a stem implant 500 inserted into a fractured humeral bone 510 , while in FIG. 8B , an implant head 525 ′ is coupled to stem implant 500 . A base surface 528 of trial head 525 lies on an anatomical neck line 530 as shown in FIG. 8A . In contrast, as shown in FIG. 8B , anatomical neck line 530 lies on first contact surface 508 and is separated from a base surface 528 ′ by linear distance D 1 . With a fracture setting, there is no resection plane to act as a reference for the seating of trial head 525 or implant head 525 ′. Further, subsiding of stem implant 500 is generally not possible due to lack of reference plane and the fact that the stem is typically cemented into the fractured humerus prior to impaction of head implant. Because of the gap between implant head 525 ′ and stem implant 500 , the implant head 525 ′ will generally sit approximately 1.5 mm higher than the trial head 525 . In other words, base surface 528 ′ or implant head 525 ′ sits approximately 1.5 mm from the anatomical neck line 530 when implant head 525 ′ is coupled to stem implant 500 . Such a situation would also occur in non-fracture settings where a reference resection plane is not available to determine the final head implant seating height or the stem is cemented prior to impaction of the head implant.
[0060] In order to account for the gap between implant head 525 ′ and stem implant 500 , for example, a humeral trial adaptor 640 as shown for example in FIGS. 9A and 9B is utilized. Trial adaptor 640 has a superior surface 641 and an inferior surface 642 . Superior surface 641 and inferior surface 642 are preferably planar surfaces separated by linear distance D 1 . An engagement portion 643 protrudes inferiorly from inferior surface 642 . Engagement portion 643 has a contact surface 644 in which a protrusion 645 protrudes outwardly from. Trial adaptor includes a first aperture 646 , a second aperture 647 and a third aperture 648 . Trial adaptor 640 further includes first and second flexible retaining portions 649 a , 649 b that extend along a length of both first and second apertures 646 , 647 .
[0061] FIG. 10A is a perspective view of a trial assembly 750 including trial adaptor 640 coupled to one embodiment of a trial cup 725 coupled to a trial insert 735 . Trial cup 725 includes a base surface 728 in which a first engagement portion 732 and a second engagement portion 734 extending outwardly therefrom. When trial adaptor 640 is coupled to trial cup 725 , first engagement portion 732 of trial cup 725 extends through first aperture 646 while second engagement portion 734 of trial cup 725 extends through third aperture 648 . First and second flexible retaining portions 649 a , 649 b come in contact with an outer surface of first engagement portion 732 of trial cup 725 and help to retain the coupling between trial adaptor 640 and trial cup 725 . As shown in FIG. 10B , trial assembly 750 is coupled to an exemplary trial or implant stem 700 . In this embodiment, contact surface 644 of trial adaptor 640 is in contact with a second contact surface 715 of trial stem while inferior surface 642 is in contact with a first contact surface 708 . Base surface 728 is separated from first contact surface 708 by linear distance D 1 .
[0062] In fracture or similar settings, trial adaptor 640 can therefore be used to account for the differences between the coupling of a trial cup or head with a trial or implant stem and an implant cup or head with an implant stem. During trialing, the surgeon or other operating room personal will use trial adaptor 640 along with a trial cup or head and a trial or implant stem which corresponds to a selected implant cup or head and the implant stem. FIGS. 11A-B are exemplary embodiments of humeral cup trial and head assemblies 850 , 850 ′. FIG. 11A shows cup trial 825 , trial adaptor 840 and stem implant 800 coupled to one another. A first engagement portion 832 of cup trial 825 extends through trial adaptor 840 and into a first catch aperture 812 while a second engagement portion 834 of cup trial 825 extends through trial adaptor 840 and into a second catch aperture 818 . A base surface 828 of cup trial 825 is separated from a first contact surface 808 of stem implant by linear distance D 1 . FIG. 11B shows head trial 825 ′, trial adaptor 840 and stem implant 800 coupled to one another. An engagement portion 833 ′ of head trial 825 ′ extends through trial adaptor 840 and into a trial recess 814 of stem implant. A base surface 828 ′ of cup trial 825 ′ is separated from a first contact surface 808 of stem implant by linear distance D 1 .
[0063] FIG. 12A is a perspective view of another embodiment of a humeral trial adaptor 940 of the present invention. Trial adaptor 940 has a superior surface 941 and an inferior surface 942 . Superior surface 941 and inferior surface 942 are preferably planar surfaces separated by linear distance D 1 . An engagement portion 933 protrudes inferiorly from inferior surface 942 . Engagement portion 933 is adapted to be received, for example, in trial recess 814 of stem implant 800 . Trial adaptor 940 includes a first aperture 946 and a third aperture 948 . Trial adaptor 940 further includes first and second retaining portions 949 a , 949 b that extend along a length of first aperture 946 .
[0064] FIG. 12B is a perspective view of a trial assembly 1150 including the humeral trial adaptor 940 of FIG. 12A coupled to one embodiment of a humeral trial cup 1125 . Trial cup 1125 includes a base surface 1128 in which a first engagement portion 1132 and a second engagement portion 1134 extending outwardly therefrom. When trial adaptor 940 is coupled to trial cup 1125 , first engagement portion 1132 of trial cup 1125 extends through first aperture 946 while second engagement portion 1134 of trial cup 1125 extends through third aperture 1148 . First and second retaining portions 949 a , 949 b come in contact with an outer surface of first engagement portion 1132 of trial cup 1125 and help to retain the coupling between trial adaptor 940 and trial cup 1125 .
[0065] FIG. 13A is a perspective view of another embodiment of a humeral trial adaptor 1040 of the present invention. Trial adaptor 1040 has a superior surface 1041 and an inferior surface 1042 . Superior surface 1041 and inferior surface 1042 are preferably planar surfaces separated by linear distance D 1 . An engagement portion 1043 protrudes inferiorly from inferior surface 1042 . Engagement portion 1043 has a contact surface 1044 adapted to come in contact with a corresponding surface of a trial stem. Trial adaptor 1040 includes a second aperture 1047 surrounded by first and second retaining portions 1049 a , 1049 b that extend along a length of second aperture 1047 .
[0066] FIG. 13B is a perspective view of a trial assembly 1150 ′ including the humeral trial adaptor 1040 of FIG. 13A coupled to one embodiment of a humeral head trial 1125 ′. Head trial 1125 ′ includes a base surface 1128 ′ in which an engagement portion 1133 ′ extends outwardly therefrom. Engagement portion 1133 ′ of head trial 1125 ′ extends through second aperture 1047 of trial adaptor 1040 and is adapted to be received, for example, into trial recess 814 of stem implant 800 . First and second retaining portions 1049 a , 1049 b come in contact with an outer surface of engagement portion 1133 ′ of head trial 1125 ′ and help to retain the coupling between trial adaptor 1040 and head trial 1125 ′. A base surface 1128 ′ of head trial 1125 ′ is separated from a first contact surface 808 of stem implant 800 (not shown in FIG. 13B ), for example, by linear distance D 1 . Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Disclosed herein are orthopedic trialing systems including a stem, an adaptor and a trial member. The stem may be a trial or implant stem. The trial member may be a cup or head. The adaptor is used to account for the difference in the coupling of the trial member and stem and an implant member and stem. The stem has a first coupling feature and a shaft portion adapted to be received in a canal of a bone of a patient. The adaptor has planar top and bottom surfaces and at least one aperture therethrough. The trial member has a second coupling feature, wherein one of the first and second coupling features of either the trial member or stem extends through the aperture of the adaptor and at least partially into the other of the first and second coupling features for coupling together the trial member, the adaptor and the stem. | 0 |
RELATED APPLICATIONS
[0001] The present application is a national stage entry according to 35 U.S.C. §371 of PCT application No.: PCT/EP2014/064827 filed on Jul. 10, 2014, which claims priority from German application No.: 10 2013 216 153.0 filed on Aug. 14, 2013, and is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] Various embodiments may relate to an electronic ballast for operating at least a first and a second cascade of LEDs, including an input with a first and a second input terminal for connecting to an alternating power supply voltage, a rectifier that is connected to the first and to the second input terminal, wherein the rectifier has an output with a first and a second output terminal, a first unit that includes the first cascade of LEDs, at least one second unit that includes the second cascade of LEDs, wherein an electronic switch is connected in parallel with the second cascade of LEDs, wherein the first unit is connected to the first output terminal of the rectifier and the at least one second unit is connected in series with the first unit, said connection being at the end of the first unit that is not connected to the first output terminal of the rectifier, a series circuit including a linear controller and a shunt resistor, wherein this series circuit is connected in series between the second unit and the second output terminal of the rectifier, as well as a setpoint value specification device for the linear controller, with a first and a second input and an output, wherein the output of the setpoint value specification device is connected to the linear controller, wherein the first input of the setpoint value specification device is connected to the shunt resistor, wherein the second input of the setpoint value specification device is connected to the tap of the first voltage divider.
[0003] What is referred to as a “cascade” of LEDs does preferably include a plurality of LEDs, but can, however, also be represented by a single LED.
BACKGROUND
[0004] In LED driver schemes in which the LED current, and thereby the grid current, are subject to linear control, and in which, due to their power consumption, it is necessary to ensure that the current drawn from the grid is largely sinusoidal, a setpoint value for the current controller has until now been derived by means of a voltage divider connected to the input voltage with a first and a second ohmic resistor. Since this input voltage is sinusoidal, both the setpoint value and, with an appropriate control concept, also the actual value of the grid current, are therefore also sinusoidal.
[0005] There are LED arrangements in which a grid current can only flow when the grid voltage is greater than the forward bias voltage of at least a portion of the LEDs used. These are LED arrangements in which, while particular LEDs of the overall arrangement can indeed be bridged by switches, a specific number of LEDs, in the present case what is known as the first cascade of LEDs are however not bridged, so saving a switch. Such arrangements are subject to the problem that the voltage tap at the voltage divider referred to above also outputs a non-negligible setpoint value during a period of time surrounding the zero transition of the grid, but a grid current corresponding to this setpoint value cannot flow. Through the use of a non-bridgeable cascade of LEDs it is possible to save one switch in the practical implementation. This cascade of LEDs is, accordingly, always in operation, provided the voltage provided at the output of the rectifier is larger than the forward bias voltage of the LEDs of this first cascade. This furthermore entails the advantage that, as long as the required forward bias voltage has not yet been reached, no current, which would merely generate heat loss there, can flow through the linear controller.
[0006] When conventional control apparatus is used for the current control this has the result that, starting at the moment at which the instantaneous value of the grid voltage drops below the forward bias voltage of the non-bridgeable portion of the LEDs, the current controller goes into saturation. When, subsequently, with increasing grid voltage it again rises above the forward bias voltage of the non-bridgeable portion of the LEDs, the current controller needs a settling time, during which the grid current is greater than the desired value corresponding to the setpoint value (control deviation). This overshoot in the grid current has a negative effect on the behavior of the overall arrangement in respect of grid current harmonics and of radio interference.
[0007] It would be conceivable, in order to solve this problem, to change the time-characteristic of the current controller in such a way that the gaps in the current are “masked out”. This, however, would entail the disadvantage that the overall speed of the current control could become too small.
SUMMARY
[0008] The present disclosure is therefore based on the object of further developing a generic electronic ballast of the type mentioned above in such a way that while providing an adequate speed of current control, overshoot of the grid current can be suppressed as far as possible.
[0009] The present disclosure is based on the idea of not connecting the first voltage divider that is used to form the setpoint value for the LED current directly between the first and second output terminals of the rectifier, but to a potential that is reduced in comparison with the voltage at the output of the rectifier by precisely the forward bias voltage of the non-bridgeable portion of the LEDs, which is to say the first cascade of LEDs. The particular effect of this is that a setpoint value greater than zero is only developed when the input voltage is greater than the forward bias voltage of the non-bridgeable portion of the LEDs.
[0010] According to various embodiments therefore the first voltage divider is connected between the coupling point of the first unit and the second unit at one end and the second output terminal of the rectifier at the other end. Through this measure it is achieved that, regardless of the tolerance-dependent and temperature-dependent forward bias voltage of the first cascade of LEDs, a setpoint value greater than zero is supplied to the current controller precisely when the voltage at the output of the rectifier exceeds the instantaneous forward bias voltage of the first cascade of LEDs. This ensures that the current controller cannot go into saturation, whereby an overshoot in the current drawn from the grid is prevented.
[0011] In various embodiments, the first voltage divider includes a first and a second ohmic resistor, wherein a capacitor is connected in parallel with the second ohmic resistor of the first voltage divider, which is connected between the tap of the first voltage divider and the second output terminal of the rectifier. This has the effect of eliminating high-frequency spikes at the tap of the first voltage divider.
[0012] According to various embodiments, the setpoint value specification device includes an operational amplifier whose inverting input represents the first input of the setpoint value specification device, and whose non-inverting input represents the second input of the setpoint value specification device. Control of the current through the cascades of LEDs can be performed particularly easily in this way. In this context, the operational amplifier is preferably connected in such a way that it acts as a P-controller, a PI-controller or as an I-controller.
[0013] According to various embodiments, a capacitor is connected in parallel with the respective cascade of LEDs. Ripple in the light is reduced by this measure, since during the pauses in the grid voltage, i.e. in those phases in which the respective cascade of LEDs is not supplied with current as a result of its forward bias voltage, power is supplied from the respectively assigned buffer capacitor.
[0014] In this connection in an advantageous manner a diode is connected in series between the LED cascade of a higher-lying unit and the buffer capacitor of a lower-lying unit. This prevents the buffer capacitor associated with a respective LED cascade from being discharged through the electronic switch that is connected in parallel. “Higher-lying” and “lower-lying” refer to the respective voltage levels at which the respective cascades of LEDs lie.
[0015] According to various embodiments, a component that is essentially constant in time in relation to the period duration of the supply grid can be added to the setpoint value formed by the first voltage divider, for example to better utilize the LEDs. This essentially constant offset would in turn form a setpoint value even in the periods of time in which no grid current can flow, which would lead to the saturation state of the current controller described above. An essentially constant offset of this sort could be generated through the addition of an essentially constant voltage to the non-inverting input of the operational amplifier.
[0016] Regardless of this, EMC disturbances and grid current harmonics can furthermore occur in those phases in which the voltage provided at the rectifier output is just larger than the forward bias voltage of the first cascade of LEDs, i.e. in the transition phases.
[0017] In order to counter these two problems, an auxiliary device may be connected in parallel with the second ohmic resistor of the first voltage divider and is designed to adjust the edge steepness of the voltage dropped across the second ohmic resistor. This auxiliary device thus promotes a further improvement in the operational behavior and optimization of the shape of the grid current curve, in that the component of the setpoint value corresponding to a constant offset, and/or the edge steepness during the fall prior to or during the rise following grid voltage zero transitions is reduced or set to zero depending on the voltage provided by the first voltage divider. In this way the steepness of the rise of the setpoint value, i.e. the rising edge of the supply voltage, or the fall in the setpoint value, i.e. the falling edge of the supply voltage, as well as the position of the edges in relation to the phase position of the input voltage, can be adjusted.
[0018] A significant reduction in the radio interference and in the grid current harmonics can thus be achieved through the auxiliary device.
[0019] This auxiliary device may include an electronic switch with a control electrode, a working electrode and a reference electrode, wherein the control electrode is connected to the tap of a second voltage divider including a first and a second ohmic resistor, which is connected in parallel with the first voltage divider. This electronic switch accordingly bridges the second ohmic resistor of the first voltage divider when the input voltage, i.e. the voltage at the output of the rectifier, undershoots a certain level. The electronic switch of the auxiliary device then becomes conductive, so that below a certain voltage, the setpoint value becomes prematurely zero. In this way transitions at which the current can flow are smoothed to prevent EMC interference. In order to establish when an LED current can flow, and when not, the auxiliary device is attached to the same tap as the voltage divider that supplies the setpoint value for the linear controller.
[0020] The second voltage divider is here preferably dimensioned such that the electronic switch reduces the setpoint value to zero when the input voltage is smaller than the forward bias voltage of the first cascade of LEDs, and that therefore no grid current can flow.
[0021] Preferably a Zener diode and/or a capacitor is connected in parallel with the second ohmic resistor of the second voltage divider, which is connected between the tap of the second voltage divider and a reference potential. Through a suitable selection of the capacitance of this capacitor mentioned immediately above, the edge steepness of the voltage across the second ohmic resistor of the first voltage divider, which corresponds to the setpoint value for the linear controller, may be adjusted in this case during the onset of the grid current. The purpose of the Zener diode is simply to limit the voltage between the reference electrode and the control electrode of the electronic switch of the auxiliary device.
[0022] Even though the present disclosure is described below for the sake of easier understandability taking the example of an electronic ballast with a first and one second unit, a large number of second units can be provided in practice.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0023] In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the disclosed embodiments. In the following description, various embodiments described with reference to the following drawings, in which:
[0024] FIG. 1 shows a schematic representation of an exemplary embodiment of an electronic ballast according to the present disclosure;
[0025] FIG. 2 and FIG. 3 : show the temporal progression of various magnitudes in an electronic ballast according to the prior art ( FIG. 2 ) and in an electronic ballast according to the present disclosure as illustrated in FIG. 1 ( FIG. 3 ).
DETAILED DESCRIPTION
[0026] FIG. 1 shows a schematic illustration of an embodiment of an electronic ballast 10 according to the present disclosure. An alternating power supply voltage V e of, for example, 230 V and 50 Hz, is applied between a first E 1 and a second E 2 input terminal. This is connected to the input of a rectifier D 002 , between whose output terminals a capacitor C 001 is connected, with the purpose of eliminating HF interference. The voltage dropped across the output terminals of the rectifier D 002 is labeled V(n 003 ).
[0027] A first, non-bridgeable cascade of LEDs is provided, of which one LED is drawn by way of example, marked as D 101 . This first cascade of LEDs forms, together with an optional first buffer capacitor C 101 that is connected in parallel with this first cascade of LEDs, a first unit EH 1 . An optional buffer capacitor C 111 is connected in parallel with a second cascade of LEDs, of which the LED D 117 is drawn by way of example. In order to stop the buffer capacitor C 111 from being discharged when the switch SW 1 is closed in the direction of the first unit EH 1 , a diode D 012 is connected between the two LED cascades. An electronic switch SW 1 is connected in parallel with the series circuit comprised of diode D 012 and of the parallel circuit comprised of the LED cascade D 117 and the buffer capacitor C 111 . The second LED cascade D 117 , the diode D 012 , the buffer capacitor C 111 and the switch SW 1 constitute a second unit EH 2 . A large number of further second units of this type can be connected in series with the first illustrated second unit EH 2 . Each of these cascades of LEDs is here bridged by the associated switch when the voltage V(n 003 ) is not sufficient to operate the respective cascade of LEDs in addition to the first cascade of LEDs, those of the unit EH 1 .
[0028] The series connection of a linear controller Q 100 and a shunt resistor R 100 is arranged in series with the units EH 1 , EH 2 . The current flowing in the drain terminal of the linear controller Q 100 is identified as I d (Q 100 ), and gives rise to a voltage drop in the shunt resistor R 100 . This current through the linear controller Q 100 corresponds to the current drawn from the supply grid and—if no buffer capacitors are used connected in parallel with the LED cascades—to the LED current.
[0029] A setpoint value specification device 12 provides a setpoint value to the control electrode of the linear controller Q 100 . The voltage dropped across the shunt resistor R 100 is fed through an ohmic resistor R 041 to the inverting input of an operational amplifier IC 1 -B for this purpose. The non-inverting input of this operational amplifier IC 1 -B is connected to the tap of a voltage divider that includes the ohmic resistors R 011 and R 012 . According to the present disclosure, this voltage divider is not connected directly between the output terminals of the rectifier D 002 , but between the coupling point N 1 of the first unit EH 1 to the second unit EH 2 at one end, and to the second output terminal of the rectifier D 002 at the other end.
[0030] In order to avoid high-frequency spikes, a capacitor C 040 is connected in parallel with the resistor R 012 . The voltage at the non-inverting input of the operational amplifier IC 1 -B is identified as V(n 019 ). The voltage at the output of the operational amplifier IC 1 -B is identified as V(n 016 ). The series connection of a capacitor C 041 and of an ohmic resistor R 043 is connected in the feedback network of the operational amplifier IC 1 -B. A PI controller is implemented in this way.
[0031] Since the voltage divider including the ohmic resistors R 011 and R 012 is not connected directly to the higher-voltage terminal of the rectifier D 002 , but to a potential that is lower than the voltage at the rectifier output by precisely the forward-bias voltage of the first cascade of LEDs, it follows that a setpoint value greater than zero is only formed when the output voltage V(n 003 ) of the rectifier D 002 is greater than the forward-bias voltage of the first cascade of LEDs.
[0032] An auxiliary device identified as 14 serves to reduce the measures required for radio interference suppression and the reduction of grid current harmonics. It permits the edge steepness before and after those phases in which the voltage provided at the rectifier output is somewhat larger than the forward bias voltage of the first cascade of LEDs, i.e. at the transition phases, to be adjusted.
[0033] This auxiliary device 14 includes a further voltage divider with the ohmic resistors R 013 and R 014 , which is connected in parallel with the first voltage divider, i.e. in particular also with the coupling point N 1 . The control electrode of a transistor Q 011 is connected to the tap of the voltage divider R 013 , R 014 . The resistors R 013 and R 014 are dimensioned here such that the transistor Q 011 reduces the setpoint value to zero when the input voltage is just a little larger than the forward bias voltage of the first LED cascade, and thus no grid current I d (Q 100 ) can flow.
[0034] On the one side a capacitor C 010 and on the other side the Zener diode D 010 are connected in parallel with the resistor R 014 .
[0035] Through a suitable selection of the capacitance of the capacitor C 010 it is thus possible to adjust the edge steepness of the voltage across R 012 , which corresponds to the setpoint value for the linear controller Q 100 , during the onset of the current I d (Q 100 ). The Zener diode D 010 only serves to limit the base-emitter voltage at Q 011 .
[0036] Through suitable dimensioning of the auxiliary device 14 it is possible to adjust the steepness in the rise of the setpoint value, i.e. at a rising edge of the voltage V(n 003 ), and of the fall in the setpoint value, i.e. at a falling edge of the voltage V(n 003 ), as well as the position of the edges in relation to the phase position of the voltage V(n 003 ) at the output of the rectifier.
[0037] FIGS. 2 and 3 show the temporal progression of various magnitudes in an electronic ballast according to the prior art ( FIG. 2 ) and an electronic ballast according to the present disclosure as illustrated in FIG. 1 ( FIG. 3 ).
[0038] The respective diagram a) shows the voltage V(n 003 ) between the output terminals of the rectifier D 002 . The temporal progression of the current I d (Q 100 ) is shown on the respective diagram b). Diagram c) shows on the one hand the temporal progression of the voltage V(n 019 ) at the non-inverting input of the operational amplifier IC 1 -B, i.e. the voltage at the tap of the first voltage divider R 011 , R 012 , as well as the temporal progression of the voltage V(n 016 ) at the output of the operational amplifier IC 1 -B, i.e. of the signals at the control electrode of the linear controller Q 100 .
[0039] The voltage V(n 003 ) is identical in the diagrams of FIG. 2 and FIG. 3 . Differences in the diagrams b) and c) result from the fact that in FIG. 2 , the setpoint value is generated, as is known from the prior art, through a tap of the voltage at the rectifier output, whereas the diagrams of FIG. 3 result from the use of an electronic ballast according to the present disclosure. As can clearly be seen, the progression of the current I d (Q 100 ) in the diagram of FIG. 2 b ) has very abrupt changes, which is disadvantageous from the point of view of radio interference suppression and of grid current harmonics. In the progression of the current I d (Q 100 ) of an electronic ballast according to the present disclosure on the other hand, see the diagram of FIG. 3 b ), such abrupt changes are not present, and the progression is smoother.
[0040] As can be seen from the diagram of FIG. 2 c , where the progression of the voltage V(n 109 ) is shown, a setpoint value is already present close to the zero transition in the prior art. As a result of this, the voltage V(n 016 ) at the output of the operational amplifier IC 1 -B rises, wherein, in the present design, no overshoot or settling of the current I d (Q 100 ) is visible. As can be seen from the corresponding progression in FIG. 3 c , these disadvantages are overcome in an electronic ballast according to the present disclosure.
[0041] While the disclosed embodiments have been particularly shown and described with reference to specific embodiments, it should 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 disclosed embodiments as defined by the appended claims. The scope of the disclosed embodiments is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced. | Various embodiments may relate to an electronic ballast for operating at least a first and a second cascade of LEDs, wherein the first cascade of LEDs is designed in such a way that the first cascade of LEDs is not be bridged. In order to provide a target value for a series regulator arranged in series with the LED cascades, a resistance voltage divider is used, which is coupled between the coupling point of the LED cascade that is not bridged and of the LED cascade that is not bridged at one end and the second output connection of the rectifier at the other end. | 8 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.