description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to aluminum can recycling apparatus and, more particularly, to recycling apparatus which receives and crushes cans for recycling and dispenses coupons.
2. Description of the Prior Art
U.S. Pat. No. 4,989,507 (Rhoades et al) discloses can crushing apparatus for collecting and crushing cans. The apparatus includes a conveyor belt onto which cans are dropped. The conveyor belt includes magnetic elements for holding onto ferrous cans. Two vacuum conduits are disposed above the conveyor. The first conduit receives aluminum cans, and the second conduit receives the ferrous cans. The ferrous cans are released from the conveyor to the conduit beyond a location in which the magnetic elements terminate. Both aluminum cans and ferrous cans are conveyed upwardly to the top of the apparatus where they are crushed. Refuse which may inadvertently be associated with the cans is separated from the cans and is discharged out of the apparatus.
U.S. Pat. No. 5,239,920 (Schuff & Burnett) discloses can crusher apparatus utilizing a housing and a can receiving slot in a lower portion of the housing. Aluminum cans fall onto a conveyor belt which transmits or transports the cans to a conduit which conveys the cans to a crusher. Ferrous cans remain in the conveyor, held by magnetic elements and move off the conveyor and are discarded. After being crushed, the aluminum cans are transported upwardly by air pressure or a moving air stream to the upper portion of the housing where they remain until they are transported out of the apparatus. The cans are moved out of the apparatus by air pressure which is the exhaust portion of the air pressure applied to the conduit which transports the cans from the conveyor to the crusher.
The apparatus of the present invention simplifies the crushing of aluminum cans for recycling and dispenses both money and coupons.
SUMMARY OF THE INVENTION
The invention described and claimed herein comprises apparatus for receiving cans, for crushing the cans, and for storing the crushed cans for recycling and for dispensing coupons. Only aluminum cans are crushed for recycling. Ferrous cans are discarded. The aluminum cans are crushed in a lower portion of the apparatus, and the crushed cans are transmitted upwardly and rearwardly to a storage bin. All of the active elements for both the crushing of the aluminum cans and for dispensing coupons are disposed on a door of a housing. The door is pivoted open to allow removal and replacement of the bin containing the crushed cans and any necessary maintenance and replacement work.
Among the objects of the present invention are the following:
To provide new and useful can recycling apparatus;
To provide new and useful can crusher apparatus for recycling aluminum cans;
To provide new and useful can crusher apparatus which rejects ferrous cans and accepts only aluminum cans;
To provide new and useful can crusher apparatus in which crushed cans are stored in a removable bin;
To provide new and useful apparatus for dispensing coupons;
To provide new and useful can crusher apparatus having a housing and a door on the housing; and
To provide new and useful can crusher apparatus having its active components secured to the door on the housing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view of the apparatus of the present invention.
FIG. 1A is a top view of the apparatus of the present invention.
FIG. 2 is a side view, in partial section, illustrating the interior of the apparatus of the present invention, taken generally along line 2--2 of FIG. 2.
FIG. 3 is a view of a portion of the apparatus of the present invention illustrating the active component secured to a pivoting door.
FIG. 4 is an enlarged view of a portion of the apparatus of the present invention.
FIG. 5 is an enlarged view of a portion of the apparatus shown in FIG. 3.
FIG. 6 is an enlarged view in partial section taken generally along line 6--6 of FIG. 3.
FIG. 7 is a bottom view of a portion of the apparatus of the present invention, taken generally along line 7--7 of FIG. 5.
FIGS. 8A-8F schematically illustrate sequentially the path of cans along the conveyor shown in FIGS. 4, 5, and 6.
FIG. 9 is a view in partial section taken generally along line 9--9 of FIG. 8E.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a front view of aluminum can recycling apparatus 10 of the present invention. FIG. 1A is a top view of the apparatus 10. The can recycling apparatus 10 comprises a generally rectangular housing with offset corner. The housing includes a front wall 30 which comprises a pivoting door.
FIG. 2 comprises a view in partial section of the can crusher apparatus 10 taken generally along line 2--2 of FIG. 1, showing the door 30 secured to the housing which includes a top wall 12, a bottom or floor 14, a rear wall 16, and a pair of side walls, of which a side wall 18 is shown in FIG. 2.
FIG. 3 is a front view of the apparatus 10 showing the door 30 pivoted open on a hinge pin 28. The pin 28 pivots on the top 12 and the bottom 14.
The active elements, those involved with the crushing or recycling of aluminum cans, and those associated with dispensing coupons, are secured to the door 30. Thus, when the door 30 is pivoted open, to the position shown in FIG. 3, all of the active elements, are readily available for servicing, as required.
The various elements involved in the recycling are shown in detail in FIGS. 3, 4, 6, and 7. FIG. 4 comprises a view of the portion of the door 30 which includes a conveyor system 70.
FIG. 5 comprises a view in partial section of the can crushing elements, including illustrating the path taken by a can through the apparatus.
FIG. 6 comprises a view in partial section taken generally along line 6--6 of FIG. 3, and complementing the illustration of FIG. 5 with respect to the can crushing apparatus.
FIG. 7 comprises a view taken generally along line 7--7 of FIG. 5, and comprises a bottom view looking upwardly through a crusher cylinder 130 and showing components associated therewith. FIG. 7 complements the illustrations of FIGS. 5 and 6.
For the following discussion, reference will generally be made to FIGS. 1-7.
As indicated above, the apparatus 10 comprises a generally rectangular or square housing with offset corners which includes the walls, as discussed above, and the front door 30 which is hingedly secured to the top 12 and bottom 14 at the side wall 18. On the exterior, or front, of the door 30 is a recess 32. The recess 32 includes a top wall 34, a back wall 36, a bottom 48, a screen 49 above the bottom 48, and a pair of side walls, of which a side wall 50 is best shown in FIG. 6. Secured to the back wall 36 of the recess 32 are such elements as a message display unit 38, a monitor 40, a coupon key pad 42, with a coupon dispenser 44 disposed at the bottom thereof, (see FIG. 1) and a coin dispenser 46.
In the side wall 36 at the screen 49 is an opening 52 for cans. The opening 52 receives the cans which are to be crushed and recycled. The opening 52 extends upwardly from the screen 49, and is best shown in FIG. 6.
A chute 60 is appropriately connected about the opening 52 and extends downwardly. The cans to be crushed fall through the chute 60 and onto a conveyor assembly 70.
Disposed on opposite walls of the chute 60 are photo cell elements 62 and 64. A can interrupts a beam between the elements 62 and 64 to activate the apparatus. The apparatus will run for a predetermined time period after the light beam is interrupted. This will be discussed in more detail below. With respect to the crushing or recycling, four motors are turned on when the apparatus is activated by the interruption of the light beam.
The conveyor assembly 70 is best shown in FIGS. 4, 5, and 6. The conveyor assembly 70 is secured to the front door 30 by appropriate support structure 72, best shown in FIG. 6. The conveyor assembly 70 includes a pair of generally parallel plates 74 and 76 spaced apart from each other. The plates 74 and 76 are joined by an end plate 78. A deflector plate 80, best shown in FIG. 4, is disposed above the plate 74 and 76 and appropriately secured thereto. The deflector plate 80 is disposed adjacent to the chute 60 to insure that cans falling through the chute 60 fall onto a belt 90 between the plate 74 and 76. The belt 90 comprises an endless belt onto which the cans fall from the chute 60 for appropriate conveyance.
An opening 82, remote from the end plate 78, extends through the plate 74. Secured to the plate 74 behind the opening 82 is a blower 84. The opening 82 is closed by a screen 86. The blower 84 blows aluminum cans to be crushed off the moving endless conveyor belt 90, as will be discussed below. The motor for the blower 84 is one of the motors activated by a falling can.
The conveyor belt 90 includes a flap 92 which extends upwardly from the belt 90. The purpose of the flap 92 is to move steel cans off the belt. The steel cans are then discarded. This will be discussed in detail below.
Extending between the plates 74 and 76 are a pair of shafts, including a shaft 98 and a shaft 102. A roller element 100 is secured to the shaft 98, and a roller element 104 is secured to the shaft 102.
Also secured to the plate 74 is a motor 96. The shaft 98 comprises a shaft for the motor 96. Thus, it is the motor 96 which drives the belt 90. The motor 96 is another of the motors activated by a falling can.
Disposed adjacent to the opening 82 and immediately below the belt 90 are magnetic elements 110. The magnetic elements 110 are strong enough to hold steel cans onto the belt 90 while the lighter, nonmagnetic, aluminum cans are blown off the belt 90 by the blower 84.
However, when the flap 92, contacts the steel cans, the flap 92 will cause the steel cans to move to the outer end of the belt 90, remote from the motor 96, and to fall off, as indicated by the large curved arrow in FIG. 4. The steel cans will thus be discarded.
The aluminum cans, on the other hand, will be blown by the blower 84 into a receiving and guide conduit 120. The conduit 120 comprises a receiver cylinder which is disposed above a crusher assembly 130. The receiver cylinder or conduit 120 includes an aperture 122 disposed oppositely the blower 84. It will be noted that the plate 76 includes an cutout 77 therein adjacent to the aperture 122 through which the aluminum cans are blown into the cylinder or conduit 120.
A guide tube 124, which is a relatively short cylindrical element, is secured to the conduit or cylinder 120 at the aperture 122. The guide tube 124 helps to make certain that the cans blown off the conveyor belt 90 fall into the conduit or cylinder 120. The cans then fall downwardly into the crusher assembly 130. This is best shown in FIG. 6.
The crusher assembly 130 includes a crusher cylinder 132 which has a larger diameter than the cylinder or conduit 120. Within the crusher cylinder 132 is a relatively large rotor 150. The rotor 150 is best shown in FIGS. 6 and 7. As indicated above, FIG. 7 comprises a bottom view, looking upwardly, taken generally along lines 7--7 of FIG. 5, and illustrates the crusher assembly and its various components. The rotor 150 crushes the cans through a steadily decreasing radius with respect to the center of rotation of the rotor 134 and the crusher cylinder 132. That is, as clearly shown in FIG. 7, the rotor 150 is asymmetrically disposed within the crusher cylinder 132.
Both the cylinder 132 and the crusher rotor 150 rotate. The dual rotation may best be understood with reference to FIG. 7. A sprocket 134 is disposed about the periphery of the cylinder 132. A drive chain 136 extends on the sprocket and is coupled to a shaft 138. A tension sprocket 137 is disposed between the sprocket 134 and the shaft 138.
The shaft 138, as best shown in FIG. 5, includes two sprockets, one for the chain 136 and one for a chain 140. The chain 140 extends to a sprocket 141 which is secured to the output shaft of a motor 144. The motor 144 is the third motor actuated by the control system in response to the broken light beam referred to above. The shaft 138 is appropriately supported and journaled for rotation.
A sprocket 142 is also secured to the output shaft of the motor 140. A drive chain 145 extends about the sprocket 142 and extends about a sprocket 147. The sprocket 147 is secured to a shaft 148. The shaft 148 is secured to the rotor 150. A tension sprocket is disposed between the sprockets 142 and 147.
Thus, activation of the motor 144 causes rotation of both the cylinder 132 and the crusher rotor 150 within the cylinder 132.
Within the cylinder 132, and disposed at the area of maximum radius between the rotor 150 and the cylinder 132, is an arm 152. At the outer end of the arm 152 is an arcuately extending deflector plate 154. The arm 152 is disposed about the shaft 148, but the shaft 148 rotates within the arm 152 such that the arm 152 and its deflector plate 154 remain fixed in place. The purpose of the deflector plate 154 is to prevent cans from falling directly through the cylinder 132, thus insuring that the cans to be crushed are crushed by the rotor 150 as it rotates within the cylinder 132.
The crusher assembly 130 is appropriately secured to the door 30 by support structure 150.
Beneath the crusher assembly 130 is a discharge conduit assembly 160, best shown in FIGS. 5 and 6. The discharge conduit assembly 160 includes a horizontal conduit portion 162, an upwardly extending conduit portion 166, and a vertical conduit portion 168. At the top or upper portion of the vertical conduit 168 is rearwardly extending nozzle portion 170. The nozzle portion is best shown in FIG. 2. Crushed cans fall into a bin 180 from the nozzle portion 170.
There is a bin portion 164 in the horizontal conduit 162 beneath the crusher cylinder 132. Crushed cans falling from the cylinder 132 fall into the bin 164, and thence into the horizontal conduit 162. The bin portion 164 is essentially a collection element to make certain that the crushed cans fall into the conduit 162.
A blower assembly 172 is connected to the horizontal conduit 162 remote from the vertical conduit 168. The blower assembly 172 includes a motor which is the fourth motor actuated in response to the broken light beam referred to above. The blower assembly 172 provides a stream of air into the conduit 162 to blow the crushed cans upwardly from the horizontal conduit 162, into the angular conduit 166 and thence upwardly into the vertical conduit 168 and out the nozzle 170 into the bin 180. The bin 180 is best shown in FIGS. 2 and 3.
The bin 180 includes a bottom 182 to which are secured four wheels 184. Extending upwardly from the bottom 182, and appropriately secured thereto and to each other, are four sides 186. The sides 186 are preferably screen, or the like.
Secured to the housing bottom 14 are two tracks 190. The wheels 184 of the bin 180 move in the tracks 190.
When the bin 180 is full of crushed cans, the door 30 is opened and the bin 190 is moved outwardly from the apparatus 10 and the filled bin is then hauled away. A replacement bin 180 is then moved into the apparatus 10 for appropriate filling with crushed cans.
The movement of the cans with respect to the conveyor assembly 70 is schematically illustrated sequentially in FIGS. 8A, 8B, 8C, 8D, 8E, and 8F. A plurality of aluminum cans 2, which are to be crushed, and recycled, and a steel can 4, which is not to be crushed, are illustrated with respect to the belt 90, the blower 84, the magnetic element 110, and the flap 92 on the belt 90, are shown in the sequential figures.
In FIG. 8A, the cans 2 and 4 are shown with respect to the belt 90 in essentially a side view. Two aluminum cans 2 are shown on the belt 92 and a can 2 and a steel can 4 are shown falling onto the belt 92.
FIGS. 8B-8F are top views of the belt 90 and the associated elements.
In FIG. 8B, the cans 2 and 4 are shown with respect to the belt 90 as the belt 90 moves in the direction shown by the large arrow. In FIG. 8C, the first aluminum can 2 is shown blown off the belt 90 by the blower 84. In FIG. 8D, the second can 2 is shown blown off the belt 90, and the steel can 4 is shown approaching the magnetic element 110.
In FIG. 8E, the steel can 4 is shown held in place with respect to the belt 90 by the magnetic element 110, while the third aluminum can 2 is shown blown off the belt 90.
In FIG. 8C, 8D, and 8E, the sequential movement of the belt 90, with particular reference to the flap 92, is illustrated. In FIG. 8E, the flap 92 is approaching the magnetic element 10 and the steel can 4. In FIG. 8F, the flap 92 is shown moving the steel can 4 along the belt. When the conveyor belt 90 reaches its roller 104 on its shaft 102, the flap 92 simply pushes the steel can 4 off the belt 90, and the steel can 4 then falls downwardly into a trash can, or the like, not shown, for appropriate disposal.
In the meantime, another aluminum can 2 is shown in FIG. 8F being blown off the conveyor belt 90, and additional aluminum cans 2 are shown approaching the blower 84.
FIG. 9 comprises a view in partial section taken generally along line 9--9 of FIG. 8E, and the relationship of the steel can 4, an aluminum can 2, the belt 90, the flap 92, and the blower 84 is illustrated. The can 2 is shown blown off the belt 90, while the steel can 4 remains on the belt 90 held in place by the magnetic element 110. The flap 92 is approaching the steel can 4, and subsequently, as discussed above, causes the can 4 to move on the belt 90 and then off the belt 90, to be disposed of. This is as shown in FIG. 8F and as discussed above.
Referring now particularly to FIGS. 1 and 6, a control box 200 is shown secured to the back wall 36 of the recess 32. The control box 200 is connected to the various elements of the apparatus, such as the message display 38, the monitor 40, the coupon keypad 42, with its dispenser 44, and the coin dispenser 46, by appropriate conductors 202, 204, 206, and 208, respectively. The control box 200, or specifically the control elements therein, which include a microprocessor and appropriate read only memory elements, also controls the four rotors specifically referred to above, including the motor of the blower 84, the conveyor motor 96, the crusher motor 144, and the motor associated with the blower 172. Microprocessor control is old and well known in the art, and thus is not discussed in detail herein. Moreover, for purposes of simplicity, the electrical connections between the control box 200 and the various motors is not illustrated. Again, such elements and connections are well known and understood in the art.
The control circuitry is actuated by a can breaking the light beam between the elements 62 and 66 (see FIG. 5). The light elements or photo elements 62 and 66 are connected to the control circuitry within the control box 200 by conductors 64 and 68, respectively. See FIG. 5 as well as FIG. 6.
Aluminum cans to be crushed and recycled are inductively counted by an inductive coil 126 disposed about the guide tube 124. A conductor 210 extends from the coil 126 to the control circuitry within the control box 200. Again, the operation of the sensing coil and its associated elements is well known and understood in the art.
Coins are disposed by the coin dispenser 46 in response to the sensing of the aluminum cans by the coil 126.
As indicated above, the control circuitry is activated when the light beam between the elements 62 and 66 is interrupted by a can falling through the chute 60. In addition to actuating the four motors discussed in detail above, the control circuitry also actuates the monitor 40, which may play a video advertising one or more products etc. The message display 38 is also actuated to provide a moving message or a plurality of sequential moving messages, which may include instructions for operating the coupon dispenser keypad 42, or any desired message or messages.
Different products or services being advertised on the message display 38 and the monitor 40 will be numbered or otherwise identified by simply keying or entering a desired number or term or whatever into the keypad 42, a coupon relating to the desired product or services is then dispensed by the coupon dispenser 44.
While a user is inserting cans to be crushed and recycled, information is being provided regarding goods and services. Coupons relative to the goods and services are then dispensed in response to input by the user through the keypad 42.
Thus, a user of the apparatus 10 receives coins for recycling aluminum cans, and receives coupons in response to a positive reaction to advertising, the reaction being the entering of specific information into the keypad.
While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, within the limits only of the true spirit and scope of the invention. | Aluminum can recycling and coupon dispenser apparatus includes a housing having a front door and a can receiving slot on the front of the door. Cans fall onto a conveyor belt which transmits or transports the cans to a conduit through which aluminum cans fall to a crusher. Ferrous cans remain on the conveyor held by magnetic elements and are pushed off the conveyor and are discarded. After being crushed for recycling, the cans are transported upwardly by a moving air stream to the upper portion of the housing and the cans fall rearwardly and downwardly to a storage bin where they remain until the bin is transported out of the apparatus. The storage bin may be removed intact and replaced by another storage bin. All of the active elements are secured to the door. The door is pivoted to remove the storage bin containing the crushed cans. Information is displayed while the can crushing is being accomplished and coupons are dispensed in response to user input on a keypad. The user input is in turn responsive to the displayed information. | 8 |
This is a continuation in part application claiming priority to U.S. patent application Ser. No. 10/623,222 filed Jul. 21, 2003 now U.S. Pat. No. 6,935,074 and U.S. patent application Ser. No. 10/693,473 filed Oct. 24, 2003 now U.S. Pat. No. 7,082,723.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Applicant's invention relates to a gutter retaining system for affixing a gutter to a building. More specifically, the present invention relates to an interlocking system that incorporates a clip for affixing gutters to a retaining member on the eaves of a building that obviates the need for using nails or screws within the gutter itself, and to the structure installed according to the system, both preassembly and as assembled. This interlocking system can incorporate a debris guard that prevents debris from enter and ultimately clogging the gutters.
2. Background Information
For years property owners have struggled with the destructive effects of water on their buildings. However, by channeling the water away from the structure, building owners can reduce the damage caused by water. This can be accomplished through the use of a gutter system. Gutters are troughs that channel water from the eaves, being the horizontal lower edge of a roof, of a building to the downspouts. The downspouts are essentially drainpipes that drain water from the roof gutters. Gutters are a critical component of a building because they prevent moisture damage by channeling water off the roof and away from the foundation. But any damaged lengths of gutter or drain pipe caused by wear, improper installation, or sagging can cause leaks which can result in water damage to the building.
Traditionally, gutters have been attached by nailing the gutter directly to the building. Building contractors typically used a spike and ferrule system, in which a narrow, tubular spacer, the ferrule, is placed between the front face of a gutter and its rear face, ensuring that the front face remains at a uniform distance from the rear face. A spike or long nail, is then punched through the outside of the front face of the gutter, through the ferrule, through the back face of the gutter, and into the wall or fascia of the structure.
Using the nail in this manner ruins the finished appearance of the gutter. In addition, once the gutter is installed it ends up with its front face tilted forward towards the ground. Once this occurs the captured rainwater and other material tends to pool along the outer edge of the gutter. The weight of this material creates a moment at the point of insertion of the nail, resulting in a force pulling the gutter away from the wall. Further, while this manner of installation has the effect (at least temporarily) of securing the gutter in place, it does not ensure that water will not run behind the gutter. In any structure where water is allowed to run and collect behind the gutter, eventually the integrity of the wood begins to weaken and the moment forces referred to above slowly pull the nail and the gutter away from the building. In periods of adverse weather, high winds can accelerate the process by getting behind the gutter and forcing it completely away from the building.
The utilization of gutter hangers is the most common way in which installers have tried to improve the integrity and life of gutter systems. In this application, a modified spacer is used, shaped like a flat plate, with both ends mined upward. One end of this spacer is inserted under the lip of the front face of the gutter, while the second end, with a pre-punched nail hole, is placed against the rear face of the gutter. A nail or screw is then inserted through the nail hole, through the rear face of the gutter, and into the building wall. A variation of this method includes placing the second end of the spacer over the top of the rear face of the gutter. The spacer is then nailed directly into the roof decking of the building or to the face of the wall, under any existing shingles. These methods of installation eliminate the unsightly appearance previously created by installing the nail or screw through the front face of the gutter. However, these hangers do not prevent the collection of water behind the gutter, nor relieve the moment created by the weight of the water pooling outwardly within the gutter.
A further problem occurs with different types of construction. The building may or may not include an additional small piece of fascia board under the eaves which is not as long as the gutter. If a piece of fascia board does exist under the eaves and the gutter system is in turn nailed to it, over time the portion of the gutter which extends below the fascia board will sag towards the building. This sagging can eventually cause leaks. Where no additional fascia board exists, this type of sagging is not seen.
Because of the problems which have been associated with traditional gutter systems and methods of installation, there is a need for a strong, sturdy gutter system. In addition, this system should be adaptable to different types of construction that may or may not incorporate an additional piece of fascia board. It is desirable that installation be easy, while ensuring that any interlocking aspect of the system is not compromised due to the primary construction of the building nor during periods of high winds or other adverse weather conditions. Preferably, this system should redistribute the water and other material captured within the gutter, such that all moments that could result are negated. Furthermore, the system should prevent any sagging due to construction that incorporates an additional piece of fascia board and incorporating a debris guard preventing the accumulation of debris.
SUMMARY OF THE INVENTION
The present invention embodies a gutter retaining system for affixing a rain gutter under the eaves of a building having a pitched roof. The gutter retaining system incorporates a gutter clip which is used in conjunction with a rain gutter and a retaining member. The gutter clip has an L-portion and a back portion. The back portion includes an upper u-portion with a hanger which is used to slip the gutter clip over the gutter. The back portion of the gutter clip also includes a nib end with a locking tip. Nib end extends slightly beyond the dimensions of the hanger and can fit within a hooked portion of the retaining member. This allows the locking tip to secure the gutter clip and gutter in place along the eaves of the building.
The L-portion of the gutter clip is useful on buildings which incorporate an additional piece of fascia board along the eaves in the construction. The L-portion fits between the gutter and the wall of the building, incorporating a base extension which can be fit against the building. In addition, the gutter clip is scored between the back portion and the L-portion which allows these two portions to be separated when desired, such as in the situation where no additional piece of fascia board is found along the eaves of the building. Where the L-portion is removed from the back portion, the L-portion would be discarded. In this situation, the vertical portion of the back portion presses against the building.
In a second embodiment, a retaining member is provided to permit the gutter system to be held against a building incorporating metal flashing. Retaining member has a mounting lip contiguous with an upper vertical section. At the junction between the mounting lip and upper vertical section is one end of horizontal section. The remainder of horizontal section drops into return which ends in a hooked portion.
In third through eighth embodiments, modified retaining members are provided to permit the gutter system to be held against a building with straight fascia, slanted fascia, and trim board as well as to permit the free floating attachment of a debris guard.
In a ninth embodiment, a modified gutter clip is provided. The modified gutter clip has a base, a vertical portion, and an elongated hanger portion. The vertical portion includes an upper u-portion which is used to slip the gutter clip over the gutter. Adjacent the upper u-portion is one end of elongated hanger portion. The opposing end of elongated hanger portion is designed to mate with lip of gutter. The base of the modified gutter clip is useful on buildings which incorporate an additional piece of trim board along the eaves in the construction. The base fits between the gutter and the wall of the building. In addition, the modified gutter clip can be scored between the vertical portion and the base which allows these two portions to be separated when desired, such as in the situation where no additional piece of trim board is found along the eaves of the building. Where the base is removed from the vertical portion, the base would be discarded. In this situation, the vertical portion presses against the building.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the gutter clip component of the preferred embodiment of the present invention.
FIG. 2 is a side view of the gutter clip component of the preferred embodiment of the present invention.
FIG. 3 is a cross-section view of the gutter clip component of the preferred embodiment of the present invention shown overlapping a gutter.
FIG. 4A is a perspective view of the gutter clip component of the preferred embodiment of the present invention with the L-portion removed.
FIG. 4B is a perspective view of the gutter clip component of the preferred embodiment of the present invention retaining the L-portion.
FIG. 5 is a cross-section view of the gutter clip component of the preferred embodiment of the present invention retaining the L-portion as shown with a gutter and retaining member against a building.
FIG. 6 is a cross-section view of the gutter clip component of the preferred embodiment of the present invention without the L-portion with a gutter and retaining member against a building.
FIG. 7 is a cross-section view of the retaining member of the second embodiment of the present invention.
FIG. 8 is a cross-section view of the gutter clip component of the preferred embodiment of the present invention without the L-portion with a gutter and the retaining member of the second embodiment against a building incorporating metal flashing.
FIG. 9 is a perspective view of the preferred embodiment of the present invention incorporating the gutter clip component, a debris guard, and retaining member of the third embodiment of the present invention utilizing a back snap in debris guard.
FIG. 10 is a perspective view of the preferred embodiment of the present invention incorporating the gutter clip component, a debris guard, and retaining member of the third embodiment of the present invention utilizing a front snap in debris guard.
FIG. 11 is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip component, a debris guard, and retaining member of the third embodiment of the present invention utilizing a back snap in debris guard.
FIG. 12 is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip component, a debris guard, and retaining member of the third embodiment of the present invention utilizing a front snap in debris guard.
FIG. 13A is a cross-section view of the retaining member of the third embodiment of the present invention.
FIG. 13B is a cross-section view of the retaining member of the fourth embodiment of the present invention.
FIG. 13C is a cross-section view of the retaining member of the fifth embodiment of the present invention.
FIG. 13D is a cross-section view of the retaining member of the sixth embodiment of the present invention.
FIG. 13E is a cross-section view of the retaining member of the seventh embodiment of the present invention.
FIG. 13F is a cross-section view of the retaining member of the eighth embodiment of the present invention.
FIG. 14A is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip component and retaining member of the eighth embodiment of the present invention.
FIG. 14B is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip component and retaining member of the fifth embodiment of the present invention.
FIG. 14C is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip component and retaining member of the fourth embodiment of the present invention.
FIG. 15 is a perspective view of the modified gutter clip of the ninth embodiment of the present invention.
FIG. 16 is a cross section view of the preferred embodiment of the present invention incorporating the modified gutter clip component and a retaining member of the fifth embodiment of the present invention.
FIG. 17 is a cross section view of the preferred embodiment of the present invention incorporating the modified clip component without the retaining member of the fifth embodiment of the present invention on straight fascia.
FIG. 18 is a cross section view of the preferred embodiment of the present invention incorporating the modified clip component without the retaining member of the fifth embodiment of the present invention on slanted fascia.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 a front view and side view, respectively, of the gutter clip 102 of the preferred embodiment of the present invention are shown. Gutter clip 102 is essentially L-shaped incorporating an L-portion 158 , a back portion 160 , a front face 120 and back face 118 . Beginning at the back portion 160 is locking tip 134 which is contiguous into nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 is contiguous with upper u-portion 110 . Upper u-portion 110 continues into vertical portion 162 . Vertical portion 162 transitions into L-portion 158 which begins at first elbow 112 . Scoring can be used on first elbow 112 to allow L-portion 158 to be easily separated from back portion 160 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . Base extension 130 is contiguous with lower u-portion 132 , lower u-portion 132 being completed at end 138 .
FIG. 3 shows a cross section view of the gutter clip 102 of the preferred embodiment of the present invention overlapping a gutter 104 . Gutter clip 102 , gutter 104 , and retaining member 122 make up a gutter retaining system 100 . Gutter clip 102 is as mentioned essentially L-shaped incorporating an L-portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 and back face 118 . Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 which is adjacent nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 continues into upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 . Back face 118 fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 to first elbow 112 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 . Vertical portion 162 transitions into L-portion 158 (See FIG. 2 ) which begins at first elbow 112 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . Base extension 130 is contiguous with lower u-portion 132 , lower u-portion 132 being completed at end 138 . The remainder of gutter 104 includes a gutter channel 156 , front wall 126 and lip 128 .
FIG. 4A is a perspective view of the gutter clip 102 of the preferred embodiment of the present invention with the L-portion 158 (See FIG. 2 ) removed. Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 (See FIG. 3 ) which is contiguous into nib end 106 (See FIG. 3 ). Nib end 106 (See FIG. 3 ) transitions into hanger 108 (See FIG. 3 ) via junction 136 (See FIG. 3 ). Hanger 108 (See FIG. 3 ) is contiguous with upper u-portion 110 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 . Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 .
In FIG. 4B a perspective view of the gutter clip 102 of the preferred embodiment of the present invention retaining the L-portion 158 (See FIG. 2 ) is shown. Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 (See FIG. 3 ) which is contiguous into nib end 106 (See FIG. 3 ). Nib end 106 (See FIG. 3 ) transitions into hanger 108 (See FIG. 3 ) via junction 136 (See FIG. 3 ). Hanger 108 (See FIG. 3 ) is contiguous with upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 (See FIG. 3 ) to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 . Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 to first elbow 112 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 . Vertical portion 162 transitions into L-portion 158 (See FIG. 3 ) which begins at first elbow 112 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . Base extension 130 is contiguous with lower u-portion 132 , lower u-portion 132 being completed at end 138 .
FIG. 5 is a cross-section view of the gutter clip 102 of FIG. 4B of the preferred embodiment of the present invention retaining the L-portion 158 (See FIG. 2 ) as shown with a gutter 104 and retaining member 122 against a building 150 . Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 which is contiguous into nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 is contiguous with upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 .
Front face 120 fits against mounting lip 146 of retaining member 122 . Mounting lip 146 ends in horizontal section 142 . One end of horizontal section 142 proceeds under the roof 152 tiles 164 while the remaining end drops into a return 140 . Return 140 ends in hooked portion 144 . Nib end 106 extends slightly beyond the dimensions of hanger 108 and therefore can fit within hooked portion 144 to allow locking tip 134 to secure gutter clip 102 and gutter 104 in place. The back of mounting lip 146 presses against a trim board 149 in front of fascia board 148 on building 150 . The thickness of L-portion 158 (See FIG. 2 ) is approximately equal to the thickness of fascia board 148 to allow for base extension 130 to fit properly against building 150 . In buildings 150 which incorporate this trim board 148 , L-portion 158 (See FIG. 2 ) provides stability to gutter 104 to prevent gutter 104 from sagging towards building 150 . The vertical portion 162 of gutter clip 102 as well as the upper u-portion 110 , hanger 108 , nib end 106 , junction 136 and locking tip 134 of gutter clip 102 are positioned under the eaves 154 of building 150 . A portion of horizontal section 142 , return 140 and hooked portion 144 of retaining member 122 are positioned under the eaves 154 of building 150 as is gutter 104 .
Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 to first elbow 112 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 . Vertical portion 162 transitions into L-portion 158 (See FIG. 2 ) which begins at first elbow 112 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . Base extension 130 is designed to fit against building 150 . Base extension 130 is contiguous with lower u-portion 132 , lower u-portion 132 being completed at end 138 . The remainder of gutter 104 includes a gutter channel 156 , front wall 126 and lip 128 .
FIG. 6 shows a cross-section view of the gutter clip 102 of FIG. 4A of the preferred embodiment of the present invention without the L-portion 158 (See FIG. 2 ) with a gutter 104 and retaining member 122 against a building 150 . Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 which is contiguous into nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 is contiguous with upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 .
Front face 120 fits against mounting lip 146 of retaining member 122 . Mounting lip 146 ends in horizontal section 142 . One end of horizontal section 142 proceeds under the roof 152 tiles 164 while the remaining end drops into a return 140 . Return 140 ends in hooked portion 144 . Nib end 106 extends slightly beyond the dimensions of hanger 108 and therefore can fit within hooked portion 144 to allow locking tip 134 to secure gutter clip 102 and gutter 104 securely in place. The back of mounting lip 146 presses against building 150 . The vertical portion 162 of gutter clip 102 as well as the upper u-portion 110 , hanger 108 , nib end 106 , junction 136 and locking tip 134 of gutter clip 102 are positioned under the eaves 154 of building 150 . A portion of horizontal section 142 , return 140 and hooked portion 144 of retaining member 122 are positioned under the eaves 154 of building 150 as is gutter 104 . Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 . The remainder of gutter 104 includes a gutter channel 156 , front wall 126 and lip 128 .
FIG. 7 is a cross-section view of the retaining member 122 a of the second embodiment of the present invention. Mounting lip 146 is provided which is contiguous with upper vertical section 206 . At the junction between mounting lip 146 and upper vertical section 206 is one end of horizontal section 142 . The remainder of horizontal section 142 drops into return. Return 140 ends in hooked portion 144 .
FIG. 8 is a cross-section view of the gutter clip component 102 (See FIG. 4A ) of the preferred embodiment of the present invention without the L-portion 158 (See FIG. 2 ) with a gutter 104 and the retaining member 122 a of the second embodiment against a building 150 incorporating metal flashing 200 held in place with nails 202 . Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 (See FIG. 5 ) which is contiguous into nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 is contiguous with upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 (See FIG. 5 ) to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 .
Front face 120 (See FIG. 2 ) fits against mounting lip 146 of retaining member 122 a . Mounting lip 146 is contiguous with upper vertical section 206 . Upper vertical section 206 is designed to extend in front of or behind metal flashing 200 . In addition, upper vertical section 206 can be used when no metal flashing 200 is provided. At the junction between mounting lip 146 and upper vertical section 206 is one end of horizontal section 142 . The remainder of horizontal section 142 drops into return 140 . Return 140 ends in hooked portion 144 . Nib end 106 extends slightly beyond the dimensions of hanger 108 and therefore can fit within hooked portion 144 to allow locking tip 134 (See FIG. 5 ) to secure gutter clip 102 and gutter 104 securely in place. The back of mounting lip 146 presses against building 150 . The vertical portion 162 (See FIG. 4A ) of gutter clip 102 as well as the upper u-portion 110 , hanger 108 , nib end 106 , junction 136 and locking tip 134 (See FIG. 5 ) of gutter clip 102 are positioned under the eaves 154 of building 150 . A portion of horizontal section 142 , return 140 and hooked portion 144 of retaining member 122 are positioned under the eaves 154 of building 150 as is gutter 104 . Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 . Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 (See FIG. 4A ). The remainder of gutter 104 includes a gutter channel 156 , front wall 126 and lip 128 .
The second embodiment can also incorporate the gutter clip 102 having the L-portion 158 as shown in FIG. 2 . Beginning at the back portion 160 (See FIG. 2 ) is locking tip 134 which is contiguous into nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 is contiguous with upper u-portion 110 . The portion of gutter clip 102 from locking tip 134 (See FIG. 5 ) to upper u-portion 110 fits inside the back wall 124 of gutter 104 . Upper u-portion 110 can be crimped to secure gutter clip 102 snugly to gutter 104 .
Front face 120 (See FIG. 2 ) fits against mounting lip 146 of retaining member 122 . Mounting lip 146 is contiguous with upper vertical section 206 . At the junction between mounting lip 146 and upper vertical section 206 is one end of horizontal section 142 . The remainder of horizontal section 142 drops into return 140 . Return 140 ends in hooked portion 144 . Nib end 106 extends slightly beyond the dimensions of hanger 108 and therefore can fit within hooked portion 144 to allow locking tip 134 (See FIG. 5 ) to secure gutter clip 102 and gutter 104 in place. The back of mounting lip 146 presses against a building 150 . The thickness of L-portion 158 (See FIG. 2 ) allows for base extension 130 to fit properly against building 150 . L-portion 158 (See FIG. 2 ) provides stability to gutter 104 to prevent gutter 104 from sagging towards building 150 . The vertical portion 162 (See FIG. 2 ) of gutter clip 102 as well as the upper u-portion 110 , hanger 108 , nib end 106 , junction 136 and locking tip 134 (See FIG. 5 ) of gutter clip 102 are positioned adjacent building 150 . A portion of horizontal section 142 , return 140 and hooked portion 144 of retaining member 122 are adjacent building 150 as is gutter 104 .
Back face 118 (See FIG. 3 ) fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 to first elbow 112 (See FIG. 3 ). Upper u-portion 110 of gutter clip 102 continues into vertical portion 162 (See FIG. 2 ). Vertical portion 162 (See FIG. 2 ) transitions into L-portion 158 (See FIG. 2 ) which begins at first elbow 112 (See FIG. 3 ). First elbow 112 (See FIG. 3 ) turns into base 114 (See FIG. 3 ) which proceeds into second elbow 116 (See FIG. 3 ). Second elbow 116 (See FIG. 3 ) turns up into base extension 130 (See FIG. 3 ). Base extension 130 (See FIG. 3 ) is designed to fit against building 150 . Base extension 130 (See FIG. 3 ) is contiguous with lower u-portion 132 (See FIG. 3 ), lower u-portion 132 (See FIG. 3 ) being completed at end 138 (See FIG. 3 ). The remainder of gutter 104 includes a gutter channel 156 , front wall 126 and lip 128 .
FIG. 9 is a perspective view of the preferred embodiment of the present invention incorporating the gutter clip 102 , a back-snap-in debris guard 200 , and retaining member of the third embodiment 202 of the present invention. Gutter clip 102 , gutter 104 and retaining member 202 make up a gutter retaining system 216 . Retaining member 202 has an upward facing lip 218 shown in more detail in FIG. 11 . This upward facing lip 218 is designed to receive a mating downward facing lip 220 (See FIG. 11 ) from one side 222 of a back-snap-in debris guard 200 . Once back-snap-in debris guard 200 is mated to upward facing lip 218 of retaining member 202 , the opposing side 224 can be mounted to the front of gutter 104 . Gutter 104 remains free floating even with the back-snap-in debris guard 200 installed.
FIG. 10 is a perspective view of the preferred embodiment of the present invention incorporating the gutter clip 102 , a front-snap-in debris guard 204 , and retaining member of the third embodiment 202 of the present invention. Gutter clip 102 , gutter 104 and retaining member 202 make up gutter retaining system 216 . At the front of gutter 104 is a receiving component 226 . This receiving component 226 is designed to receive a mating piece 228 from one side 230 of front-snap-in debris guard 204 . Once front-snap-in debris guard 204 is mated to receiving component 226 of gutter 104 , the opposing side 232 can be mounted to the retaining member 202 . Gutter 104 remains free floating even with the front-snap-in debris guard 204 installed.
FIG. 11 is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip 102 , a back-snap-in debris guard 200 , and retaining member of the third embodiment 202 of the present invention. Gutter clip 102 , gutter 104 and retaining member 202 make up a gutter retaining system 216 . Gutter clip 102 is essentially L-shaped incorporating an L portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 (See FIG. 2 ) and a back face 118 (See FIG. 2 ). Starting at the back portion 160 (See FIG. 2 ) is locking tip 134 which is adjacent nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 continues into upper u-portion 110 (See FIG. 2 ). The portion of gutter clip 102 from locking tip 134 to upper u-portion 110 (See FIG. 2 ) fits inside the back wall 124 of gutter 104 . Upper u-portion 110 (See FIG. 2 ) can be crimped to secure gutter clip 102 snugly to gutter 104 . Back face 118 (See FIG. 2 ) fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 (See FIG. 2 ) to first elbow 112 . Upper u-portion 110 (See FIG. 2 ) of gutter clip 102 continues into vertical portion 162 (See FIG. 2 ). Vertical portion 162 transitions into L-portion 158 (See FIG. 2 ) which begins at first elbow 112 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . The remainder of gutter 104 includes a gutter channel 156 and front wall 126 .
Retaining member 202 has vertical portion 234 designed to fit against building 150 . Vertical portion 234 is contiguous with an upper portion 236 of retaining member 202 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 faces building 150 . Attached to and extending away from hooked portion is upward facing lip 218 .
This upward facing lip 218 is designed to receive a mating downward facing lip 220 from one side 222 of a back-snap-in debris guard 200 . Once back-snap-in debris guard 200 is mated to upward facing lip 218 of retaining member 202 , the opposing side 224 of debris guard 200 can be mounted to the front wall 126 of gutter 104 . Gutter 104 remains free floating even with the back-snap-in debris guard 200 installed.
FIG. 12 is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip 102 , a front-snap-in debris guard 204 , and retaining member of the third embodiment 202 of the present invention. Gutter clip 102 , gutter 104 and retaining member 202 make up gutter retaining system 216 . Gutter clip 102 is essentially L-shaped incorporating an L portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 (See FIG. 2 ) and a back face 118 (See FIG. 2 ). Starting at the back portion 160 (See FIG. 2 ) is locking tip 134 which is adjacent nib end 106 . Nib end 106 transitions into hanger 108 via junction 136 . Hanger 108 continues into upper u-portion 110 (See FIG. 2 ). The portion of gutter clip 102 from locking tip 134 to upper u-portion 110 (See FIG. 2 ) fits inside the back wall 124 of gutter 104 . Upper u-portion 110 (See FIG. 2 ) can be crimped to secure gutter clip 102 snugly to gutter 104 . Back face 118 (See FIG. 2 ) fits against the outside of the back wall 124 of gutter 104 from upper u-portion 110 (See FIG. 2 ) to first elbow 112 . Upper u-portion 110 (See FIG. 2 ) of gutter clip 102 continues into vertical portion 162 (See FIG. 2 ). Vertical portion 162 transitions into L-portion 158 (See FIG. 2 ) which begins at first elbow 112 . First elbow 112 turns into base 114 which proceeds into second elbow 116 . Second elbow 116 turns up into base extension 130 . The remainder of gutter 104 includes a gutter channel 156 and front wall 126 .
Retaining member 202 has vertical portion 234 designed to fit against building 150 . Vertical portion 234 is contiguous with an upper portion 236 of retaining member 202 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 faces building 150 . Attached to and extending away from hooked portion is upward facing lip 218 .
At the front of gutter 104 is a receiving component 226 . This receiving component 226 is designed to receive a mating piece 228 from one side 230 of front-snap-in debris guard 204 . Once front-snap-in debris guard 204 is mated to receiving component 226 of gutter 104 , the opposing side 232 of debris guard 204 can be mounted to the angled member 238 of retaining member 202 . Gutter 104 remains free floating even with the front-snap-in debris guard 204 installed.
FIG. 13A is a cross-section view of the retaining member of the third embodiment 202 of the present invention. Retaining member 202 has vertical portion 234 designed to fit against building 150 (See FIG. 11 ). Vertical portion 234 is contiguous with an upper portion 236 of retaining member 202 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ). Attached to and extending away from hooked portion 240 is upward facing lip 218 .
This retaining member 202 is designed for use with roofing systems having straight fascia 148 (See FIG. 14A ) with preferably an adjacent drip edge 250 (See FIG. 14A ). Horizontal portion of retaining member 202 is placed against fascia board 148 (See FIG. 14A ). When a drip edge 250 (See FIG. 14A ) is present over fascia 148 (See FIG. 14A ), retaining member 202 is pushed under the drip edge 250 (See FIG. 14A ) to create a water tight seal. When a drip edge 250 (See FIG. 14A ) is not present, retaining member 202 ) is mounted at the top of fascia 148 (See FIG. 14A ) under roof tile or shingle 164 (See FIG. 14A ). Upward facing lip 218 adjacent hooked portion 240 is designed to receive a mating downward facing lip 220 (See FIG. 11 ) from one side 222 (See FIG. 11 ) of a back-snap-in debris guard 200 (See FIG. 11 ).
FIG. 13B is a cross-section view of the retaining member of the fourth embodiment 206 of the present invention. Vertical portion 234 is contiguous with an upper portion 236 of retaining member 206 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ). Extending at a right angle from a point 248 along vertical portion 234 is base 244 . Extending below point 248 along vertical portion 234 is extension 246 .
This retaining member 206 is designed for use with roofing systems having slanted fascia 148 (See FIG. 14C ) with preferably an adjacent drip edge 250 (See FIG. 11 ). The fascia 148 (See FIG. 14C ) is slanted from about 5 to 30 degrees. The purpose of this design is to support the back wall 124 of gutter 104 so the back wall 124 of gutter 104 remains vertical and does not allow the gutter 104 to follow the slant or angle of the fascia 148 (See FIG. 14C ). The retaining member 206 and the back wall 124 of gutter 104 are flush after installation. Vertical portion 234 of retaining member 206 is placed in front of the fascia 148 (See FIG. 14C ). When a drip edge 250 (See FIG. 14C ) is present, angled member 238 of retaining member 206 fits under the drip edge 250 (See FIG. 14C ). When a drip edge 250 (See FIG. 14C ) is not present, retaining member 206 covers fascia 148 (See FIG. 14C ) directly under the roof tiles or shingles 164 (See FIG. 14C ).
FIG. 13C is a cross-section view of the retaining member of the fifth embodiment 208 of the present invention. Retaining member 208 has vertical portion 234 designed to fit against building 150 (See FIG. 11 ). Vertical portion 234 is contiguous with an upper portion 236 and a lower portion 242 of retaining member 208 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ). Extending at a right angle from lower portion 242 is base 244 .
This retaining member 208 is designed for use with roofing systems having trim board 149 (See FIG. 14B ) next to fascia 148 (See FIG. 14B ) with preferably an adjacent drip edge 250 (See FIG. 14B ). Vertical portion 234 of retaining member 208 is placed in front of the trim board 149 (See FIG. 14B ). When a drip edge 250 (See FIG. 14B ) is present over trim board 149 (See FIG. 14B ), angled member 238 of retaining member 208 fits under the drip edge 250 (See FIG. 14B ). When a drip edge 250 (See FIG. 14B ) is not present, retaining member 208 covers trim board 149 (See FIG. 14B ) directly under the roof tiles or shingles 164 (See FIG. 14B ).
FIG. 13D is a cross-section view of the retaining member of the sixth embodiment 210 of the present invention. Retaining member 210 has vertical portion 234 designed to fit against building 150 (See FIG. 11 ). Vertical portion 234 is contiguous with an upper portion 236 and lower portion 242 of retaining member 210 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ). Attached to and extending away from hooked portion 240 is upward facing lip 218 . Extending at a right angle from lower portion 242 is base 244 .
This retaining member 210 is designed for use with roofing systems having trim board 149 (See FIG. 14B ) next to fascia 148 (See FIG. 14B ) with preferably an adjacent drip edge 250 (See FIG. 14B ). Vertical portion 234 of retaining member 210 is placed in front of the trim board 149 (See FIG. 14B ). When a drip edge 250 (See FIG. 14B ) is present over trim board 149 (See FIG. 14B ), angled member 238 of retaining member 210 fits under the drip edge 250 (See FIG. 14B ). When a drip edge 250 (See FIG. 14B ) is not present, retaining member 210 covers trim board 149 (See FIG. 14B ) directly under the roof tiles or shingles 164 (See FIG. 14B ). Upward facing lip 218 adjacent hooked portion 240 is designed to receive a mating downward facing lip 220 (See FIG. 11 ) from one side 222 (See FIG. 11 ) of a back-snap-in debris guard 200 (See FIG. 11 ).
FIG. 13E is a cross-section view of the retaining member of the seventh embodiment 212 of the present invention. Retaining member 212 has vertical portion 234 designed to fit against building 150 (See FIG. 11 ). Vertical portion 234 is contiguous with an upper portion 236 of retaining member 212 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ). Attached to and extending away from hooked portion 240 is upward facing lip 218 . Extending at a right angle from a point 248 along vertical portion 234 is base 244 . Extending below point 248 along vertical portion 234 is extension 246 .
This retaining member 212 is designed for use with roofing systems having slanted fascia 148 (See FIG. 14C ) with preferably an adjacent drip edge 250 (See FIG. 14C ). The fascia 148 (See FIG. 14C ) is slanted from about 5 to 30 degrees. The purpose of this design is to support the back wall 124 of gutter 104 so the back wall 124 of gutter 104 remains vertical and does not allow the gutter 104 to follow the slant or angle of the fascia 148 (See FIG. 14C ). The retaining member 212 and the back wall 124 of gutter 104 are flush after installation. Vertical portion 234 of retaining member 212 would be placed in front of the fascia 148 (See FIG. 14C ). When a drip edge 250 (See FIG. 14C ) is present, angled member 238 of retaining member 212 fits under the drip edge 250 (See FIG. 14C ). When a drip edge 250 (See FIG. 14C ) is not present, retaining member 212 covers fascia 148 (See FIG. 14C ) directly under the roof tiles or shingles 164 (See FIG. 14C ). Upward facing lip 218 adjacent hooked portion 240 is designed to receive a mating downward facing lip 220 (See FIG. 11 ) from one side 222 (See FIG. 11 ) of a back-snap-in debris guard 200 (See FIG. 11 ).
FIG. 13F is a cross-section view of the retaining member 214 of the eighth embodiment of the present invention. Retaining member 214 has vertical portion 234 designed to fit against building 150 (See FIG. 11 ). Vertical portion 234 is contiguous with an upper portion 236 of retaining member 214 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into a hooked portion 240 . Hooked portion 240 is designed to face building 150 (See FIG. 11 ).
This retaining member 214 is designed for use with roofing systems having straight fascia 148 (See FIG. 14A ) with preferably an adjacent drip edge 250 (See FIG. 14A ). Horizontal portion of retaining member 214 would be placed against fascia board 148 (See FIG. 14A ). When a drip edge 250 (See FIG. 14A ) is present over fascia 148 (See FIG. 14A ), retaining member 214 is pushed under the drip edge 250 (See FIG. 14A ) to create a water tight seal. When a drip edge 250 (See FIG. 14A ) is not present, retaining member 214 is mounted at the top of fascia 148 (See FIG. 14A ) under roof tile or shingle 164 (See FIG. 14A ).
FIG. 14A is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip 102 and retaining member of the eighth embodiment 214 of the present invention. Gutter clip 102 is essentially L-shaped incorporating an L-portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 (See FIG. 2 ) and a back face 118 (See FIG. 2 ). Back face 118 (See FIG. 2 ) sits against the outside of back wall 124 of gutter 104 . In this embodiment the L-portion 158 (See FIG. 2 ) sits against fascia board 148 .
Retaining member 214 has vertical portion 234 designed to fit against fascia 148 . Vertical portion 234 is contiguous with an upper portion 236 of retaining member 214 . Angled downward from upper portion 236 is angled member 238 .
Angled member 238 drops into a hooked portion 240 . Hooked portion 240 faces fascia board 148 .
FIG. 14B is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip 102 and retaining member of the fifth embodiment 208 of the present invention. Gutter clip 102 is essentially L-shaped incorporating an L-portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 (See FIG. 2 ) and a back face 118 (See FIG. 2 ). Back face 118 (See FIG. 2 ) sits against the outside of back wall 124 of gutter 104 . In this embodiment the L-portion 158 (See FIG. 2 ) is a little longer than that of FIG. 14A so as to permit it to sit against fascia board 148 .
Retaining member 208 has vertical portion 234 designed to fit against trim board 149 . Vertical portion 234 is contiguous with an upper portion 236 and a lower portion 242 of retaining member 208 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into hooked portion 240 . Hooked portion 240 is designed to face trim board 149 . Extending at a right angle from lower portion 242 is base 244 .
This retaining member 208 is designed for use with roofing systems having trim board 149 next to fascia board 148 with preferably an adjacent drip edge 250 . Vertical portion 234 of retaining member 208 is placed in front of trim board 149 . When a drip edge 250 is present over trim board 149 , angled member 238 of retaining member 208 fits under drip edge 250 . When a drip edge 250 is not present, retaining member 208 covers trim board 149 directly under the roof tiles or shingles 164 .
FIG. 14C is a cross-section view of the preferred embodiment of the present invention incorporating the gutter clip 102 and retaining member of the fourth embodiment 206 of the present invention. Gutter clip 102 is essentially L-shaped incorporating an L-portion 158 (See FIG. 2 ), a back portion 160 (See FIG. 2 ), a front face 120 (See FIG. 2 ) and a back face 118 (See FIG. 2 ). Back face 118 (See FIG. 2 ) sits against the outside of back wall 124 of gutter 104 . In this embodiment the L-portion 158 (See FIG. 2 ) sits against extension 246 of retaining member 206 .
Vertical portion 234 of retaining member 206 is contiguous with an upper portion 236 of retaining member 206 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into hooked portion 240 . Hooked portion 240 is designed to face fascia 148 . Extending at a right angle from a point 248 along vertical portion 234 is base 244 . Extending below point 248 along vertical portion 234 is extension 246 .
This retaining member 206 is designed for use with roofing systems having slanted fascia 148 with preferably an adjacent drip edge 250 . The fascia 148 is slanted from about 5 to 30 degrees. The purpose of this design is to support the back wall 124 of gutter 104 so the back wall 124 of gutter 104 remains vertical and does not allow the gutter 104 to follow the slant or angle of the fascia 148 . The retaining member 206 and the back wall 124 of gutter 104 are flush after installation. Vertical portion 234 of retaining member 206 is placed in front of fascia 148 . When a drip edge 250 is present, angled member 238 of retaining member 206 fits under the drip edge 250 . When a drip edge 250 is not present, retaining member 206 covers fascia 148 directly under the roof tiles or shingles 164 .
FIG. 15 is a perspective view of the modified gutter clip 252 of the ninth embodiment of the present invention. Modified gutter clip 252 is essentially L-shaped incorporating an L-portion 254 , a back portion 256 , a front face 258 , and a back face 260 . Back portion 256 transitions into L-portion 254 at one end at elbow 262 . Scoring can be used on first elbow 262 to allow L-portion 254 to be easily separated from back portion 256 . At the opposite end of L-portion 254 is a second elbow 264 which turns up into extension 266 . Back portion 256 at its opposite end transitions into one side of u-portion 268 . The other side of u-portion 268 drops into hanger elbow 270 . Hanger elbow is contiguous with hanger 272 . Hanger 272 ends in hanger lip 274 . Hanger 272 is essentially a horizontal section which spans the width of the gutter from hanger elbow 272 to hanger lip 274 .
FIG. 16 is a cross section view of the preferred embodiment of the present invention incorporating the modified gutter clip component 252 and a retaining member of the fifth embodiment 208 of the present invention. Modified gutter clip 252 is essentially L-shaped having an L-portion 254 . Back portion 256 at its opposite end transitions into one side of u-portion 268 . The other side of u-portion 268 drops into hanger elbow 270 . Hanger elbow 270 is contiguous with hanger 272 . Hanger 272 ends in hanger lip 274 .
Retaining member 208 has vertical portion 234 designed to fit against trim board 149 . Vertical portion 234 is contiguous with an upper portion 236 and a lower portion 242 of retaining member 208 . Angled downward from upper portion 236 is angled member 238 . Angled member 238 drops into hooked portion 240 . Hooked portion 240 is designed to face trim board 149 . Extending at a right angle from lower portion 242 is base 244 .
This retaining member 208 is designed for use with roofing systems having trim board 149 next to fascia board 148 with preferably an adjacent drip edge 250 . Vertical portion 234 of retaining member 208 is placed in front of trim board 149 . When a drip edge 250 is present over trim board 149 , angled member 238 of retaining member 208 fits under drip edge 250 . When a drip edge 250 is not present, retaining member 208 covers trim board 149 directly under the roof tiles or shingles 164 .
FIG. 17 shows a cross section view of the preferred embodiment of the present invention incorporating the modified clip component without the retaining member of the fifth embodiment of the present invention on straight fascia while FIG. 18 shows the same cross section with slanted fascia.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | A gutter retaining system incorporating a gutter clip with a gutter and retaining member. Retaining member is placed along the eaves. The gutter clip has L-portion and back portion. Back portion includes upper u-portion with hanger for slipping gutter clip over gutter for securing to gutter clip. Gutter clip has nib end with locking tip. Nib end fits within retaining member to secure gutter clip and gutter in place. L-portion fits between the gutter and building where an additional piece of board is included. The gutter clip is scored between the back portion and L-portion allowing separation if needed. A second embodiment provides a retaining member for use with metal flashing. Additional embodiments provided modified retaining members which permit the gutter system to be held against a building with straight fascia, slanted fascia, and trim board and which permit free floating attachment of a debris guard. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit of U.S. Provisional Patent Application No. 60/392,171, filed Jun. 26, 2002. The content of that application is hereby incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO AN APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] This invention relates to porphyrin-polyamine conjugate compounds used for treatment of cancer and other diseases.
BACKGROUND OF THE INVENTION
[0005] Cancer is the third most common cause of death in the world according to the World Health Organization, after heart disease and infectious disease. Cancer is the second most common cause of death (after heart disease) in the developed world. Accordingly, discovery of new and effective treatments for cancer is a high priority for health care researchers.
[0006] Cancer is often treated by using chemotherapy to selectively kill or hinder the growth of cancer cells, while having a less deleterious effect on normal cells. Chemotherapeutic agents often kill rapidly dividing cells, such as cancer cells; non-malignant cells which are dividing less rapidly are affected to a lesser degree. Other agents, such as antibodies attached to toxic agents, have been evaluated for use against cancers. These agents target the cancer cells by making use of a characteristic specific to the cancer, for example, higher-than-normal rates of cell division, or unique antigens expressed on the cancer cell surface.
[0007] As toxic agents specifically targeted against cancer cells can enhance therapeutic efficacy, reduce undesirable side effects, or both, many efforts have been made to achieve selective localization of well-defined chemical materials in malignant tumors. A significant advance in the field occurred with the introduction of tetraphenylporphine sulfonates (TPPS), which are non-naturally occurring porphyrins (Winkelman J. (1962) Cancer Res. 22:589). A hematoporphyrin derivative (HPD) was also found to localize in tumors (Lipson R L, Baldes, E J, & Gray M S (1967) Cancer 20: 2255). HPD is a complex mixture of porphyrins currently used as a sensitizer derivative that concentrates in tumor cells and destroys them after the tumor is irradiated with light or a laser beam (Dougherty T J, (1987) Photochem. Photobiol. 45:879). A wide variety of porphyrins and porphyrin analogues have been found to be selectively taken up by tumors, such as the naturally occurring porphyrins; for example, the octacarboxylic uroporphyrins, the tetracarboxylic coproporphyrins, and the dicarboxylic protoporphyrin. Synthetic porphyrins are also selectively taken up by tumors; among them are the meso-tetraphenyl porphyrins and the different porphyrin sulfonates TPPS 4 , TPPS 3 , TPPS 2a and TPPS 1 , which are listed in order of decreasing number of sulfonic acid substituents and decreasing hydrophilicity. Many factors determine the uptake and concentration of porphyrins in the tumors; one important factor is the structure (hydrophobicity, size, polarity) of the drug; another important factor is the formulation in which it is delivered (Sternberg E and Dolphin D (1996) Current Med Chemistry 3, 239). The mechanism(s) of porphyrin localization in tumors is still not entirely clear; the more hydrophobic porphyrins are preferentially incorporated in the lipid core of lipoproteins. Tightly aggregated porphyrins circulate as unbound pseudomicellar structures which can be entrapped in the interstitial regions of the tumor, can be localized in macrophages, or can enter neoplastic cells via pinocytotic processes. Low density lipoproteins (LDL), which are endocytosed by neoplastic cells through a specific receptor-mediated pathway, display the most selective release of porphyrins into the tumors (Jori G (1989) Photosensitizing Compounds, Ciba Foundation Symp 146, pp 78-94).
[0008] The present invention describes the synthesis and cytotoxic actions of porphyrin-polyamine conjugates. They are taken up by the tumor cells due to their porphyrin moiety, while the polyamine moiety provides the cytotoxic effects (see International Patent Application Nos. WO 00/66587 and WO 02/10142, and U.S. Pat. Nos. 6,392,098, 5,889,061, and 5,677,350).
SUMMARY OF THE INVENTION
[0009] The invention provides porphyrin-polyamine conjugate compounds and compositions comprising such compounds.
[0010] In one embodiment, the invention embraces a composition comprising a compound according to the formula
[0011] wherein at least one of J 1 , J 2 , J 3 , J 4 , J 5 , J 6 , J 7 and J 8 is independently M, where M is selected from the group consisting of
—(B-A-B) x -G-(B-A-B) m —(N(P)—B-A-B) n —K
[0012] wherein each A is independently selected from the group consisting of: a nonentity, C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 3 -C 12 cycloalkyl, C 3 -C 8 cycloaryl, C 3 -C 12 cycloalkenyl, C 3 -C 12 cycloalkynyl, C 1 -C 12 alkanol, C 3 -C 12 cycloalkanol, and C 3 -C 8 hydroxyaryl;
[0013] each B is independently selected from the group consisting of: a nonentity, C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 3 -C 12 cycloalkyl, C 3 -C 8 cycloaryl, C 3 -C 12 cycloalkenyl, C 3 -C 12 cycloalkynyl, C 1 -C 12 alkanol, C 3 -C 12 cycloalkanol, and C 3 -C 8 hydroxyaryl;
[0014] and with the proviso that each —B-A-B— unit contain at least one carbon atom;
[0015] wherein G is independently selected from the group consisting of —N(P)—, —(C═O)—N(P)—, —N(P)—(C═O)—, and a nonentity;
[0016] x is independently 0 or 1;
[0017] m is independently 0 or 1;
[0018] n is independently an integer from 0 to 20;
[0019] each P is independently selected from the group consisting of H and C 1 -C 12 alkyl;
[0020] K is independently selected from the group consisting of H, C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 3 -C 12 cycloalkyl, C 3 -C 8 cycloaryl, C 3 -C 12 alkyl, cycloalkenyl, C 3 -C 12 cycloalkynyl, C 1 -C 12 alkanol, C 3 -C 12 cycloalkanol, and C 3 -C 8 hydroxyaryl, and Q;
[0021] where each Q is independently selected from the group consisting of
[0022] where each P is independently selected from the group consisting of H and C 1 -C 12 alkyl, each D is selected from the group consisting of H and C 1 -C 32 alkyl, y is an integer from 1 to 8, and z is an integer from 0 to 5, and where the Q moiety is attached to the remainder of the molecule at any C or N atom in the Q moiety (including C atoms in the D or P moieties) by removing a hydrogen atom, a P substituent, or a D substituent of the Q moiety to form an open valence for attachment to the remainder of the molecule;
[0023] and where the remaining members or member of J 1 , J 2 , J 3 , J 4 , J 5 , J 6 , J 7 and J 8 are each independently selected from the group consisting of H, —B-A-B, —COOH, —SO 3 H, —B-A-B—COOH, or —B-A-B—SO 3 H, where each A and each B are independently selected as defined above and with the proviso that each —B-A-B— unit has at least one carbon atom.
[0024] In another embodiment, M excludes moieties of the form
—K 1 -G 5 -L 5 -(N(P 5 )-A 5 ) n -K 2
[0025] where K 1 is independently selected from the group consisting of C 1 -C 8 alkyl and where the valence to the left of K 1 attaches to the porphyrin ring;
[0026] G 5 is —O—, —(C═O)—, —C(═O)—O—, —O—(C═O)—, —O—(C═O)—O—, —O—(C═O)—N—, —N—(C═O)—O—, or a nonentity;
[0027] L 5 is C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 3 -C 8 cycloaryl, C 1 -C 8 alkoxy, C 1 -C 8 alkyl-C 3 -C 8 cycloalkyl, C 1 -C 8 alkyl-C 3 -C 8 cycloaryl, C 1 -C 8 alkoxy-C 3 -C 8 cycloaryl, C 3 -C 8 cycloalkyl-C 3 -C 8 cycloaryl, C 3 -C 8 cycloalkyl-C 1 -C 8 alkyl, C 3 -C 8 cycloaryl-C 1 -C 8 alkyl, C 3 -C 8 cycloaryl-C 1 -C 8 alkoxy, C 3 -C 8 cycloaryl-C 3 -C 8 cycloalkyl, or a nonentity;
[0028] each A 5 is independently selected from the group consisting of C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 3 -C 8 cycloalkyl, C 3 -C 8 cycloaryl, C 3 -C 8 cycloalkenyl, and C 3 -C 8 cycloalkynyl;
[0029] P 5 is selected from the group consisting of H and C 1 -C 8 alkyl;
[0030] n is an integer from 2 to 8;
[0031] and K 2 is independently selected from the group consisting of H, C 1 -C 8 alkyl,
[0032] C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 3 -C 8 cycloalkyl, C 3 -C 8 cycloaryl, C 3 -C 8 cycloalkenyl, C 3 -C 8 cycloalkynyl, C 1 -C 8 alkanol, C 3 -C 8 cycloalkanol, and C 3 -C 8 hydroxyaryl.
[0033] In another embodiment, G is independently selected from —(C═O)—N(P)— and —N(P)—(C═O)—. In another embodiment, the Q moiety is attached to the remainder of the molecule at any N atom in the Q moiety by removing a P substituent of the Q moiety to form an open valence for attachment to the remainder of the molecule. In another embodiment, each A and B substituent, if present, is selected from C 1 -C 12 alkyl. In another embodiment, at least one A substituent comprises a cyclopropane group.
[0034] In another embodiment, the invention embraces a composition comprising a compound according to the formula
[0035] where J 1 and J 2 are independently —(B-A-B) x -G-(B-A-B) m —(N(P)—B-A-B) n —K; J 3 , J 4 , J 6 and J 8 are independently selected from methyl and ethyl; and J 5 and J 7 are independently selected from methyl, ethyl, and —SO 3 H. In another embodiment, J 1 and J 2 are independently —(B-A-B)-G-(B-A-B)—(N(P)—B-A-B) n —K. In another embodiment, at least one B-A-B unit comprises a cycloalkyl moiety, such as a cyclopropyl moiety. In another embodiment, J 1 and J 2 are independently —C 1 —C 12 alkyl-G-C 1 -C 12 alkyl-(N(P)—B-A-B) n —K. In another embodiment, J 1 and J 2 are independently —C 1 -C 12 alkyl-(C═O)—N(P)—C 1 —C 12 alkyl-(N(P)—B-A-B) n —K. In another embodiment, J 1 and J 2 are independently —(CH 2 ) 2 C(═O)N(P 2 )—C 1 -C 4 alkyl-[NH(CH 2 CH 2 CH 2 CH 2 )] f C 1 -C 12 alkyl, where P 2 is H, methyl, or ethyl, and f is an integer from 1 to 10.
[0036] In still further embodiments, J 1 and J 2 are identical.
[0037] In still further embodiments, whenever any embodiment comprises a Q moiety (that is, whenever any K is Q), only one D moiety is selected from the group consisting of C 1 -C 32 alkyl and all remaining D moieties are H; three P groups are selected from the group consisting of —H and —CH 3 and the fourth P group is absent and the Q moiety is attached to the remainder of the molecule at that valence; and y is 2,3, or 4 and z is 0, 1, or 2.
[0038] In further embodiments, whenever any embodiment comprises a Q moiety, Q can be
BRIEF DESCRIPTION OF THE DRAWING(S)
[0039] [0039]FIG. 1. is a graph depicting the in vitro effects of increasing concentrations of SL-11209 on the growth of cultured human prostate cancer cells DUPRO.
[0040] [0040]FIG. 2. is a graph depicting the in vitro effects of increasing concentrations of SL-11211 on the growth of cultured human prostate cancer cells DUPRO.
[0041] [0041]FIG. 3. is a graph depicting the in vitro effects of increasing concentrations of SL-11209 on the survival of cultured human prostate cancer cells DUPRO after 5 days of treatment.
[0042] [0042]FIG. 4. is a graph depicting the in vitro effects of increasing concentrations of SL-11211 on the survival of cultured human prostate cancer cells DUPRO after 3 days of treatment.
[0043] [0043]FIG. 5. is a graph depicting the in vitro effects of increasing concentrations of SL-11211 on the survival of cultured human prostate cancer cells DUPRO after 5 days of treatment.
[0044] [0044]FIG. 6. is a graph depicting the in vitro effects of increasing concentrations of SL-11217 on the survival of cultured human prostate cancer cells DUPRO after 3 and 5 days of treatment.
[0045] [0045]FIG. 7. is a graph depicting the in vitro effects of increasing concentrations of SL-11211 on the survival of cultured human prostate cancer cells PC3after 5 days of treatment.
[0046] [0046]FIG. 8. is a graph depicting the in vitro effects of increasing concentrations of SL-11217 on the survival of cultured human prostate cancer cells PC3after 5 days of treatment.
[0047] [0047]FIG. 9. is a graph depicting the in vitro effects of increasing concentrations of SL-11237 on the survival of cultured human prostate cancer cells PC3 after 5 days of treatment.
[0048] [0048]FIG. 10. is a graph depicting the in vitro effects of 10 μM SL-11217 and SL-11237 on the growth of cultured human pancreatic cancer cells BxPC3.
[0049] [0049]FIG. 11. is a graph depicting the in vitro effects of 10 μM SL-11217 and SL-11237 on the growth of cultured human pancreatic cancer cells Panc1.
[0050] [0050]FIG. 12. is a graph depicting the in vitro effects of increasing concentrations of SL-11217 on the survival of cultured human brain tumor cells U251MG NCI after 3 days of treatment.
[0051] [0051]FIG. 13. is a graph depicting the in vitro effects of increasing concentrations of SL-11237 on the survival of cultured human brain tumor cells U251MG NCI after 3 days of treatment.
[0052] [0052]FIG. 14 depicts the effects of SL-11237 via oral administration. Male athymic nude mice were given subcutaneous injections of 0.75×10 6 DU145 cells on Day 0. Beginning on Day 10, mice were treated once weekly for 3 weeks with acidified water, 100 mg/kg, or 500 mg/kg of SL-11237 via oral gavage at 10 ml/kg dosing volume (the third treatment was actually 400 mg/kg in the high dose group). The top panel depicts average tumor volume in the mice. The bottom panel depicts average body weight of the mice.
DETAILED DESCRIPTION OF THE INVENTION
[0053] The invention is directed to various novel porphyrin-polyamine conjugate compounds and compositions containing them as described herein. The invention includes all salts of the compounds described herein. Particularly preferred are pharmaceutically acceptable salts. Pharmaceutically acceptable salts are those salts which retain the biological activity of the free bases and which are not biologically or otherwise undesirable. The desired salt may be prepared by methods known to those of skill in the art by treating the compound with an acid. Examples of inorganic acids include, but are not limited to, hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, and phosphoric acid. Examples of organic acids include, but are not limited to, formic acid, acetic acid, propionic acid, glycolic acid, pyruvic acid, oxalic acid, maleic acid, malonic acid, succinic acid, fumaric acid, tartaric acid, citric acid, benzoic acid, cinnamic acid, mandelic acid, sulfonic acids, and salicylic acid. Salts of the compounds with amino acids, such as aspartate salts and glutamate salts, can also be prepared.
[0054] The invention also includes all stereoisomers of the compounds, including diastereomers and enantiomers, as well as mixtures of stereoisomers, including, but not limited to, racemic mixtures. Unless stereochemistry is explicitly indicated in a structure, the structure is intended to embrace all possible stereoisomers of the compound depicted.
[0055] The term “alkyl” refers to saturated aliphatic groups including straight-chain, branched-chain, cyclic groups, and combinations thereof, having the number of carbon atoms specified, or if no number is specified, having up to 12 carbon atoms. “Straight-chain alkyl” or “linear alkyl” groups refers to alkyl groups that are neither cyclic nor branched, commonly designated as “n-alkyl” groups. Examples of alkyl groups include, but are not limited to, groups such as methyl, ethyl, n-propyl, isopropyl, butyl, n-butyl, isobutyl, sec-butyl, t-butyl, pentyl, n-pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, neopentyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and adamantyl. Cyclic groups can consist of one ring, including, but not limited to, groups such as cycloheptyl, or multiple fused rings, including, but not limited to, groups such as adamantyl or norbornyl. Preferred subsets of alkyl groups include C 1 -C 12 , C 1 -C 10 , C 1 -C 8 , C 1 -C 6 , C 1 -C 4 , C 1 -C 2 , C 3 -C 4 , C 3 , and C 4 alkyl groups.
[0056] “Substituted alkyl” refers to alkyl groups substituted with one or more substituents including, but not limited to, groups such as halogen (fluoro, chloro, bromo, and iodo), alkoxy, acyloxy, amino, hydroxyl, mercapto, carboxy, benzyloxy, phenyl, benzyl, cyano, nitro, thioalkoxy, carboxaldehyde, carboalkoxy and carboxamide, or a functionality that can be suitably blocked, if necessary for purposes of the invention, with a protecting group. Examples of substituted alkyl groups include, but are not limited to, —CF 3 , —CF 2 —CF 3 , and other perfluoro and perhalo groups.
[0057] “Hydroxyalkyl” specifically refers to alkyl groups having the number of carbon atoms specified substituted with one —OH group. Thus, “C 3 linear hydroxyalkyl” refers to —CH 2 CH 2 CHOH—, —CH 2 CHOHCH 2 —, and —CHOHCH 2 CH 2 —.
[0058] The term “alkenyl” refers to unsaturated aliphatic groups including straight-chain (linear), branched-chain, cyclic groups, and combinations thereof, having the number of carbon atoms specified, or if no number is specified, having up to 12 carbon atoms, which contain at least one double bond (—C═C—). Examples of alkenyl groups include, but are not limited to, —CH 2 —CH═CH—CH 3 ; and —CH 2 —CH 2 -cyclohexenyl, where the ethyl group can be attached to the cyclohexenyl moiety at any available carbon valence. The term “alkynyl” refers to unsaturated aliphatic groups including straight-chain (linear), branched-chain, cyclic groups, and combinations thereof, having the number of carbon atoms specified, or if no number is specified, having up to 12 carbon atoms, which contain at least one triple bond (—C≡C—). “Hydrocarbon chain” or “hydrocarbyl” refers to any combination of straight-chain, branched-chain, or cyclic alkyl, alkenyl, or alkynyl groups, and any combination thereof. “Substituted alkenyl,” “substituted alkynyl,” and “substituted hydrocarbon chain” or “substituted hydrocarbyl” refer to the respective group substituted with one or more substituents, including, but not limited to, groups such as halogen, alkoxy, acyloxy, amino, hydroxyl, mercapto, carboxy, benzyloxy, phenyl, benzyl, cyano, nitro, thioalkoxy, carboxaldehyde, carboalkoxy and carboxamide, or a functionality that can be suitably blocked, if necessary for purposes of the invention, with a protecting group.
[0059] For all of the foregoing definitions, preferred subsets of the groups include C 1 -C 12 , C 1 -C 10 , C l -C 8 , C l -C 6 , C l -C 4 , C 1 -C 2 (when chemically possible), C 3 -C 4 , C 3 , and C 4 groups.
[0060] “Aryl” or “Ar” refers to an aromatic carbocyclic group having a single ring (including, but not limited to, groups such as phenyl) or multiple condensed rings (including, but not limited to, groups such as naphthyl or anthryl), and includes both unsubstituted and substituted aryl groups. “Substituted aryls” refers to aryls substituted with one or more substituents, including, but not limited to, groups such as alkyl, alkenyl, alkynyl, hydrocarbon chains, halogen, alkoxy, acyloxy, amino, hydroxyl, mercapto, carboxy, benzyloxy, phenyl, benzyl, cyano, nitro, thioalkoxy, carboxaldehyde, carboalkoxy and carboxamide, or a functionality that can be suitably blocked, if necessary for purposes of the invention, with a protecting group.
[0061] “Heteroalkyl,” “heteroalkenyl,” and “heteroalkynyl” refer to alkyl, alkenyl, and alkynyl groups, respectively, that contain the number of carbon atoms specified (or if no number is specified, having up to 12 carbon atoms) which contain one or more heteroatoms as part of the main, branched, or cyclic chains in the group. Heteroatoms include, but are not limited to, N, S, O, and P; N and O are preferred. Heteroalkyl, heteroalkenyl, and heteroalkynyl groups may be attached to the remainder of the molecule either at a heteroatom (if a valence is available) or at a carbon atom. Examples of heteroalkyl groups include, but are not limited to, groups such as —O—CH 3 , —CH 2 —O—CH 3 , —CH 2 —CH 2 —O—CH 3 , —S—CH 2 —CH 2 —CH 3 , —CH 2 —CH(CH 3 )—S—CH 3 , —CH 2 —CH 2 —NH—CH 2 —CH 2 —, 1-ethyl-6-propylpiperidino, 2-ethylthiophenyl, and morpholino. Examples of heteroalkenyl groups include, but are not limited to, groups such as —CH═CH—NH—CH(CH 3 )—CH 2 —. “Heteroaryl” or “HetAr” refers to an aromatic carbocyclic group having a single ring (including, but not limited to, examples such as pyridyl, thiophene, or furyl) or multiple condensed rings (including, but not limited to, examples such as imidazolyl, indolizinyl or benzothienyl) and having at least one hetero atom, including, but not limited to, heteroatoms such as N, O, P, or S, within the ring. Unless otherwise specified, heteroalkyl, heteroalkenyl, heteroalkynyl, and heteroaryl groups have between one and five heteroatoms and between one and twelve carbon atoms. “Substituted heteroalkyl,” “substituted heteroalkenyl,” “substituted heteroalkynyl,” and “substituted heteroaryl” groups refer to heteroalkyl, heteroalkenyl, heteroalkynyl, and heteroaryl groups substituted with one or more substituents, including, but not limited to, groups such as alkyl, alkenyl, alkynyl, benzyl, hydrocarbon chains, halogen, alkoxy, acyloxy, amino, hydroxyl, mercapto, carboxy, benzyloxy, phenyl, benzyl, cyano, nitro, thioalkoxy, carboxaldehyde, carboalkoxy and carboxamide, or a functionality that can be suitably blocked, if necessary for purposes of the invention, with a protecting group. Examples of such substituted heteroalkyl groups include, but are not limited to, piperazine, substituted at a nitrogen or carbon by a phenyl or benzyl group, and attached to the remainder of the molecule by any available valence on a carbon or nitrogen, —NH—SO 2 -phenyl, —NH—(C═O)O-alkyl, —NH—(C═O)O-alkyl-aryl, and —NH—(C═O)-alkyl. If chemically possible, the heteroatom(s) as well as the carbon atoms of the group can be substituted. The heteroatom(s) can also be in oxidized form, if chemically possible.
[0062] The term “alkylaryl” refers to an alkyl group having the number of carbon atoms designated, appended to one, two, or three aryl groups.
[0063] The term “alkoxy” as used herein refers to an alkyl, alkenyl, alkynyl, or hydrocarbon chain linked to an oxygen atom and having the number of carbon atoms specified, or if no number is specified, having up to 12 carbon atoms. Examples of alkoxy groups include, but are not limited to, groups such as methoxy, ethoxy, and t-butoxy.
[0064] The term “alkanoate” as used herein refers to an ionized carboxylic acid group, such as acetate (CH 3 C(═O)—O (−1) ), propionate (CH 3 CH 2 C(═O)—O (−1) ), and the like. “Alkyl alkanoate” refers to a carboxylic acid esterified with an alkoxy group, such as ethyl acetate (CH 3 C(═O)—O—CH 2 CH 3 ). “ω-haloalkyl alkanoate” refers to an alkyl alkanoate bearing a halogen atom on the alkanoate carbon atom furthest from the carboxyl group; thus, ethyl ω-bromo propionate refers to ethyl 3-bromopropionate, methyl ω-chloro n-butanoate refers to methyl 4-chloro n-butanoate, etc.
[0065] The terms “halo” and “halogen” as used herein refer to Cl, Br, F or I substituents.
[0066] “Protecting group” refers to a chemical group that exhibits the following characteristics: 1) reacts selectively with the desired functionality in good yield to give a protected substrate that is stable to the projected reactions for which protection is desired; 2) is selectively removable from the protected substrate to yield the desired functionality; and 3) is removable in good yield by reagents compatible with the other functional group(s) present or generated in such projected reactions. Examples of suitable protecting groups can be found in Greene et al. (1991) Protective Groups in Organic Synthesis, 2nd Ed. (John Wiley & Sons, Inc., New York). Amino protecting groups include, but are not limited to, mesitylenesulfonyl (Mes), benzyloxycarbonyl (CBz or Z), t-butyloxycarbonyl (Boc), t-butyldimethylsilyl (TBDIMS or TBDMS), 9-fluorenylmethyloxycarbonyl (Fmoc), tosyl, benzenesulfonyl, 2-pyridyl sulfonyl, or suitable photolabile protecting groups such as 6-nitroveratryloxy carbonyl (Nvoc), nitropiperonyl, pyrenylmethoxycarbonyl, nitrobenzyl, dimethyl dimethoxybenzil, 5-bromo-7-nitroindolinyl, and the like. Hydroxyl protecting groups include, but are not limited to, Fmoc, TBDIMS, photolabile protecting groups (such as nitroveratryl oxymethyl ether (Nvom)), Mom (methoxy methyl ether), and Mem (methoxy ethoxy methyl ether), NPEOC (4-nitrophenethyloxycarbonyl) and NPEOM (4-nitrophenethyloxymethyloxycarbonyl).
[0067] Synthesis of Porphyrin-Polyamine Conjugates: Overview
[0068] Syntheses are described with reference to the schemes below. The synthesis of SL-11211 (Scheme 1) started with acetal 1 that was protected by mesitylene sulfonation to give 2. Alkylation of the known triamide 3 with 4-bromobutyronitrile following the procedure described previously (see Examples), reduction of the resulting nitrile and mesitylene sulfonation of the free amine gave octaamide 4. Treatment of 4 with 1,4-dibromobutane gave 5, that was then condensed with 2 to afford 6. Cleavage of the acetal residue of 6 resulted in the aldehyde 7, that was subjected to reductive amination with ethylamine to give 8. The amine was then condensed with mesoporhyrin dihdrochloride to the porphyrin diamide 9; deprotection of the amino residues of 9 gave SL-11211.
[0069] The synthesis of SL-11233 (Scheme 2) started with the known triamide 10 that was alkylated with 1,4-dibromobutane to give 11. The latter is condensed with 2 to give 12, the acetal cleaved to aldehyde 13, and the latter reductively aminated to 14. Condensation of 14 with deuteroporphyrin IX 2,4-disulfonic acid gave 15. Cleavage of the protecting groups in 15 allowed the synthesis of SL-11233.
[0070] The synthesis of SL-11235 started with the condensation of 8 and deuteroporphyrin IX-2,4-disulfonate to give 16 (Scheme 3). Deprotection of the amino residues gave SL-11235 eicosahydrobromide.
[0071] The synthesis of SL-11236 started with the condensation of 8 and N-methylmesoporphyrin IX to give 17, that was then deprotected to give SL-11236 eicosahydrobromide (Scheme 3).
[0072] The synthesis of SL-11237 started with the previously described cyclic amine 18 (patent cyclic polyamines) that was condensed with mesoporphyrin IX. dihydrochloride to give SL-11237 (Scheme 3).
[0073] The synthesis of SL-11217 (Scheme 4) started with the known cyclopropyl derivative 19, that was hydrolyzed to the acid and the latter transformed into its chloride 20. Condensation of 20 with a protected N-ethyl 1,4-diaminobutane gave 21, that was reduced with diborane and then acylated with mesitylenesulfonyl chloride to give 22. Alkylation of 22 with dibromobutane in the presence of sodium iodide gave 23, that was condensed with ethylamine to give 24.
[0074] Condensation of 24 with mesoporphyrin IX dihydrochloride gave 25, deprotection of the amino residues gave SL-11217 hydrobromide.
[0075] The synthesis of SL-11209 started with the known amine 26 that was alkylated with the benzyl ether of 4-bromobutanol to give 27 (Scheme 5). Hydrolysis of the benzyl ether gave the alcohol 28, the alcohol was protected by reaction with t-butyloxycarbonyl anhydride to give 29, and the latter oxidized to the aldehyde 30. Reductive amination of 30 gave 31. In tandem, reduction of the diester of mesoporphyrin gave the dialdehyde 32. Condensation of 32 with 31, followed by acid deprotection of the amino residues gave SL-11209.
[0076] The synthesis of SL-11210 started with the known nitrile 33 that was reduced to the amine and the latter condensed with 32 following a reductive amination procedure (Scheme 6). Deprotection of the amino residues gave SL-11210.
[0077] Reductive amination procedures allowed the condensation of 18 and aldehyde 32 that gave SL-11257 (Scheme 7)
[0078] Therapeutic use of Porphyrin-Polyamine Conjugate Compounds
[0079] Porphyrin-polyamine conjugate compounds of the present invention are useful for treatment of a variety of diseases caused by uncontrolled proliferation of cells, including cancer, particularly prostate cancer. The compounds are used to treat mammals, preferably humans. “Treating” a disease using a porphyrin-polyamine conjugate compound of the invention is defined as administering one or more porphyrin-polyamine conjugate compounds of the invention, with or without additional therapeutic agents, in order to prevent, reduce, or eliminate either the disease or the symptoms of the disease, or to retard the progression of the disease or of symptoms of the disease. “Therapeutic use” of the porphyrin-polyamine conjugate compounds of the invention is defined as using one or more porphyrin-polyamine conjugate compounds of the invention to treat a disease, as defined above.
[0080] In order to evaluate the efficacy of a particular porphyrin-polyamine conjugate compound for a particular medicinal application, the compounds can be first tested against appropriately chosen test cells in vitro. In a non-limiting example, porphyrin-polyamine conjugate compounds can be tested against tumor cells, for example, prostate tumor cells. Exemplary experiments can utilize cell lines capable of growing in culture as well as in vivo in athymic nude mice, such as LNCaP. Horoszewicz et al. (1983) Cancer Res. 43:1809-1818. Culturing and treatment of carcinoma cell lines, cell cycle and cell death determinations based on flow cytometry; enzyme assays including ODC, SAMDC and SSAT activities; and high pressure liquid chromatography detection and quantitation of natural polyamines and polyamine analogs are described in the art, for example, Mi et al. (1998) Prostate 34:51-60; Kramer et al. (1997) Cancer Res. 57:5521-27; and Kramer et al. (1995) J. Biol. Chem. 270:2124-2132. Evaluations can also be made of the effects of the porphyrin-polyamine conjugate compound on cell growth and metabolism.
[0081] Analysis begins with IC 50 determinations based on dose-response curves ranging from 0.1 to 1000 μM performed at 72 hr. From these studies, conditions can be defined which produce about 50% growth inhibition and used to: (a) follow time-dependence of growth inhibition for up to 6 days, with particular attention to decreases in cell number, which may indicate drug-induced cell death; (b) characterize porphyrin-polyamine conjugate compound effects on cell cycle progression and cell death using flow cytometry (analysis to be performed on attached and detached cells); (c) examine porphyrin-polyamine conjugate compound effects on cellular metabolic parameters. Porphyrin-polyamine conjugate compound effects can be normalized to intracellular concentrations (by HPLC analysis), which also provide an indication of their relative ability to penetrate cells. Marked differences in porphyrin-polyamine conjugate compound uptake can be further characterized by studying the compound's ability to utilize and regulate the polyamine transporter, as assessed by competition studies using radiolabeled spermidine, as previously described in Mi et al. (1998). Porphyrin-polyamine conjugate compounds could also enter the cells by a diffusion mechanism.
[0082] In vivo Testing of Porphyrin-Polyamine Conjugate Compounds
[0083] Porphyrin-polyamine conjugate compounds found to have potent anti-proliferative activity in vitro towards cultured carcinoma cells can be evaluated in in vivo model systems. The first goal is to determine the relative toxicity of the compounds in non-tumor-bearing animals, such as DBA/2 mice. Groups of three animals each can be injected intraperitoneally with increasing concentrations of a porphyrin-polyamine conjugate compound, beginning at, for example, 10 mg/kg. Toxicity as indicated by morbidity is closely monitored over the first 24 hr. A well-characterized polyamine analog compound, such as BE-333, can be used as an internal standard in these studies, since a data base has already been established regarding acute toxicity via a single dose treatment relative to chronic toxicity via a daily×5 d schedule. Thus, in the case of porphyrin-polyamine conjugate compounds, single dose toxicity relative to BE-333 is used to project the range of doses to be used on a daily×5 d schedule. The toxicity of the porphyrin-polyamine conjugate compound can also be tested versus the free polyamine compound, that is, versus the same polyamine which is present in the porphyrin-polyamine conjugate compound but without a conjugated porphyrin.
[0084] After the highest tolerated dosage on a daily×5 d schedule is deduced, antitumor activity is determined. Typically, tumors can be subcutaneously implanted into nude athymic mice by trocar and allowed to reach 100-200 mm 3 before initiating treatment by intraperitoneal injection daily×5 d. Most porphyrin-polyamine conjugate compounds can be given in a range between 10 and 200 mg/kg. Porphyrin-polyamine conjugate compounds can be evaluated at three treatment dosages with 10-15 animals per group (a minimum of three from each can be used for pharmacodynamic studies, described below). Mice can be monitored and weighed twice weekly to determine tumor size and toxicity. Tumor size is determined by multi-directional measurement from which volume in mm 3 is calculated. Tumors can be followed until median tumor volume of each group reaches 1500 mm 3 (i.e., 20% of body weight), at which time the animals can be sacrificed. Although the initial anti-tumor studies focuses on a daily×5 d schedule, constant infusion can be performed via Alzet pump delivery for 5 days since this schedule dramatically improves the anti-tumor activity of BE-333 against A549 human large cell hung carcinoma. Sharma et al. (1997) Clin. Cancer Res. 3:1239-1244. In addition to assessing anti-tumor activity, free porphyrin-polyamine conjugate compound levels and free polyamine levels in tumor and normal tissues can be determined in test animals.
[0085] Methods of Administration of Porphyrin-Polyamine Conjugate Compounds
[0086] The porphyrin-polyamine conjugate compounds of the present invention can be administered to a mammalian, preferably human, subject via any route known in the art, including, but not limited to, those disclosed herein. Methods of administration include but are not limited to, oral, intravenous, intraarterial, intratumoral, intramuscular, topical, inhalation, subcutaneous, intraperitoneal, gastrointestinal, and directly to a specific or affected organ. The porphyrin-polyamine conjugate compounds described herein are administratable in the form of tablets, pills, powder mixtures, capsules, granules, injectables, creams, solutions, suppositories, emulsions, dispersions, food premixes, and in other suitable forms. The compounds can also be administered in liposome formulations. The compounds can also be administered as prodrugs, where the prodrug undergoes transformation in the treated subject to a form which is therapeutically effective. Additional methods of administration are known in the art.
[0087] The pharmaceutical dosage form which contains the compounds described herein is conveniently admixed with a non-toxic pharmaceutical organic carrier or a non-toxic pharmaceutical inorganic carrier. Typical pharmaceutically-acceptable carriers include, for example, mannitol, urea, dextrans, lactose, potato and maize starches, magnesium stearate, talc, vegetable oils, polyalkylene glycols, ethyl cellulose, poly(vinylpyrrolidone), calcium carbonate, ethyl oleate, isopropyl myristate, benzyl benzoate, sodium carbonate, gelatin, potassium carbonate, silicic acid, and other conventionally employed acceptable carriers. The pharmaceutical dosage form can also contain non-toxic auxiliary substances such as emulsifying, preserving, or wetting agents, and the like. A suitable carrier is one which does not cause an intolerable side effect, but which allows the novel porphyrin-polyamine conjugate compound(s) to retain its pharmacological activity in the body. Formulations for parenteral and nonparenteral drug delivery are known in the art and are set forth in Remington's Pharmaceutical Sciences, 18th Edition, Mack Publishing (1990). Solid forms, such as tablets, capsules and powders, can be fabricated using conventional tableting and capsule-filling machinery, which is well known in the art. Solid dosage forms, including tablets and capsules for oral administration in unit dose presentation form, can contain any number of additional non-active ingredients known to the art, including such conventional additives as excipients; desiccants; colorants; binding agents, for example syrup, acacia, gelatin, sorbitol, tragacanth, or polyvinylpyrollidone; fillers, for example lactose, sugar, maize-starch, calcium phosphate, sorbitol or glycine; tableting lubricants, for example magnesium stearate, talc, polyethylene glycol or silica; disintegrants, for example potato starch; or acceptable wetting agents such as sodium lauryl sulfate. The tablets can be coated according to methods well known in standard pharmaceutical practice. Liquid forms for ingestion can be formulated using known liquid carriers, including aqueous and non-aqueous carriers, suspensions, oil-in-water and/or water-in-oil emulsions, and the like. Liquid formulations can also contain any number of additional non-active ingredients, including colorants, fragrance, flavorings, viscosity modifiers, preservatives, stabilizers, and the like. For parenteral administration, porphyrin-polyamine conjugate compounds can be administered as injectable dosages of a solution or suspension of the compound in a physiologically acceptable diluent or sterile liquid carrier such as water or oil, with or without additional surfactants or adjuvants. An illustrative list of carrier oils would include animal and vegetable oils (e.g., peanut oil, soy bean oil), petroleum-derived oils (e.g., mineral oil), and synthetic oils. In general, for injectable unit doses, water, saline, aqueous dextrose and related sugar solutions, and ethanol and glycol solutions such as propylene glycol or polyethylene glycol are preferred liquid carriers. The pharmaceutical unit dosage chosen is preferably fabricated and administered to provide a final concentration of drug at the point of contact with the cancer cell of from 1 μM to 10 mM. More preferred is a concentration of from 1 to 100 μM. The optimal effective concentration of porphyrin-polyamine conjugate compounds can be determined empirically and will depend on the type and severity of the disease, route of administration, disease progression and health and mass or body area of the patient. Such determinations are within the skill of one in the art. Porphyrin-polyamine conjugate compounds can be administered as the sole active ingredient, or can be administered in combination with another active ingredient, including, but not limited to, cytotoxic agents, antibiotics, antimetabolites, nitrosourea, vinca alkaloids, polypeptides, antibodies, cytokines, etc.
EXAMPLES
[0088] The following examples are provided to illustrate the invention, and are not intended to limit the invention in any manner.
Synthesis of SL-11211
Example 1
N-Mesitylenesulfonyl 4-aminobutyraldehyde diethyl acetal 2
[0089] Amine 1 (Aldrich) (3.5 g, 21.7 mol) was dissolved in a mixture of chloroform (30 ml) and 1N sodium hydroxide (24 ml) and 15 ml of mesitylenesulfonyl chloride dissolved in 15 ml of chloroform were added at 5° C. The mixture was stirred for 2 h, the reaction mixture was then diluted with chloroform (50 ml), the organic layer was separated, washed with a saturated solution of ammonium chloride, dried (Na 2 SO 4 ), and evaporated to dryness. The residual oil crystallized after drying and was used in the next step without further purification; 7.0 g (95%) of 2 were obtained; 1 HNMR (CDCl 3 ): ppm 1.15(t,6H), 1.55 (m,4H), 2.30 (s, 3H), 2.65 (s, 6H), 2.95 (q, 2H), 3.40-3.55 (m, 4H), 4.40 (t, 1H), 4.90 (t, 1H), 6.95 (s, 2H); 13 CNMR (CDCl 3 ): ppm 15.19, 20.80, 22.85, 24.55, 30.83, 42.39, 61.40, 102.41, 131.84, 133.82, 138.99, 141.92.
Example 2
[0090] [0090] 1 N, 6 N, 11 N, 16 N, 21 N, 26 N, 31 N, 36 N-Octakis(mesitylensulfonyl)-1,6,11,16,21,26,31,36-octaazaoctatriacontane 4 was obtained starting with compound 3 (U.S. PAT APPL. 60/329,982) following the homologation procedure described in WO 00/66587; namely, alkylation with 4-bromobutyronitrile, followed by reduction of the nitrile and protection of the free amino residue with mesitylenesulfonyl chloride. Starting with 7 g of 3, 5.6 g (70%) of 4 were obtained over the aforementioned three synthetic steps; 1 HNMR (CDCl 3 ): 0.95 (t,3H), 1.30 (m, 28H), 2.30 (s, 24H), 2.55 (m, 48H), 2.75 (t, 1H), 3.0 (m, 30H), 6.95 (, 16H); 13 CNMR (CDCl 3 ): 12.71, 20.93, 22.78, 24.49, 24.79, 25.68, 40.07, 41.91, 44.59, 44.95, 131.98, 133.39, 138.94, 139.96, 142.06.
Example 3
3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N-Octakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38-octaaza-42-bromo-dotetracontane 5
[0091] To a solution of amide 4 (5.6 g, 2.8 mmol) and 1,4-dibromobutane(3.6 g, 16.8 mmol) in 45 ml of DMF kept at 5° C. was added 135 mg (3.36 mmol) of NaH (60% dispersion in mineral oil) with constant stirring. The mixture was kept at 22° C. for 18 h; the solvent was then evaporated to dryness, the residue dissolved in chloroform, washed twice with a saturated solution of ammonium chloride, the organic layer separated, dried (Na 2 SO 4 ) and evaporated to dryness. The residue was crystallized from ethyl acetate-hexane; 5.3 g (88%) of 5 were obtained; mp 109° C.; 1 HNMR (CDCl 3 ): 0.95 (t, 3H), 1.40 (m, 32H), 2.30 (s, 24H), 2.50 (m, 48H), 3.00 (m,32H), 3.25 (t, 2H), 6.95 (s, 16H); 13 CNMR (CDCl 3 ): 12.68, 20.89, 22.68, 24.42, 25.78, 29.61, 32.77, 40.03, 44.51, 44.89, 45.04, 131.95, 133.46, 139.91, 142.28.
Example 4
3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N, 43 N-Nonakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38,43-nonaaza-heptatetracontylaldehyde diethyl acetal 6
[0092] To a solution of amide 5 (5.19 g, 2.43 mmol) and acetal 2 (0.915 g, 2.67 mmol) in 50 ml of DMF kept at 5° C. was added 128 mg (3.20 mmol) of NaH (60% dispersion in mineral oil) with constant stirring. The mixture was kept at 22° C. for 18 h and the work up followed the procedure reported for 5 ; 5.0 g (86%) of 6 were obtained; mp 102.4° C.; 1 HNMR (CDCl 3 ): 0.95 (t, 3H), 1.15 (t, 6H ), 1.30 (m, 36H), 2.30 (s, 27H), 2.50 (s, 54H), 3.05 (m,36H), 3.45 (m,m, 4H), 6.95 (s,18H); 13 CNMR (CDCl 3 ): 12.68, 15.26, 20.89, 22.67, 24.57, 30.81, 40.04, 4456, 44.88, 45.23, 102.31, 131.88, 133.39, 139.91, 142.19.
Example 5
3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N, 43 N-Nonakis(mesitylenesulfonyl)-3,8,13,18,28,33,38,43-nonaaza-heptatetracontylaldehyde 7
[0093] Acetal 6 (5.0 g) was dissolved in acetone (140 ml) and water (1.5 ml), Amberlyst-15 resin (600 mg) was added and the reaction mixture was stirred for 1 h; the resin was filtered, the solvent evaporated to dryness in vacuo, and the oily residue was used in the next step without further purification; 1 HNMR (CDCl 3 ): 0.95 (t,3H), 1.30(m,36H), 1.72 (m,2H), 2.30 (s,27H), 2.52(s,s, 54H), 3.05 (m,36H), 6.95(s,18H), 9.60 (s, 1H); 13 CNMR (CDCl 3 ): 12.85, 19.89, 21.07, 22.92, 24.60, 24.92, 40.21, 40.79, 44.73, 45.06, 132.13, 133.54, 140.10, 142.47, 200.94; MS (MALDI): 2345.2 (M+Na + ), 2361.2 (M+K + ).
Example 6
3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N, 42 N-Nonakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38,42,47-decaaza-nonatetracontane 8
[0094] To a solution of 4.2 g (1.7 mmol ) of aldehyde 7 in 120 ml of DCE, were added 7 ml (8 eq) of a 2M solution of ethylamine in THF. The mixture was kept at 22° C. for 18 h with constant stirring, after which sodium triacetoxyborohydride (720 mg, 3.4 mol) was added. After 2 h at 22° C., the mixture was washed (2×20 ml) with a saturated solution of sodium bicarbonate, dried, and evaporated to dryness. The residue was purified by flash chromathography using Cl 3 CH/MeOH (5% to 10%) as eluant; 2.8 g (68%) of 8 were recovered; 1 HNMR (Cl 3 CD): 0.95 (t,3H), 1.10 (t,3H), 1.30(m, 36H), 2.25 (s, 27H), 2.50(m, 58H), 3.05 (m, 36H), 2.25 (s, 27H), 2.50 (m, 58H), 3.05 (m, 36H), 6.95 (s, 18H); 13 CNMR (CDCl 3 ): 12.66, 14.53, 20.89, 22.74, 24.70, 39.99, 43.73, 44.50, 44.84, 45.17, 48.57, 131.93, 133.31, 139.90,142.28; MS (MALDI): 2351.92 (M+H + ), 2373.10 (M+Na + ), 2389.97 (M+K + ).
Example 7
Mesoporphyrin IX-bis[ 3 N, 8 N, 13 N 18 N, 23 N, 28 N, 33 N, 38 N, 42 N-nonakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38,42,47-decaazanonatetracontyl amide] 9
[0095] A mixture of amine 8 (750 mg, 0.3 mmol), mesoporphyrin IX (102 mg, 1.4 mmol), and diisopropylethylamine (0.25 ml, 1.4 mmol) in 30 ml of DMF were cooled to 5° C. and kept under a nitrogen atmosphere while 204 mg (0.54 mmol) of HBTU were added. The reaction mixture was stirred for 2 h, the solvent evaporated to dryness, the residue dissolved in chloroform, washed twice with a saturated bicarbonate solution, the organic layer dried (Na 2 SO 4 ) and evaporated to dryness. The residue was purified by chromathography on silica gel using ethyl acetate:hexane (9:1) as eluant; 630 mg (75%) of 9 were recovered; MS (ESI): 5239.3 (M+H + ); 5261.3 (M+Na + ).
Example 8
Porphyrin conjugate SL-11211 eicosahydrobromide
[0096] Porphyrin amide 9 (630 mg) was dissolved in a mixture of methylene chloride (12 ml). 30% hydrogen bromide in glacial acetic acid (12 ml), and phenol (900 mg). The reaction mixture was kept at 22° C. for 18 h with stirring, the reaction product was then extracted into water (35 ml), the aqueous layer washed with methylene chloride (3×12 ml), the aqueous solution evaporated to dryness, and the residue crystallized from water/ethanol; 300 mg of SL-11211 hydrobromide
[0097] (86%) were obtained; mp. 250° C. (dec); MS (ESI): 1958.4 (M+H + , free base), 1980 (M+Na + ).
Example 9
3 N, 8 N, 13 N-Tri(mesitylenesulfonyl)-3,8,13-triaza-17-bromoheptadecane 11
[0098] Intermediate 11 was prepared starting with 10 (ref) and following the procedure described for 5. Starting with 3.6 g of 10 were obtained 2.77 g (65%) of 11; 1 HNMR (CDCl3): 0.98 (t,3H), 1.40 (m, 8H), 1.65 (m,4H), 2.30 (s, 9H), 2.60 (s,18H), 3.10 (m,12H), 3.30 (t, 2H), 6.95 (s,6H); 13 CNMR (CDCl 3 ): 12.75, 20.91, 22.72, 24.58, 25.85, 29.66, 32.79, 40.07, 44.59, 45.10, 131.90, 133.23, 140.03, 142.32.
Example 10
3 N, 8 N, 13 N, 18 N-Tetrakis(mesitylenesulfonyl)-3,8,13,18-tetraaza-doeicosanylaldehyde diethyl acetal 12
[0099] Prepared from 11 following the procedure described for 6. Starting with 2.8 g of 11 were obtained 3.5 g (97%) of acetal 12; 1 HNMR (CDCl 3 ): 1.00 (t, 3H), 1.15 (t, 6H), 1.35 (m, 16H), 2.35 (s, 12H), 2.55(s, 24H), 2.10(m,16H), 3.50 (m, 4H), 4.35 (t,1H), 6.95(s, 8H); 13 CNMR (CDCl 3 ):12.70, 15.26, 20.87, 22.44, 24.52, 30.81, 40.04, 44.55, 45.00, 45.23, 61.18, 102.31, 131.87, 133.35, 139.97, 142.18.
Example 11
3 N, 8 N, 13 N, 18 N-Tetrakis(mesitylenesulfonyl)-3,8,13,18-tetraaza-doeicosanylaldehyde 13
[0100] The aldehyde was obtained from 12 following the procedure described for 7. From 3.5 g of acetal 12, were obtained 2.9 g (90%) of aldehyde 13; 1 HNMR (CDCl 3 ): 0.95 (t, 3H), 1.35(m, 12H), 1.75 (m,2H), 2.30(m, 14H), 2.45(s, 24H), 3.05 (m, 2H), 2.30 (m, 14H), 2.45 (s, 24H), 3.05 (m, 16H), 6.95 (s, 8H), 9.60 (s, 1H); 13 CNMR (CDCl 3 ): 12.63, 19.68, 20.80, 22.67, 24.68, 26.32, 39.98, 40.54, 43.70, 44.50, 45.06, 131.88, 133.04, 140.32, 142.22, 200.71.
Example 12
3 N, 8 N, 13 N, 18 N-Tetrakis(mesitylenesulfonyl)-3,8,13,18,23-pentaazapentacosane 14
[0101] Amine 14 was prepared from 13 following the procedure described for 8. Starting with 4.7 g of 13 were obtained 3.5 g (72%) of amine 14; 1 HNMR (CDCl 3 ): 1.00 (t, 3H), 1.15(t, 3H), 1.40 (m, 16H), 2.30(s, 12H), 2.60 (m, 28H), 3.10(m, 16H), 6.95(s, 8H); 13 CNMR(CDCl 3 ): 11.70, 12.65, 20.83, 22.69, 23.46, 24.67, 39.96, 42.59, 44.47, 45.07, 46.60, 131.81, 133.26, 139.82, 142.36.
Example 13
2,4-Disulfonyl-Deuteroporphyrin IX-bis[ 3 N, 8 N, 13 N, 18 N-tetrakis(mesitylenesulfonyl)-3,8,13,18,23-pentaazapentacosyl amide] 15
[0102] Porphyrin conjugate 15 was prepared by condensation of 14 with deuteroporphyrin IX disulfonate following the procedure described for 9. From 200 mg of 14 and 70 mg of the porphyrin, 144 mg (55%) of 15 were obtained; MS(MALDI): 2808.79 (M+H + ), 2830.55 (M+Na + ), 2853 (M+2Na + ), 2875.52 (M+3Na + ).
Example 14
Porphyrin conjugate SL-11233 decahydrobromide
[0103] Conjugate SL-11233 was obtained from 15 following the procedure described for SL-11211. From 144 mg of 15 were obtained 60 mg (55%) of SL-11233 decahydrobromide; MS (ESI): 1350 (M+H + , M=free base).
Example 15
2,4-Disulfonyl-Deuteroporphyrin IX-bis[ 3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N, 42 N-nonakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38,42,47-decaaza-nonatetracontyl amide] 16
[0104] Porphyrin conjugate 16 was prepared by condensation of amine 8 (216 mg) and deuteroporphyrin IX disulfonate (34 mg) following the procedure described for 9; 140 mg (57%) of 16 were obtained; MS(MALDI): 5342 (M+H + ), 5363 (M+Na + ).
Example 16
Porphyrin conjugate SL-11235 eicosahydrobromide
[0105] Conjugate SL-11235 was obtained from 140 mg of 16 following the procedure described for the synthesis of SL-11211; 70 mg (72%) of SL-11235 eicosahydrobromide were obtained; MS (MALDI): 2062.0 (M+H + , M=free base), 1031 (M*/2), 688.0 (M*/3).
Example 17
N-Methyl mesoporphyrin IX-bis[ 3 N, 8 N, 13 N, 18 N, 23 N, 28 N, 33 N, 38 N, 42 N-nonakis(mesitylenesulfonyl)-3,8,13,18,23,28,33,38,42,47-decaaza-nonatetracontyl amide] 17
[0106] Amide 17 was prepared by condensation of amine 8 (404 mg) with N-methyl mesoporphyrin IX (50 mg) following the procedure described for 9; 226 mg (50%) of 17 were obtained; MS (MALDI): 5253 (M+H + ).
Example 18
Porphyrin Conjugate SL-11236 Eicosahydrobromide
[0107] SL-11236 was prepared from 215 mg of 17 following the procedure described for the synthesis of SL-11211; 75 mg (52%) of SL-11236 eicosahydrobromide were obtained; MS(MALDI): 1972.0 (M+H + , M=free base), 1989.0 (M+NH 4 + ), 986.6 (M + /2).
Example 19
Porphyrin Conjugate SL-11237 Decahydrochloride
[0108] SL-11237 was prepared by condensation of 424 mg (0.6 mmol) of amine 18 and 191 mg (0.3 mmol) of mesoporphyrin IX following the procedure described for 9. SL-11237 was purified by chromathography on silica gel using chloroform/methanol/ammonium hydroxide: 8/2/0.1 as eluant; the eluted residue was further crystallized from methanol/hydrogen chloride/ethyl acetate; 430 mg (73%) of SL-11237 decahydrochloride were obtained; MS(ESI): 1579.6 (M+H + , M=free base), 1725.6 (M+4HCl), 1871.8 (M+8HCl), 790.23 (M + /2), 527.21 (M + /3), 790.23(M + /2).
Synthesis of SL-11217
Example 20
trans-2-Cyanocyclopropanecarbonyl Chloride 20
[0109] 1N Sodium hydroxide (71.9 ml, 71.9 mmol) was added to a solution of nitrile 19 (Payne G B, JOC (1967) 32, 3351) (10.0 g, 71.9 mmol) in 40 ml of methanol. The mixture was stirred during 1h, the methanol was evaporated, conc. HCl was added to pH 2, the solution extracted with ethyl ether (3×30 ml), the pooled organic layers were dried (Na 2 SO 4 ) and evaporated to dryness. The residual solid (7.4 g, 93%) was used in the next step without further purification. It was dissolved in thionyl chloride (13 ml), the mixture was heated to 65° C./4 h, the thionyl chloride was then distilled off and 20 was purified by distillation at 50° C./0.5 mm; 4.3 g (54% over two steps) were obtained; 1 HNMR (Cl 3 CD): 1.80 (m, 2H), 2.25 (m, 1H), 2.80 (m, 1H); 13 CNMR (Cl 3 CD); 8.62, 1701, 30.20, 117.46, 171.34.
Example 21
trans 2-Nitrile-1-(N-ethyl-N-mesitylenesulfonyl-aminobutyl)cyclopropanecarboxamide 21
[0110] A solution of acyl chloride 20 (4.36 g, 33.7 mmol) in THF (43 ml) was added dropwise to a solution of N-ethyl-N(mesitylenesulfonyl)-1,4-diamine (10.0 g, 33.7 mmol) (ref) and triethylamine (2.9 ml) in 100 ml of THF while the mixture was kept at 5° C. under nitrogen. Triethylammonium chloride precipitated; the mixture is further kept at 22° C. during 18 h, then extracted with ethyl acetate (80 ml), the organic layer washed with 2N HCl (10 ml), then with a saturated ammonium chloride solution (10 ml), dried (Na 2 SO 4 ), and evaporated to dryness. The residue was purified by flash chromathography on silica gel using hexane/ethyl acetate: 6/4 as eluant; 10.3 g (78%) of 21 were obtained; 1 HNMR (CDCl 3 ): 10.2 (t, 3H), 1.35(m,1H), 1.55 (m, 5H), 1.90 (m, 1H), 2.05 (m, 1H), 2.35 (s, 3H), 2.60 (s, 6H), 3.25 (m, 6H), 6.35 (t, 1H), 6.95 (s, 2H); 13 CNMR (Cl 3 CD): 4.44, 12.59, 20.87, 22.62, 22.69, 25.00, 26.37, 39.42, 40.04, 44.63, 120.14, 131.91, 133.23, 140.00, 142.37, 168.17.
Example 22
trans 1N-(Mesitylenesulfonyl)-2N(mesitylenesulfonyl)-2N(1′-N,N-(mesitylenesulfonyl) ethylaminobutyl) 1,2-diaminomethylcyclopropane 22
[0111] Amide 21 (8.5 g, 21.7 mmol) was dissolved in 40 ml of THF, 156 ml of THF.1M BH3 were added and the solution was heated at 70° C. during 2 h. The solution was cooled to 5° C., 30 ml of 6N HCl was slowly added while stirring, and the mixture was kept at 5° C. during 18 h. The pH of the mixture was then adjusted to pH 10 with 50% potassium hydroxide, the oil that separated was extracted into chloroform (3×50 ml), the organic extracts were dried (Na 2 SO 4 ), and evaporated to dryness. The residue was dissolved in 100 ml of chloroform, 50 ml of 2N sodium hydroxide were added, the mixture cooled to 5° C., and mesitylenesulfonyl chloride (8.2 g, 386 mmol) dissolved in 10 ml of chloroform were added with efficient stirring. After 2 h, the organic layer was separated, dried (Na 2 SO 4 ), and evaporated to dryness. The residue was purified by flash chromathography on silica gel using hexane/ethyl acetate: 7/3 as eluant; 11.33 g (69% over two steps) of 22 were obtained; 1 HNMR (Cl 3 CD): 0.40 (t, 2H), 0.95 (m, 5H), 1.25 (m, 4H), 2.25 (s, 9H), 2.35-2.65 (m, s, s, 20H), 2.85-3.30 (m, 8H), 5.50 (t, 1H), 6.95 (s, 6H); 13 CNMR (CDCl 3 ) 10.02, 12.63, 16.15, 17.57, 20.87, 22.63, 22,69, 22.89, 24.01, 24.61, 39.97, 44.49, 44.89, 46.52, 48.28, 131.85, 132.34, 133.39, 133.97, 139.01, 139.97, 140.30, 141.73, 142.22, 142.60; MS (TOF): 768.2 (M+Na + ), 784.2 (M+K + ).
Example 23
3 N, 8 N, 13 N-Tris(mesitylenesulfonyl)-17-iodo-((E)-10,11-cyclopropane)-3,8,13-triaza-heptadecane 23
[0112] Triamide 22 (10.3 g, 13.8 mmol) was dissolved in 100 ml of DMF, cooled to 5° C., and sodium hydride (662 mg, 16.5 mmol) was added. The reaction mixture reached 22° C. when 1,4-dibromobutane (29.8 g, 138 mmol) and sodium iodide (20.7 g, 138 mmol) were added, and the mixture was heated at 75° C. for 90 min. The solution was evaporated to dryness, the residue dissolved in chloroform, the solution was washed with sodium thiosulfate, dried (Na 2 SO 4 ), and evaporated to dryness. The residue was purified on a silica gel column using hexane/ethyl acetate; from 8/2 to 7/3 as eluant; 10.8 g (84%) of 23 were obtained; 1 HNMR (Cl 3 CD): 0.40 (m, 2H), 0.80 (m, 2H), 1.02 (t, 3H), 1.40(m, 4H), 1.60 (m, 4H), 2.30 (s, 9H), 2.60 (s, 18H), 2.80-3.30 (m, 14H), 6.95 (s, 6H); 13 CNMR (Cl 3 CD): 5.73, 11.01, 12.73, 16.07, 20.93, 22.74, 24.41, 25.65, 27.96, 29.62, 30.35, 32.92, 40.03, 44.40, 44.58, 45,24, 131.93, 140.09, 142.34, 142.48.
Example 24
3 N, 8 N, 13 N, 18 N-Tris(mesitylenesulfonyl)-((E)-10,11-cyclopropane) 3,8,13,18-tetraazaeicosane 24
[0113] Triamide 23 (10.8 g, 11.6 mmol) was dissolved in 25 ml of THF and a 2 M ethylamine solution in methanol was added (150 ml). The solution was heated at 65° C. during 16 h, then evaporated to dryness, the residue dissolved in chloroform, the chloroform washed with a concentrated solution of ammonium chloride, dried (Na 2 SO 4 ), evaporated to dryness, and the residue purified by column chromathography on silica gel using from 5% to 10% methanol in chloroform as an eluant; 9.3 g (94%) of 24 were obtained; 1 HNMR (Cl 3 CD): 0.40 (t, 2H), 0.80 (m, 3H), 1.03 (t, 3H), 1.20 (t, 3H), 1.35 (m, 4H), 1.55 (m,4H), 2.25 (s, 9H), 2.40-3.35 (s, m, 34H), 6.95 (s, 6H); 13 CNMR (Cl 3 CD): 11.02, 12.70, 13.70, 16.04, 20.90, 22.71, 24.37, 24.76, 25.57, 40.02, 43.43, 44.57, 45.18, 45.33, 48.02, 48.83, 131.91, 133.13, 140.04, 142.34; MS (ESI): 846 (M+H + ).
Example 25
Mesoporphyrin IX-bis[ 3 N, 8 N, 13 N, 18 N-tris(mesitylenesulfonyl)-((E)-10,11-cyclopropane)-3,8,13,18-tetrazaeicosanylamide] 25
[0114] Porphyrin diamide 25 was prepared by the condensation of 8.9 g (10.5 mmol) of 24 and mesoporphyrin IX (3.2 g, 5 mmol) following the procedure described for 9; 9.24 g (83%) of 25 were obtained; MS (MALDI): 2241 (M+Na + ).
Example 26
SL-11217 Octahydrobromide
[0115] SL-11217 was prepared by cleavage of the protecting groups of 4.6 g of 25 following the procedure described for the synthesis of SL-11211; 3.4 g (96%) of SL-11217 octahydrobromide were obtained; mp>250° C. (dec), crystallized from methanol/ethyl acetate; MS (ESI): 1128.2 (M+H+), 1150 (M+Na + ), 1167 (M+K + ), 564.6 (M + /2).
Synthesis of SL-11209 Dodecahydrochloride
Example 27
Benzyl 3 N, 8 N, 13 N, 18 N-Tetrakis(mesitylenesulfonyl)-3,8,13,18-tetraazauneicosanyl Alcohol 27
[0116] A suspension of NaH (60% in mineral oil, 440 mg, 14 mmol) in DMF (50 ml) was slowly added to a stirred solution of benzyl-4-bromobutyl ether (3.33 g, 13.7 mmol) and amide 26 (5.41 g, 5.48 mmol) (WO 00/66587) in DMF (100 ml) kept at 5° C. The reaction mixture was stirred for 10 h at 50° C., quenched with 5 ml of H 2 O at 0° C., and evaporated to dryness in vacuo. The residue was taken up in ethyl acetate, washed with H 2 O, and purified on a silica gel column using ethyl acetate/hexane: 3/7 as eluant; 5.1 g, (81%) of 27 were obatained; 1 H-NMR (CDCl 3 ): 0.97 (t, J=7.1 Hz, 3H), 1.2-1.5 (m, 16H), 2.27 (s, 3H), 2.29 (s, 9H), 2.55 (s, 24H), 2.9-3.2 (m, 16H), 3.31 (t, J=6.0 Hz), 4.41 (s, 2H), 6.9-7.0 (m, 8H), 7.2-7.4 (m, 5H).
Example 28
3,8,13,18-Tetrazauneicosanyl Alcohol 28
[0117] A solution of 30% HBr in glacial acetic acid (90 ml) was added to a stirred solution of 27 (4.50 g) and phenol (12.65 g) in methylene chloride (45 ml) at 0° C. The cooling bath was removed and the reaction mixture was stirred for 24 h at 20° C. The reaction mixture was quenched with H 2 O (90 ml), washed with methylene chloride, and concentrated to dryness in vacuo. The residue was cooled to 0° C., basified with 2N sodium hydroxide (9 ml), followed by 50% potassium hydroxide (9 ml). The product was extracted with chloroform (7×10 ml); 1.07 g (81%) of 28 were obtained; 1 H-NMR (CDCl 3 ): 1.10 (t, J=7 Hz, 3H), 1.40-1.75 (m, 16H), 2.55-2.75 (m, 16H ), 3.57 (t, J=5.0 Hz); 13 C-NMR (CDCl 3 ): 15.23, 27.55, 27.92, 28.58, 32.35, 44.02, 49.35, 49.66, 49.80, 62.32.
Example 29
3 N, 8 N, 13 N, 18 N-Tetrakis(butyloxycarbonyl)-3,8,13,18-tetrazauneicosanyl Alcohol 29
[0118] A solution of 10% sodium carbonate (26 ml) was added to a solution of tetramine 28 (634 mg, 1.92 mmol) in dioxane (16 ml). Di-tert-butyl dicarbonate (2.5 g, 11.5 mmol) in dioxane (16 ml) was added into the reaction mixture at 0° and stirred for 10 h at 20° C. The reaction mixture was diluted with chloroform (200 ml), washed with water, then with brine, dried (Na 2 SO 4 ), evaporated to dryness, and purified by chromathography on a silica gel column using ethyl acetate/hexane:4/6 as eluant; 1.34 g, (96%) of 29 were obtained; 1 H-NMR (CDCl 3 ): 1.09 (t, J=7.1 Hz, 3H), 1.4-1.7 (m, 52 H), 3.05-3.3 (m, 16H), 3.67 (t, J=5.8 Hz, 2H).
Example 30
3 N, 8 N, 13 N, 18 N-Tetrakis(butyloxycarbonyl)-3,813,18-tetrazauneicosanyl aldehyde 30
[0119] Oxalyl chloride (2N solution in methylene chloride, 0.821 μl, 1.64 mmol) was diluted with anhydrous methylene chloride (6 ml) at −60+ C. DMSO (223 μl, 2.59 mmol) in methylene chloride (3 ml) was added to the mixture, the latter stirred for 5 min at −60° C., and 29 (1.12 g, 1.53 mmol) dissolved in methylene chloride (9 ml) was added to the reaction mixture. After 30 min of stirring at −60° C., triethylamine (1.06 ml, 14.46 mmol) was added to the reaction mixture and the temperature was allowed to rise to 20° C. (ca. 1.5 h). The reaction mixture was diluted with methylene chloride, washed with H 2 O, saturated sodium bicarbonate, and brine. The organic layer was concentrated to dryness in vacuo and purified by column chromatography on silica gel using ethyl/acetate/hexane:3/7 as eluant; 989 mg (89%) of 30 were obtained; 1 H-NMR (CDCl 3 ): 1.09 (t, J=7.0 Hz, 3H), 1.4-1.6 (m, 48H ), 1.84 (m, 2H ), 2.45 (t, J=6.8, 2H), 3.05-3.3 (m, 16H), 9.78 (s, 1H).
Example 31
3 N, 8 N, 13 N, 18 N, 23 N-Tetrakis(butyloxycarbonyl)-3,8,13,18,23-pentaza-pentaeicosane 31
[0120] Platinum oxide (100 mg) was reduced in methanol (30 ml) with hydrogen at 30 psi. for 15 min. Aldehyde 30 (989 mg, 1.36 mmol) dissolved in a 2M solution of ethylamine in ethanol (7 ml) was added to the hydrogenation flask, and the mixture hydrogenated for 10 h at 50 psi. The catalyst was removed by filtration through celite and the filtrate was concentrated to dryness in vacuo; 1.0 g (99%) of 31 were obtained; 1 H-NMR (CDCl 3 ): 1.09 (t, J=7.6 Hz, 3H), 1.12 (t, J=7.2 Hz, 3H), 1.3-1.65 (m, 50H, CH 2 ), 1.66 (m, 2H), 2.71 (m, 2H), 3.1-3.3 (m, 18H). MS-MALDI (m/z):758.8 (M + , 100%), 744 (30%).
Example 32
1 3,5,8-Tetramethyl-2,4-diethyl-6,7-di(propionaldehyde)porphyrin 32
[0121] Diisobutylaluminum hydride (1.16 ml of 1.5 M solution in toluene, 1.74 mmol) was added to a solution of mesoporphyrin IX dimethyl ester (500 mg, 0.84 mmol) in CH 2 Cl 2 (10 ml) at −78° C., the mixture was stirred at this temperature for 1 h, then quenched with a saturated solution of NH 4 Cl (1 ml), followed by a 3.7% solution of HCl (2 ml). The temperature of the reaction mixture was allowed to rise to 20° C., the product was extracted with CH 2 Cl 2 , dried (Na 2 SO 4 ), and purified on a column of silica gel using ethyl acetate/hexane:3/7 as eluant, 330 mg (73%) of 32 were obtained; 1 HNMR (CDCl 3 ): 1.86 (t, J=7.6 Hz, 6H), 3.39 (t, J=7.4 Hz, 6H), 3.60 (s, 6H), 3.62 (s, 6H), 4.0-4.2 (m, 4H), 4.5-4.45 (m, 4H), 9.97 (s, 1H), 10.04 (s, 1H), 10.05 (s, 1H), 10.06 (s, 1H), 10.065 (s, 1H), 10.07 (s, 1H).
Example 33
SL-11209 Dodecahydrochloride
[0122] Amine 31 (182 mg, 0.24 mmol) and dialdehyde 32 (58 mg, 0.11 mmol) were mixed in 1,2-dichloroetane (3 mL) and sodium triacetylborohydride (60 mg, 0.28 mmol) was added at 22° C., the mixture was stirred for 3.5 h and then quenched with a solution of sodium bicarbonate. The reaction mixture was diluted 3 times with chloroform, washed with H 2 O, dried (Na 2 SO 4 ) and concentrated to dryness in vacuo. The residue was dissolved in methylene chloride, cooled to 0° C. and trifluoroacetic acid added. After stirring for 1.5 h, the cooling bath was removed, the mixture was evaporated to dryness.
[0123] The residue was dissolved in 10% HCl, the aqueous layer washed with chloroform, and the water removed in vacuo; 134 mg (74%) of crude SL-11209 were obtained. The product was purified by HPLC (Column: 21.5 mm×250 mm, C 18 Dynamax, eluent A=0.1% TFA, eluent B=0.088% TFA in 90% acetonitrile). The pure product was dissolved in 10% HCl (5 mL), and evaporated to dryness in vacuo. 1 H NMR (D 2 O): 1.16 (t, J=7.0 Hz, 6H), 1.34 (t, J=7.3 Hz, 6H), 1.60-2.00 (m, 38H), 2.50-2.70 (m, 4H), 2.90-3.30 (m, 40 H) 3.50-3.65 (m, 4H), 3.75 (s, 6H), 3.82 (s, 6H), 4.20-4.35 (m, 4H), 4.45-4.60 (m, 4H), 10.5 (bs, 4H). MS (MALDI), 1240.6 [M+Na] + , 1218.4, [M+1] + .
SLIL-11210 Dodecahydrochloride
Example 34
1,3,5,8-Tetramethyl-2,7-diethyl-6,7-bis[ 3′ N, 8′ N, 13′ N, 18′ N-tetrakis (mesitylenesulfonyl)-3′,8′,13′,18′,23′-pentaazaheptaeicosane]porphyrin 34
[0124] A solution of nitrile 33 (1.6 g, 1.5 mmol) (U.S. PAT APPL. 60/329,982) in ethanol (90 ml) and chloroform (1.6 ml) was hydrogenated in the presence of PtO 2 (160 mg) under 50 psi for 10 h, the suspension filtered through a celite cake, evaporated to dryness and dried in vacuo. The product was dissolved in 1,2-dichloroetane (10 mL), dialdehyde 32 (370 mg, 0.69 mmol) was added followed by triethylamine (0.23 ml, 1.67 mmol). The reaction was stirred for 20 h, after which sodium triacetylborohydride (352 mg, 1.66 mmol) was added and the mixture further stirred for 3.5 h. The reaction mixture was quenched with a solution of sodium bicarbonate, thrice its volume of chloroform was added; the organic layer was washed with H 2 O, dried, and evaporated to dryness in vacuo. The residue was dissolved in methylene chloride (20 mL), cooled to 0° C., made basic with 2N sodium hydroxide (5 mL) and mesitylsulfonyl chloride (333 mg, 1.5 mmol) was added. After 10 h of stirring at 22° C. and following the usual workup the reaction product was purified by column chromatography on silica gel using chloroform/ethyl acetate; 9/1 as eluant; 729 mg (35%) of 34 were obtained; 1 H NMR (CDCl 3 ): 0.93 (t, J=7.14 Hz), 1.05-1.50 (m,) 1.50-1.70 (m), 1.90 (t, J=7.14 Hz), 2.05 (s), 2.07 (s), 2.08 (s), 2.13 (s), 2.16 (s), 2.21 (s), 2.24 (s), 2.29 (s), 2.41 (s), 2.45 (s), 2.49 (s), 2.52 (s), 2.70-3.10 (m), 3.10-3.25 (m), 3.40-3.52 (m), 3.53 (s), 3.54 (s), 3.66 (s), 3.85-4.00 (m), 4.0-4.2 (m), 5.97 (s), 6.02 (s), 6.75 (s), 6.79 (s), 6.84 (s), 6.87 (s), 6.92 (s), 9.69 (s), 10.08 (s), 10.14 (s); MS (MALDI), 3007.02 [M+Na] + , 2985.05 [M+1] + , 2983.95 [M] + , 1493.58 [M] 2+ .
Example 35
SL-11210 Dodecahydrochloride
[0125] SL-11210 was prepared from 34 following the procedure described for the synthesis of SL-11211. From 730 mg of 34 were obtained 360 mg (69%) of the dodecahydrobromide; 1 HNMR (D 2 O): δ 1.34 (t, J=7.3 Hz, 6H), 1.70-2.00 (m, 38H), 2.50-2.70 (m, 4H), 3.05-3.35 (m, 36H), 3.40-3.55 (m, 4H), 3.78 (2s, 6H), 3.82 (2s, 6H), 4.20-4.40 (m 4H), 4.40-4.60 (m, 4H), 10.40 (bs, 4H). MS (free base, MALDI), 1161.95 [M] + . The dodecahydrobromide was converted into dodecahydrochloride after HPLC purification and treatment of the eluate with 20% HCl. MS (free base, MALDI), 1162.02 [M] + , 581.82 [M] 2+ .
Example 36
SL-11257 Dodecahydrochloride
[0126] Amine 18 (310 mg, 0.44 mmol), dialdehyde 32(118 mg, 0.22 mmol), and triethylamine (0.16 ml) were dissolved in 27 ml of dichloroethane. The reaction was kept at 22° C. during 18 h, sodium triacetoxyborohydride (186 mg, 10.9 mmol) was then added, the reaction mixture was kept for further 2 h, it was then diluted with chloroform, the solution washed with saturated sodium bicarbonate, dried (Na 2 SO 4 ), and evaporated to dryness. The residue was purified by column chromathography on silica gel using chloroform/methanol/ammonium hydroxide; 8/2/0.3 as eluant; 190 mg of SL-11257 were obtained. After purification by HPLC, 90 mg (20%) of pure material were obtained; MS (MALDI): 1551.8 (M+H + , M=free base), 311.18 (M + /2), 388.79(M + /4), 517.8 (M + /3), 776.03 (M + /2).
Example 37
MTT assay
[0127] A conventional MTT assay was used to evaluate percent cell survival. Exponentially growing monolayer cells were plated in 96-well plates at a density of 500 cells per well and allowed to grow for 24 hours. Serial dilutions of the drugs were added to the wells. Six days after drug treatment, 25 μl of MTT solution (5 mg/ml) was added to each well and incubated for 4 hours at 37° C. Then 100 μl of lysis buffer (20% sodium dodecyl sulfate, 50% DMF, and 0.8% acetic acid, pH 4.7) was added to each well and incubated for an additional 22 hours. A microplate reader (“EMAX”-brand, Molecular Devices, Sunnyvale, Calif.) set at 570 nm was used to determine the optical density of the cultures. Results are expressed as a ratio of the optical density in drug-treated wells to the optical density in wells treated with vehicle only. Tables 1, 2, and 3 below describe the results of the assays on various cell lines. FIGS. 1 - 13 also indicate the effects of the compounds on various cell lines.
[0128] Other suitable assays for testing the compounds of the invention are described in International Patent Application Nos. WO 00/66587 and WO 02/10142, and U.S. Pat. Nos. 6,392,098, 5,889,061, and 5,677,350
TABLE 1 Effect of Porphyrin Polyamine Analogues on Human Prostate Tumor Cell Growth by the MTT assay ID 50 (μM) values for Human prostate tumor Cell Lines Tsu-pr1- Compounds DuPro PC-3 DU145 LnCap Tsu-pr1 ADR SL-11209 1.4 1.7 — — — SL-11211 0.46 1.7 — — 0.35 0.66 SL-11217 3.6 2.8 — — — — SL-11233 1.4 3.9 >31.25 >31.25 — — SL-11235 0.12 0.45 0.17 0.2 — — SL-11236 0.08 0.49 0.14 0.2 — — SL-11237 1.9 1.7 — — 1.87 12.62
[0129] [0129] TABLE 2 Effect of Porphyrin Polyamine Analogs on Human Pancreatic Cancer Cell Growth by MTT Assay. ID 50 (μM) values for Human Pancreatic Cancer Cell Lines Compounds BxPC-3 Panc-1 SL-11217 6.87 6.38 SL-11237 5.92 12.45
[0130] [0130] TABLE 3 Effect of Porphyrin Polyamine Analogs on Human Brain Tumor Cell Growth by MTT Assay. ID 50 (μM) values for Human Brain Tumor Cells U251MG Compounds NCI SL-11217 5.65 SL-11237 2.30
Example 38
Oral Administration of SL-11237
[0131] Male athymic nude mice were given subcutaneous injections of 0.75×10 6 DU145 cells on Day 0. Beginning on Day 10, mice were treated once weekly for 3 weeks with acidified water, 100 mg/kg, or 500 mg/kg of SL-11237 via oral gavage at 10 ml/kg dosing volume (the third treatment was actually 400 mg/kg in the high dose group). The results are depicted in FIG. 14, where the top panel depicts average tumor volume in the mice. The bottom panel of FIG. 14 depicts average body weight of the mice. Oral administration thus provides an effective and convenient means of administering the compounds of the invention.
[0132] All references, publications, patents and patent applications mentioned herein are hereby incorporated by reference herein in their entirety.
[0133] 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 apparent to those skilled in the art that certain changes and modifications may be practical. Therefore, the description and examples should not be construed as limiting the scope of the invention, which is delineated by the appended claims. | Porphyrin-polyamine conjugate compounds are disclosed which have anticancer and antitumor effects. The porphyrin moiety selectively localizes in tumors, while the polyamine moiety serves as a cytotoxic agent. Methods of making and using the porphyrin-polyamine conjugate compounds are also disclosed. | 2 |
RELATED APPLICATION DATA
[0001] The present application claims priority to Japanese Application No. P2000-134327 filed Apr. 28, 2000, which application is incorporated herein by reference to the extent permitted by law.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a semiconductor device having bumps, a method for fabricating the same, and a method for forming bumps.
[0003] More specifically, the present invention relates to a semiconductor device having bumps able to ease thermal stress to prevent damage due to thermal stress and therefore of high reliability, a method for fabricating the same, and a method for forming bumps.
[0004] Along with the increasingly small size of electronic apparatuses, attempts have been made to use compact semiconductor packages of sizes similar to the size of a chip of a flip-chip structure. A large number of electronic circuits are integrated on such a small package, so many connection terminals are necessary. On the other hand, due to the reduced size, the problem arises that the space for arranging these connection terminals is insufficient. In such a small semiconductor package, DIPs or other connection terminals of the related art cannot be used.
[0005] As a solution to this problem, attempts have been made for flip chip mounting where a large number of small projecting electrodes (bumps) are formed on the bottom surface of a semiconductor integrated circuit chip, many electrodes are formed on a printed wiring board at positions corresponding to those bumps, and the electrodes on the wiring board and the bumps formed on the semiconductor integrated circuit chip are directly bonded. Such flip chip mounting has the advantage that many bumps can be formed even on the bottom surface of a semiconductor integrated circuit chip of a limited space.
[0006] As a method for connecting bumps and electrodes, attempts have been made to seal a semiconductor integrated circuit chip and a wiring board by a resin to connect and affix them.
[0007] Summarizing the problem to be solved by the invention, a large number of semiconductor integrated circuit chips are of a type using silicon for their semiconductor substrates. The linear thermal expansion coefficient of a silicon chip is much smaller than that of a wiring board. For example, the former is no more than 10% of the latter. As a result of the large difference of the linear thermal expansion coefficients, thermal stress appears when the temperature changes.
[0008] In most cases, the linear thermal expansion coefficient of the semiconductor integrated circuit chip is also largely different from that of the sealing resin. Similarly, the linear thermal expansion coefficient of the wiring board is often different from that of the sealing resin.
[0009] As a result of the difference of the linear thermal expansion coefficients, when the temperature rises during operation of the semiconductor integrated circuit chip, thermal stress appears between the semiconductor integrated circuit chip and the wiring board between which the sealing resin is interposed.
[0010] In a flip-chip structure designed for compactness, there is no mechanism for easing stress such as a lead frame. Therefore, if flip chip mounting is adopted, there could be deformation of the semiconductor integrated circuit chip, decline of bonding between bumps and electrodes, or even loss of the bonded state.
[0011] As shown here, although a reduced size is aimed at with flip chip mounting, sometimes the reliability of the semiconductor device could decline because of poor bonding or loss of bonding caused by thermal stress.
[0012] Accordingly, it is desirable to improve the reliability against thermal stress for a flip chip mounting semiconductor device which does not have a mechanism such as a lead frame for easing stresses.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to find the conditions for increasing the reliability against thermal stress in a flip chip mounting structure.
[0014] Another object of the present invention is to provide a flip chip mounting semiconductor device of high reliability and a method for fabricating such a semiconductor device on the basis of the above conditions.
[0015] Still another object of the present invention is to provide a method for forming bumps on a semiconductor integrated circuit chip on the basis of the above conditions.
[0016] According to a first aspect of the present invention, there is provided a semiconductor device comprising a wiring board formed with a plurality of electrodes, a semiconductor integrated circuit chip formed with a plurality of bumps, and a sealing resin for bonding the electrodes and bumps at corresponding positions and further surrounding the bonding portions of the electrodes and bumps to adhere the wiring board and semiconductor integrated circuit chip, wherein each individual bump is formed under the condition that quantities ΦA, H, and F are in the region defined by the following formula A:
a L <((Φ A×F )/ H )< a U ( A )
[0017] where,
[0018] ΦA denotes the top diameter of a bump bonded with an electrode,
[0019] H denotes the height of a bump, defined as the distance from the semiconductor integrated circuit chip to the end of the bump bonded with an electrode,
[0020] F denotes the linear thermal expansion coefficient of the sealing resin,
[0021] a L denotes the lower limit, and
[0022] a U denotes the upper limit.
[0023] Up until now, it was thought that high bumps were preferable. This is because the large number of bumps formed on a semiconductor integrated circuit chip are uneven in height, the large number of electrodes formed on the wiring board are uneven in height, the bottom surface of the semiconductor integrated circuit chip is not completely flat, and the surface of the wiring board is not completely flat. Furthermore, when a bump and a electrode are bonded, the semiconductor integrated circuit chip and the wiring board may warp or deform. They may also deform due to shrinkage of the sealing resin at time of curing. High bumps are preferable when considering the margin for eliminating such unevenness.
[0024] Studies and experiments of the inventors of the present invention have revealed that there are optimal values to dimensions of individual bumps defined by the above formula A.
[0025] Note that when considering the height of bumps, the height of electrodes formed on the wiring board should be considered, too.
[0026] This is because due to the height of the bumps and the height of the electrodes, a gap is maintained between the wiring board and the semiconductor integrated circuit chip to prevent contact of the wiring board and the semiconductor integrated circuit chip, and the conditions of the sealing resin are optimized for interposition between the wiring board and the semiconductor integrated circuit chip for maintaining bonding of bumps and electrodes and for sealing.
[0027] Preferably, the sealing resin is a thermosetting resin.
[0028] Further, as a condition for the above formula to stand, the linear thermal expansion coefficient of the wiring board is 10 times that of a semiconductor integrated circuit chip and the linear thermal expansion coefficient of the thermosetting sealing resin is in the range from 20 to 70 ppm.
[0029] Specifically, the bump comprises gold, and the electrode comprises a conductive metal.
[0030] It is desirable that the electrode be harder than the bump. When applying pressure for bonding, it is desirable that the electrode not deform while the bump deforms.
[0031] Preferably, the lower limit a L is about 100, and the upper limit a U is about 125.
[0032] Specifically, the bump height H is in the range from about 20 μm to about 25 μm.
[0033] More specifically, the top diameter ΦA of a bump is no more than 50 μm.
[0034] These regions of the bump height and top diameter ΦA are realistic bump dimensions giving good reliability against thermal stress.
[0035] According to a second aspect of the present invention, there is provided a semiconductor device comprising a wiring board formed with a plurality of electrodes, a semiconductor integrated circuit chip formed with a plurality of bumps, and a sealing resin for bonding the electrodes and bumps at corresponding positions and further surrounding the bonding portions of the electrodes and bumps to adhere the wiring board and semiconductor integrated circuit chip, wherein each individual bump is formed under the condition that quantities ΦA and L are in the region defined by the following formula B,
( b 1 ×L/ 2)<Φ A <( b 2 ×L/ 2) (B)
[0036] where,
[0037] ΦA denotes the top diameter of a bump bonded with an electrode,
[0038] L denotes the interval (distance) between adjacent bumps,
[0039] b 1 denotes a first coefficient, and
[0040] b 2 denotes a second coefficient.
[0041] Because the shorter the interval between adjacent bumps, the larger the number of bumps able to be formed, a short interval is desirable. However, studies and experiments of the inventors of the present invention have found there is a limit defined by the above formula B.
[0042] For example, the first coefficient b 1 is about 0.75, and the second coefficient b 2 is about 0.85.
[0043] In addition, according to a third aspect of the present invention, there is provided a semiconductor device comprising a wiring board formed with a plurality of electrodes, a semiconductor integrated circuit chip formed with a plurality of bumps, and a sealing resin for bonding the electrodes and bumps at corresponding positions and further surrounding the bonding portions of the electrodes and bumps to adhere the wiring board and semiconductor integrated circuit chip, wherein each individual bump is formed under the condition that quantities ΦA, H, and F are in the region defined by the above formula A, and the interval between adjacent bumps is in the region defined by the above formula B.
[0044] The semiconductor device according to the third aspect of the present invention is a combination of the semiconductor device satisfying the conditions of bump dimensions according to the above first aspect and the semiconductor device satisfying the conditions of the bump interval according to the above second aspect.
[0045] According to the third aspect of the present invention, there is able to provide a semiconductor device displaying reliability against thermal stress and able to be arranged with a practical number of bumps.
[0046] In addition, according to a fourth aspect of the present invention, there is provided a method for forming a plurality of bumps on a semiconductor integrated circuit chip used for a semiconductor device comprising a wiring board formed with a plurality of electrodes, a semiconductor integrated circuit chip formed with a plurality of bumps, and a sealing resin for bonding the electrodes and bumps at corresponding positions and further surrounding the bonding portions of the electrodes and bumps to adhere the wiring board and semiconductor integrated circuit chip, wherein (a) adjacent bumps are formed under the condition that the interval between adjacent bumps is defined by the above formula B, and (b) each individual bump before bonding with an electrode is formed to have an initial height H 0 including an additional part for compensating for deformation caused by bonding so that the dimensions ΦA and H and the quantity F of each individual bump are in the region defined by the formula A, and each individual bump is formed in a near spherical shape so that the top diameter ΦA satisfies the formula A after bonding with an electrode,
[0047] A bump before bonding is formed to have a larger height to include a part for exactly compensating for deformation caused by a pressure during bonding.
[0048] In addition, according to a fifth aspect of the present invention, there is provided a method for fabricating a semiconductor device comprising a wiring board formed with a plurality of electrodes, a semiconductor integrated circuit chip formed with a plurality of bumps, and a sealing resin for bonding the electrodes and bumps at corresponding positions and further surrounding the bonding portions of the electrodes and bumps to adhere the wiring board and semiconductor integrated circuit chip, the method comprising:
[0049] (a) a step for forming bumps, wherein adjacent bumps are formed under the condition that the interval between adjacent bumps is defined by the above formula B, and each individual bump before bonding with an electrode is formed to have an initial height H 0 including an additional part for compensating for deformation caused by bonding so that the dimensions ΦA and H and the quantity F of each individual bump are in the region defined by the formula A, and each individual bump is formed in a near spherical shape so that the top diameter ΦA satisfies the formula A after bonding with an electrode,
[0050] (b) a step, which is separate from the bump forming step, for forming electrodes on the wiring board, wherein adjacent electrodes are formed under the condition that the interval between adjacent electrodes is defined by the above formula B, and each electrode is formed so that its head is same as or larger than the top diameter ΦA of a bump,
[0051] (c) a step for heating a film-like thermosetting resin on a surface of the wiring board formed with electrodes at a first heating temperature and pressing by a first pressure within a first time period to temporarily fix the thermosetting resin on the wiring board,
[0052] (d) a step for putting together the semiconductor integrated circuit chip and the wiring board so that each bump formed on the semiconductor integrated circuit chip and each electrode formed on the wiring board face each other with the thermosetting resin interposed between them, and
[0053] (e) a step for heating and pressing at a temperature higher than the first heating temperature, by a second pressure, and within only a second time period, to satisfy the formula A while the film-like thermosetting resin is interposed between each bump and each electrode that face each other, wherein each bump pushes the film-like thermosetting resin apart and is bonded with an electrode at a corresponding position.
[0054] Preferably, the second heating temperature is higher than the glass transition temperature of the thermosetting resin. Because of such a heating temperature, the sealing resin will be completely set in a glass state to reliably bond bumps and electrodes and firmly adhere the wiring board and the semiconductor integrated circuit chip to seal them.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the accompanying drawings, in which:
[0056] [0056]FIG. 1 is a sectional view of the outer appearance of a semiconductor according to an embodiment of the present invention;
[0057] [0057]FIGS. 2A to 2 C are partial views illustrating a basic method for forming a bump before bonding with an electrode;
[0058] [0058]FIGS. 3A and 3B are partial views continuing from FIGS. 2A to 2 C, illustrating a basic method for forming a bump before bonding with an electrode;
[0059] [0059]FIG. 4 is an enlarged view of bumps just formed on a semiconductor integrated circuit chip (IC chip) and electrodes formed on a wiring board;
[0060] [0060]FIG. 5 shows the results of inspection of the thermal fatigue lifetime up to destruction of the semiconductor device in FIG. 1 under a temperature cycle test in a range from −25° C. to 125° C. when forming a semiconductor device by using the resins listed in Table 1 as the sealing resin of the present embodiment;
[0061] [0061]FIG. 6 is a view illustrating the effect of the difference of linear thermal expansion coefficients of a wiring board, an IC chip, and a sealing resin on a semiconductor device when applying a negative temperature load;
[0062] [0062]FIG. 7 shows graphs of the results of an analysis of decomposing the stress acting on the bonding surface of a bump with an electrode;
[0063] [0063]FIGS. 8A to 8 C are views of the stress acting on a bump and an electrode wiring pattern when the bump height is large;
[0064] [0064]FIGS. 9A to 9 C are views of the stress acting on a bump and an electrode wiring pattern when the bump height is small; and
[0065] [0065]FIG. 10 shows graphs of the relation between the bump height and the equivalent-stress when changing the diameter (referred to as top diameter ΦA) of a bump in contact with an electrode wiring pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Below, a preferred embodiment according to the present invention will be described with reference to the accompanying drawings.
[0067] [0067]FIG. 1 is a sectional view of the outer appearance of a semiconductor device according to an embodiment of the present invention.
[0068] The semiconductor device 1 illustrated in FIG. 1 comprises a wiring board 12 and a silicon IC chip 14 as examples of a wiring board and a semiconductor integrated circuit chip of the present invention.
[0069] On the surface of the wiring board 12 that faces the IC chip 14 , a number of electrodes 122 are formed.
[0070] When the wiring board 12 and the IC chip 14 are placed together face-to-face, the electrodes 122 and bumps 142 at corresponding positions contact each other, and the wiring board 12 and IC chip 14 are electrically connected.
[0071] Between the wiring board 12 and IC chip 14 , there is a predetermined gap over which the electrodes 122 and bumps 142 are connected. In this gap, a thermosetting resin, for example, an epoxy resin or other sealing resin 16 is interposed and is then heated to bond the wiring board 12 and the IC chip 14 and seal the surrounding of the electrodes 122 and bumps 142 .
[0072] Method for Forming Bumps
[0073] A basic method for forming bumps before bonding with electrodes is described below with reference to FIGS. 2A to 2 C and FIGS. 3A and 3B.
[0074] In FIG. 2A, an IC chip 14 is placed on a heatable working stand 102 .
[0075] On the IC chip 14 , an aluminum pad 144 is formed in a region where a bump will be formed. A passivation film 146 is formed around the pad.
[0076] Above the IC chip, a capillary 104 is provided. The capillary 104 is formed with a hole for passing a gold wire 106 . Above the capillary 104 , a clamper 110 is provided for holding the gold wire 106 . In FIGS. 2A to 2 C, the clamper 106 holds the upper end of the gold wire 106 .
[0077] The capillary 104 is moved up and down by a not illustrated hoisting and lowering mechanism. In FIG. 2A, the capillary 104 is moved up at a higher position.
[0078] Above the IC chip 14 near the front end of the capillary 104 , a torch 112 is provided.
[0079] In FIG. 2A, a high voltage is applied to the torch 112 , causing the torch 112 to discharge and spark to the end of the gold wire 106 positioned at the end of the capillary 104 positioned near the torch 112 . Due to this, the end of the gold wire 106 sticking out from the end of the capillary 104 turns into a gold small spherical body (hereinafter, referred to as a gold ball) which is the forerunner of a bump.
[0080] The gold ball 120 , which is illustrated as a bump 142 in FIG. 4, is formed in a near spherical shape at the end of the capillary 104 .
[0081] Below, a brief description will be made of the size of the gold ball 120 . The dimensions of the bump 142 will be briefly explained first, and details will be given later. As described in the fourth aspect of the present invention, ΦA, H, and F are used to denote the top diameter of a bump bonded with an electrode, the height of a bump defined as the distance from the semiconductor integrated circuit chip to the end of the bump bonded with an electrode, and the linear thermal expansion coefficient of the sealing resin, respectively. By a leveling operation employing a leveling plate 114 in FIG. 3B and in the way illustrated in FIG. 4, a bump before bonding with an electrode 122 is formed to have an initial height H 0 including a part that will be deformed during the bonding process so that the dimensions of the bump 142 will be in the region defined by the above formula A. Namely, it is desirable that a bump not bonded with an electrode 122 yet (gold ball 120 ) is formed to have a larger height to include exactly the part that will be deformed by the pressure during bonding. In consideration of the deformation caused by such a leveling operation, it is desirable that the gold ball 120 is formed somewhat larger.
[0082] The bumps illustrated in FIG. 4 are formed in the above way and then pressed against aluminum pads 144 by a method described later with reference to FIG. 2B and FIG. 2C, whereby part of each bump is changed in shape. Note that the definition of the up-down direction in FIG. 4 is reverse to that in FIGS. 2A to 2 C.
[0083] In FIG. 2B, the clamper 110 is opened and the gold wire 106 is released. The capillary 104 is lowered toward the aluminum pad 144 on the IC chip 14 , and the gold ball 120 formed at the end of the capillary 104 is pressed against the aluminum pad 144 by applying a certain pressure. In this state, an ultrasonic wave is applied and the working stand 102 is heated so that the gold ball 120 is melted and fixed on the aluminum pad 144 .
[0084] After the gold ball 120 is fixed on the aluminum pad 144 , as shown in FIG. 2C, the capillary 104 is hoisted away from the aluminum pad 144 so that the gold wire 106 projects a predetermined length (tail length) out of the capillary 104 for forming the next gold ball. During this operation, the clamper 110 is opened to keep the gold wire 106 released.
[0085] In FIG. 3A, the clamper 110 is closed to hold the gold wire 106 . Then, the capillary 104 is moved upward, hence the gold wire 106 is under tension. Due to this tension, at the boundary between the crystal portion of the gold wire 106 and the re-crystalized portion formed by the spark, the gold ball 120 portion is torn off from the gold wire 106 and a bump is formed.
[0086] The distance by which the capillary 104 is moved up defines the length of the gold wire 106 sticking out of the end of the capillary 104 . The latter in turn defines the size of the gold ball 120 formed by the spark from the torch 112 , so it is the ascent or descent distance of the capillary 104 that defines the size of the bump 142 before bonding (gold ball 120 ). Consequently, in the present embodiment, the size of the gold ball 120 is controlled by the distance moved by the capillary 104 .
[0087] By this method, a desired number of bumps can be formed sequentially. For this, for example, the working stand 102 may be shifted.
[0088] After a desired number of bumps are formed, as shown in FIG. 3B, a leveling plate 114 is placed on these bumps 142 formed on the surface of the IC chip 14 to apply a leveling load so that all the bumps 142 formed on the surface of the IC chip 14 have the same specified height.
[0089] While details of the dimensions of the bump 142 will be given later, here, as described in the fourth aspect of the present invention, ΦA, H, and F are used to denote the top diameter of a bump bonded with an electrode, the height of a bump defined as the distance from the semiconductor integrated circuit chip to the end of the bump bonded with an electrode, and the linear thermal expansion coefficient of the sealing resin, respectively. In order for the dimensions of bumps 142 to be in the region defined by the above formula A, it is desirable that each individual bump before bonding with an electrode 122 , as illustrated in FIG. 4, is formed to have an initial height H 0 including a part which will be deformed during bonding, and a leveling plate 114 is employed to unify the heights of all these bumps. Namely, it is desirable that a bump not bonded with an electrode 122 yet (gold ball 120 ) is formed to have an excess height to include exactly the part that will be deformed by the pressure during bonding.
[0090] Consequently, as shown in FIG. 4, a number of bumps 142 each having a bottom diameter ΦB and height H 0 are formed on the surface of the IC chip 14 at a pitch interval L.
[0091] [0091]FIG. 4 is an enlarged view of bumps 142 just formed on the IC chip 14 and electrodes 122 formed on a later explained wiring board 12 .
[0092] Method for Forming Electrodes
[0093] Below, a description will be given of a method for forming electrodes 122 on the wiring board 12 .
[0094] The electrodes 122 of height H d are formed, as shown in FIG. 4, at the same pitch interval as the bumps 142 and at positions corresponding to those many bumps on the IC chip 14 using for example aluminum, copper, or another conductive metal by a well known method of forming electrodes.
[0095] In the present embodiment, for example, the electrode 122 is formed by using for example copper as its basic portion, and is nickel plated and gold plated then.
[0096] The basic material copper is a conductive metal harder than gold of the bumps 142 . While bumps 142 are deformed when they are pressed against the electrodes 142 during bonding, it is desirable that the conductive metal forming the basic portion of the electrodes 122 have a high enough rigidity that the electrodes 122 do not deform. Copper may also be replaced by other metals, for example, aluminum.
[0097] The outermost gold plating is for raising the bonding ability of both relatively soft metals and preventing erosion when bonding with the gold bumps 142 .
[0098] The intermediate nickel plating is for enabling stable plating of gold on the surface of copper.
[0099] Method for Fabricating Semiconductor Device 1
[0100] Below, a description will be given of a method for putting together the wiring board 12 formed with an electrode wiring pattern 122 and the IC chip 14 formed with bumps 142 face-to-face so that the electrode wiring pattern 122 and bumps are connected and for sealing with a sealing resin by the method described above to form the semiconductor device 1 shown in FIG. 1.
[0101] (a) A film-like bonding layer of the same size as the IC chip 14 is prepared. As the film-like bonding layer, use is made of for example a film-like bonding layer of a thermosetting adhesive, for example, an epoxy resin.
[0102] (b) This film-like bonding layer is placed on the surface of the wiring board 12 where the electrodes 122 are formed. For temporary fixing, for example, this layer is heated to the first heating temperature of 80° C. and applied with the first pressure of 3 kg/cm 2 for the first time period of 3 seconds as defined in the present invention. By this heating and pressure, the film-like bonding layer is thermally set and temporarily fixed on the wiring board 12 .
[0103] (c) Next, the surface of the IC chip 14 where the bumps 142 are formed is made to face the surface of the wiring board 12 where the electrodes 122 are formed, and the corresponding electrodes 122 and bumps 142 are pressed against each other with the thermally set film-like bonding layer in between.
[0104] (d) Under this condition, the IC chip 14 and the wiring board are given a higher pressure and heated to a higher temperature than in the preceding temporary fixing step, for example, heated to the second heating temperature of 180° C. to 239° C. and given a second pressure of 3 to 5 kg/cm 2 for the second time period of 20 to 30 seconds as defined in the present invention.
[0105] By this heating and pressure, the bumps 142 push apart the film-like bonding layer thermally set in a temporary fixing state and are in direct contact (bonding) and electrical connection with electrodes 122 at corresponding positions.
[0106] The second heating temperature described above of for example 180° C. to 239° C. is one example of a temperature higher than the glass transition temperature of the thermosetting resin. It is preferable that this heating temperature is higher than the glass transition temperature of the thermosetting resin. Examples of the glass transition temperatures of the sealing resin 16 are shown in Table 1.
[0107] Table 1 presents the linear thermal expansion coefficients, modules of elasticity, and glass transition points of sealing resin types A to H.
TABLE 1 Types and Material Properties of Sealing Resins Linear thermal Glass expansion Module of transition Type of coefficient elasticity temperature resin α1 (ppm) (GPa) (Tg) A 21 7.0 163 B 23 6.5 140 C 29 9.2 140 D 32 4.0 138 E 38 3.5 138 F 40 4.9 140 G 47 4.5 119 H 60 2.4 134
[0108] In the present invention, designed to avoid the problem of thermal stress, as described later in detail, although the magnitude of the linear thermal expansion coefficient of a sealing resin 16 is of importance, as the sealing resin 16 of the present embodiment, use can be made of the sealing resins shown in Table 1 which have linear thermal expansion coefficients (ppm) ranging from 20 to 60 or so or, in a wider region, from 15 to 70 or so.
[0109] The second pressure causes the bumps 142 to push apart the film-like bonding layer thermally set in a temporary fixing state to come into direct contact with the electrodes 122 at corresponding positions, and deforms the bumps 142 to a certain degree, but it is not so strong as to deform and damage the electrodes 122 . For example, it is in the range from 3 to 5 kg/cm 2 .
[0110] Due to the above process, the semiconductor device 1 of the structure illustrated in FIG. 1 is formed. Namely, in the state where the bumps of the IC chip 14 and the corresponding electrodes 122 of the wiring board 12 are electrically connected, their surroundings are sealed by the sealing resin 16 and the wiring board 12 and the IC chip 14 are adhered.
[0111] [0111]FIG. 5 shows the results of inspection of the thermal fatigue lifetime up to destruction of the semiconductor device in FIG. 1 under a temperature cycle test in a range from −25° C. to 125° C. when forming a semiconductor device 1 by using the resins A to H listed in Table 1 as the sealing resin 16 .
[0112] In FIG. 5, the horizontal axis represents the number of temperature cycles, while the vertical axis represents the equivalent-stress (MPa). Note that the equivalent-stress is the von Misess stress.
[0113] The results presented in FIG. 5 show that the magnitude of the linear thermal expansion coefficient of the sealing resin 16 does not directly influence the maximum stress of the sealing resin 16 , while the maximum stress acting on the gold bump 142 increases with a rise of the linear thermal expansion coefficient of the sealing resin 16 , and the lifetime of the bump 142 becomes short when the linear thermal expansion coefficient of the sealing resin 16 is large. This is because if the linear thermal expansion coefficient of the sealing resin 16 is high, the sealing resin 16 displaces due to thermal stress, and because of the displacement, the bonding portions of the bumps 142 and electrodes 122 are warped. Further, if repeatedly warped, the bonding between bumps 142 and electrodes 122 turns poor or may even be loosened.
[0114] From the viewpoint of the thermal stress, a small linear thermal expansion coefficient of the sealing resin 16 results in high reliability.
[0115] If heating in the above way, as illustrated in FIG. 6, because of the difference of linear thermal expansion coefficients of the wiring board 12 , IC chip 14 , and sealing resin 16 , thermal stress begins to act on the semiconductor device 1 .
[0116] [0116]FIG. 6 is a view of a state when a negative temperature load is applied.
[0117] The linear thermal expansion coefficient of the IC chip 14 comprising mainly silicon is 10 times smaller than that of the wiring board 12 , so when a negative temperature load is applied, the contraction of the wiring board is larger than the IC chip 14 , and the wiring board bends to the side of the IC chip 14 .
[0118] If the semiconductor device 1 is heated to the high temperature side, because the linear thermal expansion coefficient of the sealing resin 16 is larger than that of the electrode 122 side of the wiring board 12 , the electrode 122 side of the wiring board 12 expands while the opposite side contracts. In the same way, because the linear thermal expansion coefficient of the bump side 142 of the IC chip 14 , which is mainly comprised of silicon, is smaller than that of the sealing resin 16 , the sealing resin side of the IC chip 14 expands and the opposite side contracts.
[0119] On the contrary, if the semiconductor device 1 is cooled to the low temperature side, expansion and contraction will occur in a way contrary to that shown in FIG. 8.
[0120] Such expansion and contraction cause thermal stress acting on the gold bumps 142 of the IC chip 14 . FIG. 5 shows the results associated with this situation.
[0121] From the results of FIG. 5, it is clear that the thermal fatigue lifetime of the semiconductor device is dominated by the amplitude of the stress occurring on the bonding surface between the gold bumps 142 formed on the IC chip 14 and the wiring pattern 122 formed on the wiring board 12 .
[0122] Accordingly, in order to improve the reliability of the connection of the semiconductor device 1 against thermal stress, it is desirable to reduce as small as possible the amplitude of the stress which occurs on the bonding surface between the bumps 142 and the electrode wiring pattern 122 .
[0123] Therefore, the inventors of the present invention did an analysis of decomposing the stress acting on the bonding surface of a bump 142 that is in contact with an electrode 122 . The results are presented in FIG. 7. In FIG. 7, the horizontal axis is the bump height, and the vertical axis is the amplitude of the equivalent-stress Note that the results shown in this figure were obtained under the conditions of a size of the IC chip 14 of 9 mm×0.4 mm, a thickness of the wiring board 12 of 0.7 mm, a bump 142 of a diameter of 30 μm at its front end and of a contact diameter of 23 μm with the electrode wiring pattern 122 , and a core material including a 50 μm build-up layer of FR-4.
[0124] The central curve shows the amplitude of the equivalent-stress which was obtained by numerical calculation such as the limited element method.
[0125] σ Z represents the amplitude of stress in Z direction, namely, along the Z-Z axis in FIG. 1.
[0126] σ XZ stands for the amplitude of a shearing stress relevant to the Z-Z direction and the horizontal direction (X direction) perpendicular to the Z-Z direction.
[0127] The curve of the amplitude of the equivalent-stress shows the equivalent-stress is a minimum when the bump height is about 18 μm. The reason is examined below with reference to FIGS. 8A to 8 C.
[0128] [0128]FIGS. 8A to 8 C are views illustrating the stress acting on the bumps 142 and electrodes 122 .
[0129] A larger height of bumps 142 implies a thicker sealing resin 16 . That is, the sealing resin 16 contributes to the compressing force or contracting force.
[0130] For example, when the sealing resin 16 around the cooled bumps 124 contracts, because the total contraction of the sealing resin 16 in its thickness direction is proportional to its thickness, it increases with the thickness of the sealing resin 16 . If this contraction evenly distributes over the entire bump 142 , the contraction per unit length (per unit length along the thickness direction) is the same, so the stress on the bump 142 does not increase. This phenomenon happens mainly near the bonding surface between the bump 142 and the electrode wiring pattern 122 , which receives a contracting force from the sealing resin 16 and makes the bump 142 contract. Therefore when the bump 142 is high, namely, as illustrated in FIG. 8C, the thickness of the sealing resin 16 is higher than that in FIG. 8B. As the stress σ Z acting on the bump 142 increases, the above phenomenon occurs.
[0131] In FIG. 8C, warping occurs locally mainly along the edge of the bonding surface of a bump 142 and an electrode 122 .
[0132] Next, the case of a lower bump 142 will be considered with reference to FIGS. 9A to 9 C.
[0133] As shown in FIG. 9B, a lower bump 142 implies a close distance between the IC chip 14 having a small linear thermal expansion coefficient and the wiring board 12 having a large linear thermal expansion coefficient. As a result, a shearing stress τ XZ acts on the bump 142 .
[0134] If the bump 142 is low, because the metal structures of the IC chip 14 and the wiring board 12 are close, the semiconductor device 1 is bended more, and the shearing stress τ XZ per unit volume increases.
[0135] If the bump 142 is high, as shown in FIG. 9C, contrary to FIG. 9B, the warping of the device 1 becomes smaller.
[0136] As illustrated in FIG. 5, there is a strong correlation between the thermal fatigue lifetime and the equivalent-stress occurring on the bump 142 , so as shown in FIG. 7, the fact that the equivalent-stress is at a minimum relative to the height of the bump 142 implies there is an optimum height of the bump 142 that optimizes the reliability of the semiconductor device 1 against thermal stress.
[0137] The inventors of the present invention performed experiments to search for such an optimum value. The results are presented in FIG. 10.
[0138] [0138]FIG. 10 shows graphs of the relation between the bump height and the equivalent-stress when changing the diameter (referred to as a top diameter ΦA) of a bump 142 in contact with an electrode 122 to ΦA=30 μm, 40 μm, and 50 μm. The horizontal axis represents the bump height, and the vertical axis represents the equivalent-stress
[0139] [0139]FIG. 10 shows that there is an optimum value of the bump height that gives a minimum amplitude of the equivalent-stress for a constant top diameter ΦA. Further, the minimum of the amplitude of the equivalent-stress increases with a decreasing top diameter ΦA of the bump.
[0140] Examining the graph of FIG. 10 in more detail, as shown by the two dashed lines, there are an optimum height H and an optimum top diameter ΦA of a bump that give a constant ratio ΦA/H with respect to the bump height H.
[0141] Further, from the fact that the optimum height of a bump 142 increases with a decreasing linear thermal expansion coefficient F (ppm) of the sealing resin 16 , the dimensions of a bump become optimum in the region from a L to a U , which is the region satisfying the following formula (1):
a L <((Φ A×F )/ H )< a U (1)
[0142] As shown in FIG. 4 and FIG. 9C, ΦB, H 0 , H, and ΦA are used to denote the bottom diameter of the bump 142 , the initial height of the bump 142 , the height of the bump 124 in contact with an electrode 122 , and the top diameter, that is, the diameter of the contacting portion of the bump 142 bonded with an electrode 122 .
[0143] The height of an electrode is represented by Hd.
[0144] After studying various situations of the top diameter ΦA from the results in FIG. 10, it is found ΦA=45 μm and H=20 μm are the optimum values when F=50 ppm.
[0145] After experiments on various linear thermal expansion coefficients F of the sealing resin 16 presented in Table 1 and various top diameters ΦA, it is found for a gold bump 142 , the preferable height H and top diameter ΦA of the bump 142 satisfy the following formula. Namely, when a L =100 and a U =125 in formula (1),
100<(( ΦA×F )/ H )<125 (2)
[0146] In addition, if considering the matter from a different point of view, a larger top diameter ΦA of a bump can decrease the amplitude of the equivalent-stress and thus raise the reliability of the semiconductor device 1 against thermal stress. However, because of the constraints from the interval with adjacent bumps 142 and electrodes 122 , the top diameter. ΦA of a bump 142 can not be made unlimitedly large.
[0147] As shown in FIG. 4, if representing the interval between adjacent bumps as L (μm), it is found the region defined by the following formula (3) is the permitted region in which the IC chip 14 and the wiring board 12 can be bonded.
(b 1 ×L/ 2)<Φ A <( b 2 ×L/ 2) (3)
[0148] According to the experiments by the inventors, if the coefficients b 1 =0.75 and b 2 =0.85, a flip chip of high reliability against thermal stress and a long lifetime can be realized.
(0.75 ×L/ 2)<Φ A <(0.85× L/ 2) (4)
[0149] Therefore, in principle, what has to be done is just to form bumps satisfying the formulae (1) and (3) (or formulae (2) and (4)).
[0150] In practice, however, if the bump height is less than 20 μm, because the wiring board 12 sinks when the bumps 142 and the electrode wiring pattern 122 are pressed for bonding, the wiring board 12 may touch the IC chip 14 , and there may be insufficient bonding among the many bonded bumps 142 and the electrode wiring pattern 122 .
[0151] From this point of view, it is concluded the bump height cannot be less than 20 μm.
[0152] Further, it is also clarified if the top diameter ΦA is less than 50 μm, the optimum bump height H will not be 25 μm or more as long as the linear thermal expansion coefficient of the sealing resin 16 is not too small.
[0153] From this point of view, when the top diameter ΦA is less than 50 μm, the bump height is simply defined by the following formula (5):
20< H (μ m )<25 (5)
[0154] Note that strictly the height of a bump is determined by both the initial height H 0 of the bump and the height Hd of an electrode 122 . In the present embodiment, the bump height H was studied assuming the total height Hd of an electrode 122 is Hd=16 μm including for example 12 μm thick copper, 3 to 0.5 μm thick nickel plating, and 0.02 μm thick gold plating.
[0155] Therefore, when the height Hd of an electrode 122 is smaller than the above value, the bump height can be made larger accordingly.
[0156] In the above embodiment, the electrode 122 was assumed to be comprised of 12 μm thick copper covered by 3 to 5 μm thick nickel plating and 0.02 μm thick gold plating, gold was used for the bump 142 , and the sealing resins 16 listed in Table 1 were used, but the present invention is not limited to this embodiment. Numerous materials and thicknesses are applicable.
[0157] In addition, as an example., the semiconductor integrated circuit chip of the present invention is described as an IC chip using silicon, but the invention is not limited to silicon-based IC chips. For example, a chip using a compound semiconductor may also be used.
[0158] Numerous modifications can also be made without departing from the basic concept and scope of the present invention.
[0159] Summarizing the effects of the invention, according to the present invention, the conditions have been found for avoiding poor bonding or losing bonding between a projecting electrode (bump) formed on a semiconductor integrated circuit chip and an electrode formed on a wiring board even under thermal stress.
[0160] According to the present invention, based on such conditions, a flip chip semiconductor device of high reliability can be provided. | A semiconductor device able to maintain a bonding state between a bump and an electrode and having high reliability even under thermal stress, wherein a sealing resin is interposed to bond the electrodes and bumps between a wiring board formed with a plurality of electrodes and an IC chip formed with a plurality of bumps, the bumps being formed under the condition that the following formula is satisfied.
100 <((Φ A×F )/ H )< 125
where ΦA represents the top diameter of a bump bonded with an electrode, H the height of a bump projecting from the IC chip and bonded with an electrode, and F the linear thermal expansion coefficient of the sealing resin. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates to a self-equilibrating measuring balance for example for use in weighing articles or for monitoring varying pressures.
2. Description of the Prior Art.
For measuring water movements and water level changes, for instance in the sea or in waterways, use is conventionally made of a pressure sensor arranged at the measuring point, and comprising a cell closed by an elastically-deformable wall, which cell is connected by a first duct to a source of compressed air with a constant air supply, and which by means of a second duct communicates with the ambient air, a pressure gauge being, furthermore, connected to the supply duct. The pressure measured by this pressure gauge is correlated with the flow resistance caused by the cell, which, in turn, is correlated with the deflection of the deformable wall, and, therefore, with the pressure at the location of the sensor. In this manner it is possible remotely to measure pressures, and more particularly continuously varying pressures, with high sensitivity. The pressure variations correlated to water levels and water movements have to be recorded over very long periods so that recording instruments are used. Since, generally, the recording instruments are positioned in remote places in which often no electricity supply is available, these instruments should be as simple and reliable as possible, and should be provided with individual energy sources so as to be anble to work without maintenance for a relatively long time. Therefore simple mechanical recording instruments, for instance with a clockwork drive, and simple reliable pressure gauges are preferred.
For such purposes it has been proposed to use a selfequilibrating balance comprising a balance arm supported on a fulcrum and provided, at one end, with a fixed mass, a pressure sensing cell suitable for sensing the pressure being connected to said arm. Furthermore, a travelling mass is mounted on this balance arm, which is movable by means of a screwed spindle driven by an electric motor, the latter being controlled by means of a circuit comprising two contacts co-operating with a contact finger at one end of the balance arm, so as to cause the motor to rotate in a sense such that the travelling mass is displaced so as to restore the equilibrium of the balance. This screwed spindle is coupled to a mechanical recording instrument for recording the pressure measured.
Such a pressure measuring mechanism operates reliably, the electrical motor for displacing the travelling mass needing very little current, and thus being able to run for an adequate length of time on batteries. Together with a mechanical recorder with a clock-work drive a very reliable unit is obtained, which can operate for a relatively long period without maintenance. At intervals the batteries are to be replaced and the clock-work is to be wound, but this can be done when the paper-roll with te pressure record is taken away for processing.
Previously proposed measuring balances, however, appear to have, at a pressure of for instance 10 to 20 m. of water, a measuring error of about 1 to 2%, i.e., about 100 to 200 mm. of water, which inaccuracy is too large for some purposes. This inaccuracy is, perhaps, a consequence of the fact that a very accurate adjustment of the travelling weight moved along a rod is not possible because of the friction and inertia of the weight, and of the unavoidable lost motion in the driving members acting on the weight, and possibly also as a consequence of friction between these driving members and the mass which influence the latter's vertical movements. The spring reaction of the contact springs can also be a disturbing factor promoting overshooting of the equilibrium position, and the restoration thereof is delayed or prevented by the aforementioned factors.
It is an object of the invention to provide a selfequilibrating measuring balance which has a substantial improvement in its accuracy in comparison with previously proposed balances.
SUMMARY OF THE INVENTION
According to the present invention there is provided a self-equilibrating balance for measuring progressively changing parameters, a balance arm, means defining a fulcrum supporting said balance arm, a fixed mass mounted at one end of the balance arm, means for applying a force related to said parameter to the arm, a screwed spindle extending alongside the balance arm, a travelling mass mounted on the screwed spindle, said travelling mass having the shape of a body of revolution arranged to roll along the upper edge of the balance arm and comprising a frame mounted on said screwed spindle and confining the body of revolution, two driving members mounted on the frame and both contacting in the equilibrium position of the balance arm the body of revolution substantially without friction, and guide means serving to maintain the body of revolution centrally, in the transverse sense, on the arm, drive means for the travelling mass, and guide means for the frame extending parallel to the balance arm.
Preferably the body of revolution is a sphere, the driving members and guide means contacting the sphere in the equilibrium position in the sequential plane of the sphere. These driving members and guide means may be wheels or balls in order to obtain substantially rolling friction.
The fixed contact springs co-operating with the contact finger of the balance arm may be in the form of L-shaped wires, one leg of each wire being clamped near its extremity, and extending substantially horizontally, and the other legs being positioned symmetrically at an angle with respect to the horizontal plane, the contact finger of the balance extending in the V-shaped space between these legs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are, respectively, a diagrammatic side view with parts broken away and a diagrammatic plan view of one embodiment of a balance in accordance with the invention;
FIG. 3 is a view, to an enlarged scale, of a travelling weight of the balance shown in two different positions; and
FIG. 4 is a perspective view of a contact assembly of the balance.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The balance shown comprises a fixed support 1 and a fulcrum 2 for supporting a balance arm 3 provided, at one end, with a fixed mass 4, and, furthermore, a rod 5 is coupled to this arm 3, which rod is adapted to transmit the force to be measured to the arm. For measuring pressures, this rod will be connected for example, to a pressure-sensing cell. At the other end of the arm 3 a contact finger 6 is provided which is arranged to contact fixed contact springs 7 and 8 on leaving the equilibrium position, these contact springs being connected in an electric circuit 9 for controlling a reversible electric motor 10, the contact finger 6 also being connected in the circuit through the arm.
The motor 10 is coupled by means of gears 11 to a horizontal screwed spindle 12 supported in bearings, not shown. On this spindle one or more nuts 13 connected to a slide 14 are provided, which slide is slidable in a horizontal guide 15. A sprocket wheel 16 for driving a recording apparatus is mounted on the spindle 12, and, furthermore, this spindle can be coupled to a digital counter 17 indicating the number of revolutions of the spindle corresponding to the position of the slide 14 on the guide 15 and on the arm 3.
Two pairs of thin wheels or discs 18 and 19 respectively are supported on pins mounted on the slide 14, the wheels 18 lying in the vertical median plane of the balance arm, and the wheels 19 lying in a vertical plane normal to that of the wheels 18. a travelling mass in the form of a sphere 20 is situated between the wheels 18 and 19 which is adapted to roll on the upper edge of the balance arm 3. The first pair of wheels 18 acts as driving members. The wheels 18 and 19 are so positioned that in the equilibrium position of the arm 6, they all contact the equator of the sphere 20, the contact being substantially point-wise, and virtually no play is present.
FIG. 3 shows, to an enlarged scale, the relative position of the sphere 20 and wheels 18. In the equilibrium position shown in continuous lines, both wheels 18 contact the equator of the sphere 20 substantially point-wise. When, on disturbing the equilibrium, the balance arm takes up the position indicated with broken lines, the sphere 20 must be moved uphill, i.e. to the right in FIG. 3, so that on moving the slide 14 the sphere will be driven along by the wheel 18 at the lower side. Since the wheels 18 are now situated lower than the equatorial plane of the sphere, and, therefore, in front of a smaller parallel circle of this sphere, some play will be present, and the sphere 20 will be driven by gravity against the wheel 18 at the lower side and this brings about movement of the sphere. The other wheel 18 is, then, unloaded and remains at a short distance from the sphere. This automatically obtained play in respect of the inoperative wheel prevents generation of jamming or friction forces during the upward displacement of the sphere, and this play becomes smaller as the equilibrium position is approached. In the equilibrium position the play completely disappears, so that this position is unambiguously defined.
Lateral support can also be provided by guide means, such as wheels similar to wheels 18, as shown. On leaving the equilibrium position some lateral play will develop which is, generally, admissible. Instead of the wheels, vertical ribs can be used which always contact the equator of the sphere, so that no lateral play will occur. Balls or horizontal wheels can also be used, in particular for lateral support, and these generate slightly less friction.
Instead of a sphere a flat circular disc can be used which is similarly carried by two wheels, and which, for instance, can be provided at both sides with a central ball, which balls bear against the flat side edges of the slide 14. Also lateral support by means of two or more wheels is possible. However a sphere has a smaller contact surface and has better lateral stability.
FIG. 4 shows a preferred embodiment of the contact springs 7 and 8 cooperating with the contact finger 6. These springs comprise L-shaped wires, made, for example, of gold, one leg 7', 8' of each spring being horizontally oriented and being clamped near its free end so that these legs act as torsion springs. The other legs 7" and 8" extend substantially symmetrically with respect of the horizontal. The contact finger 6 extends into the V-shaped interspace between these legs, and on contacting and slightly bending a leg 7"or 8", the finger 6 will scrape along said finger so that a self-cleaning action, and, moreover, a small damping is obtained. The contact reaction is very small which is important since, at the accuracy and sensitivity obtained in this balance, this reaction will play an important part. Such contact springs can easily be arranged accurately symmetrically, and can also be made jointly adjustable transversely to the direction of the contact finger 6 so that the sensitivity can be adjusted. Although this balance has, in the first place, been designed for the aforesaid pressure measurements, it will be clear that it is also suitable for other force measurements. | An accurate measuring balance for measuring forces or pressures, comprising a travelling mass for bringing a balance arm to equilibrium, which travelling mass is shaped as a body of revolution which can roll on the upper edge of the balance arm, and is mounted in a frame which is movable by an electric motor in the longitudinal direction of the balance arm. The frame comprises rotatable members contacting, in the equilibrium position of the balance, the body at both sides in the horizontal median plane. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a method of producing methionine by hydrolyzing 5-(β-methylmercaptoethyl)hydantoin in the presence of a basic potassium compound, which can significantly decrease corrosion of reaction vessels, and enables long-term stable production of methionine.
BACKGROUND OF THE INVENTION
[0002] A method of obtaining methionine by hydrolyzing 5-(β-methylmercaptoethyl)hydantoin (hereinafter to be referred to as M-hydantoin) is generally performed in the presence of a basic potassium compound such as potassium carbonate and the like, as shown by the following formula.
[0000]
[0003] As to the general reaction conditions for this hydrolysis, the pressure is within the range of about 0.5 to 1.5 MPaG and the temperature is within the range of about 150 to 200° C. The corrosion of reaction vessels under such conditions is extremely severe in both the liquid phase part and the gaseous phase part. Reaction vessels made of SUS304L stainless steel are so severely corroded that a 3 mm-thick tray is penetrated in about 3 months under the conditions. In addition, even corrosion resistance of a high-grade austenitic chrome-nickel stainless steel, which has been accepted as more corrosion-resistant, is insufficient under this environment.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to provide a method of producing methionine by hydrolyzing M-hydantoin in the presence of a basic potassium compound, which can effectively prevent corrosion of reaction vessels in both the liquid phase and gaseous phase of a hydrolysis solution even at a higher temperature, and enables a longer period of stable production of methionine.
[0005] The present inventors have conducted intensive studies in an attempt to reduce corrosion of hydrolysis reaction vessels even at a higher temperature, and found that when the potassium concentration of the reaction system is not more than a particular level, corrosion of reaction vessels in both the liquid phase and gaseous phase of a hydrolysis solution can be effectively prevented even at a higher temperature, which resulted in the completion of the present invention.
[0006] Accordingly, the present invention relates to
[0000] [1] a method of producing methionine, comprising hydrolyzing 5-(β-methylmercaptoethyl)hydantoin in water in the presence of a basic potassium compound in a reaction system having a potassium concentration of not more than 9 wt % at a temperature of not less than 170° C.; and
[2] the method of the above-mentioned [1], wherein the hydrolysis is performed in a reaction vessel having the inner surface made of stainless steel having a Cr element content of 21.0 to 30.0 wt %, a Ni element content of 4.5 to 11.0 wt %, a Mo element content of 1.0 to 5.0 wt %, a N element content of 0.05 to 0.50 wt % and a W element content of not more than 5.0 wt %.
EFFECT OF THE INVENTION
[0007] Using the production method as described in the present invention, methionine can be produced stably for a longer period of time, since the corrosion of reaction vessels is effectively prevented when M-hydantoin is hydrolyzed even at a higher temperature in the presence of a basic potassium compound. Hence, the method has invaluable industrial applicability.
DESCRIPTION OF EMBODIMENTS
[0008] In the present invention, methionine is obtained in the form of a potassium salt, by hydrolyzing M-hydantoin in water in the presence of a basic potassium compound.
[0009] Examples of the basic potassium compound include potassium hydroxide, potassium carbonate, potassium hydrogen carbonate and the like, and two or more kinds thereof can also be used as necessary.
[0010] The amount of the basic potassium compound is generally 1 to 10 mol per 1 mol of M-hydantoin, based on potassium.
[0011] The hydrolysis is performed in water. The amount of the water is generally 2- to 20-fold weight relative to M-hydantoin.
[0012] In addition, the hydrolysis is generally performed using a reaction vessel made of stainless steel.
[0013] In the present invention, it is important that the potassium concentration of the reaction system (based on potassium) be maintained at not more than 9 wt %, at which corrosion of the reaction vessel is effectively prevented even at a higher temperature. The above-mentioned potassium concentration is preferably 7.0 to 8.0 wt %.
[0014] The reaction temperature of the hydrolysis is not less than 170° C. To shorten the reaction time and reduce the amount of the basic potassium compound, it is preferably not less than 180° C., more preferably 180 to 220° C.
[0015] Ammonia and carbon dioxide gas generated during the hydrolysis are recovered and utilized in the M-hydantoin-formation step.
[0016] Then, carbon dioxide gas is introduced into the obtained hydrolysis solution to neutralize the solution, whereby methionine is crystallized. The neutralization and crystallization is performed under pressurized condition with carbon dioxide gas, and the precipitated methionine is filtered and separated and, where necessary, washed with water and dried to give methionine as a product.
[0017] In the present invention, the reaction vessel to be used for hydrolysis is preferably one having an inner surface made of stainless steel having a Cr element content of 21.0 to 30.0 wt %, a Ni element content of 4.5 to 11.0 wt %, a Mo element content of 1.0 to 5.0 wt %, a N element content of 0.05 to 0.50 wt % and a W element content of not more than 5.0 wt %. In the present invention, the reaction vessel also includes the parts that come into contact with the hydrolysis solution such as auxiliary valves, piping and the like.
[0018] When the Cr element content of the above-mentioned stainless steel is less than 21.0 wt %, good corrosion resistance to hydrolysis cannot be performed and, when it exceeds 30.0 wt %, brittleness becomes marked. The Cr element content is preferably 23.5 to 29.5 wt %.
[0019] The presence of Ni element is known to decrease the corrosion resistance of stainless steel to hydrolysis. However, a substantial decrease in the corrosion resistance is not observed within the above-mentioned range, and rather, a mechanical property and processability-improving effect is observed. The Ni element content is preferably 5.0 to 8.5 wt %.
[0020] When the Mo element content of the above-mentioned stainless steel is less than 1.0 wt %, good corrosion resistance to hydrolysis cannot be performed and, when it exceeds 5.0 wt %, stainless steel shows poor processability and sigma phase embrittlement is promoted. The Mo element content is preferably 1.0 to 4.0 wt %.
[0021] When the N element content of the above-mentioned stainless steel is less than 0.05 wt %, good corrosion resistance to hydrolysis cannot be performed and, when it exceeds 0.50 wt %, nitride is precipitated in stainless steel, which will decrease its toughness. The N element content is preferably 0.05 to 0.40 wt %.
[0022] When the W element content of the above-mentioned stainless steel exceeds 5.0 wt %, sigma phase is formed to markedly increase brittleness of the stainless steel.
[0023] The stainless steel to which the production method of the present invention can be applied is not particularly limited as long as it contains the above-mentioned chemical components. Examples of the commercially available stainless steel containing the above-mentioned components include SUS329J4L, SCS10, UNSS39274, UNSS32808, UNSS32760, UNSS32750, UNSS32707, UNSS32906 and the like, and use thereof is economical.
[0024] As for other elements not mentioned above, the presence thereof is not limited as long as the corrosion resistance to hydrolysis at a higher temperature is not markedly impaired, and examples thereof include C element, Si element, Mn element, P element, S element, Cu element and the like. Preferable contents thereof are: C element content not more than 0.03 wt % , Si element content not more than 0.80 wt %, Mn element content not more than 1.10 wt %, P element content not more than 0.03 wt %, S element content not more than 0.03 wt %, and Cu element content not more than 1.00 wt %.
[0025] In the present invention, Cu element is hardly contained in the above-mentioned stainless steel. That is, its content may be limited to an ultratrace amount, for example, not more than 1.00 wt %.
EXAMPLES
[0026] The present invention is explained in more detail in the following by referring to Examples, whereas the Examples are merely embodiments, and the present invention is not limited thereby. In the Examples, the chemical components of alloy A (stainless steel) were measured by a fluorescence X-ray analyzer.
Example 1
[0027] A hydrolysis supply solution (potassium concentration: 7.5 wt %), which is a mixture of 5-(β-methylmercaptoethyl)hydantoin and potassium carbonate, was continuously supplied from the top of an autoclave (supply rate 700 g/hr), and hydrolysis was performed while maintaining pressure 1.0 MPaG and temperature 180° C., during which a reaction product containing a methionine potassium salt was taken out from the bottom part of the autoclave and the generated gas was released from the top of the autoclave. Alloy A shown in Table 1 (composition shown in Table 1, the rest is mostly Fe) was inserted in the liquid phase of the reaction system and maintained for 4 hr to perform a corrosion test.
[0028] The results of the corrosion test were obtained by calculating corrosion rate (thickness reduction per year) from the corrosion level measured (decrease in test piece weight per unit time and unit area). The results are shown in Table 1.
Example 2
[0029] In the same manner as in Example 1 except that the pressure was changed to 2.4 MPaG, and the hydrolysis temperature was changed to 220° C., the corrosion test was performed. The results are shown in Table 1.
Comparative Example
[0030] In the same manner as in Example 1 except that the potassium concentration was changed to 10 wt %, the corrosion test was performed. The results are shown in Table 1.
[0000]
TABLE 1
K
temper-
concen-
corrosion
ature
tration
chemical components (wt %)
rate
alloy
(° C.)
(wt %)
Cr
Ni
Mo
N
W
(mm/year)
Ex. 1
alloy
180
7.5
24.92
7.25
3.08
0.15
0.26
4.16
A
Ex. 2
alloy
220
7.5
24.92
7.25
3.08
0.15
0.26
4.28
A
Comp.
alloy
180
10
24.92
7.25
3.08
0.15
0.26
10.31
Ex.
A
[0031] From Table 1, it is appreciated that when the potassium concentration of the reaction system is not more than 9 wt %, the corrosion rate is of the same level as 180° C. even when the hydrolysis temperature is 220° C.
INDUSTRIAL APPLICABILITY
[0032] Using the production method as described in the present invention, methionine can be produced stably for a longer period of time, since the corrosion of reaction vessels is effectively prevented when M-hydantoin is hydrolyzed even at a higher temperature in the presence of a basic potassium compound. Hence, the method has invaluable industrial applicability. | The present invention aims to provide a method of producing methionine by hydrolyzing M-hydantoin in the presence of a basic potassium compound, which can effectively prevent corrosion of reaction vessels in both the liquid phase and gaseous phase of a hydrolysis solution even at a higher temperature, and enables a longer period of stable production of methionine. Provided is a method of producing methionine, comprising hydrolyzing 5-(β-methylmercaptoethyl)hydantoin in water in the presence of a basic potassium compound in a reaction system having a potassium concentration of not more than 9 wt % at a temperature of not less than 170° C. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to a novel process for preparation of a pharmaceutically pure polymorphic form I of Olanzapine. More particularly this invention relates to precipitating substantially pure Olanzapine Form I from a solution containing crude olanzapine.
BACKGROUND OF THE INVENTION
[0002] The compound 2-methyl-4-(4-methyl-1-piperazinyl)-10H-thieno[2,3-b][1,5]benzodiazepine [olanzapine] is useful for treating-psychotic patients and mild anxiety states. Preparation of olanzapine and its acid salts having pharmaceutical properties particularly in the treatment of central nervous system disorders has been disclosed in U.S. Pat. No. 5,229,382 (hereinafter referred to as the '382 patent). This patent does not refer to any specific polymorphic crystalline form of olanzapine.
[0003] Olanzapine exists in two important polymorphic forms, known as Form I and Form II, distinguishable by X-ray powder diffractrometry. EP 733,635 claims Form II of olanzapine and designates the product obtained according to the process described in previous the '382 patent as Form I. It also describes the preparation of Form II olanzapine from ethyl acetate. This patent further adds that anhydrous Form I of olanzapine is metastable and is therefore not well suited for commercial use in pharmaceutical formulations.
[0004] However, it has been discovered that anhydrous Form I olanzapine, is stable and is therefore well adapted for commercial use in pharmaceutical formulations. Accordingly there is a need for a process to prepare olanzapine Form I free from the Form II impurity. It is desirable to prepare the substantially pure anhydrous Form I olanzapine to assure uniformity of product.
[0005] Although example 1 of the '382 patent discloses a process to obtain olanzapine Form I by recrystallization of olanzapine from acetonitrile, the polymorphic form in these experiments was characterized for its X-ray Powder diffraction and showed that the d values for this product matched with those of olanzapine Form II claimed in EP 733,635. It is therefore inferred that recrystallization of Olanzpine in acetonitrile produces form II and not Form I.
[0006] WO 02/18390 discloses a process for the preparation of form I of olanzapine by crystallization of raw olanzapine, olanzapine hydrate or its polymorphic form II from methylene chloride. It has been found that extending the duration of the process of olanzapine crystallization from methylene chloride to yield sufficiently pure final crystalline form I leads to the formation of the additional contaminating compound, especially during heating at reflux temperature. Also repeated crystallization from methylene chloride lead only to a progressive accumulation of the impurity to levels unacceptable in view of the purity requirements for the pharmaceutical materials.
[0007] WO03101997 A1 [equivalent to US 2004/0048854 A1] discloses a process of preparation of Form I olanzapine free of the Form II impurity. According to this patent olanzapine is purified in an acidic medium followed by extraction with organic solvents. The resulting mixture is then basified under cold conditions and then extracted using low boiling organic solvents. Further, it discloses that a basic solvent (such as toluene and methanolic sodium hydroxide) is critical to separate out Olanzapine Form I.
[0008] WO 03/055438 discloses a process of seeding a solution of an alcoholic solution with substantially pure form I, prior to crystallization to obtain Form I as a product.
[0009] Until now, there has been no disclosure of obtaining Olanzapine Form I by precipitation, which generally is a much more simpler technique. Thereby, the inventors of the present application have discovered a novel method for obtaining substantially pure Olanzapine Form I by precipitation technique.
[0010] The present invention related to a process for preparation of substantially pure Olanzapine Form I. The polymorphic Form I herein represents the Form I as defined in EP 733,635 and WO96/30375. The X-ray diffractogram of this polymorphic form exhibits the characteristic inter-planar distances d (in angstroms): 9.94, 8.55, 8.24, 6.88, 6.24, 5.58, 5.30, 4.98, 4.83, 4.72, 4.62, 4.53, 4.46, 4.29, 4.23, 4.08, 3.82, 3.74, 3.69, 3.58, 3.50, 3.33, 3.28, 3.21, 3.11, 3.05, 2.94, 2.81, 2.75, 2.65, 2.63, 2.59.
OBJECT OF THE INVENTION
[0011] The object of the present invention is to develop a new process for the preparation of substantially pure Form I olanzapine.
[0012] Another object of the invention is to develop a new process for the preparation of substantially pure Form I olanzapine by precipitation technique. Form I prepared by the present invention also has satisfactory color and thermal stability for use in pharmaceutical solid dosage form.
SUMMARY OF THE INVENTION
[0013] In order to achieve the said object the present invention provides a process for converting crude grade olanzapine into substantially pure Form I olanzapine by precipitation technique. The process involves dissolving crude olanzapine in a water-miscible solvent, and adding water to the solution to precipitate the product
[0014] The present invention relates to a process for converting crude Olanzapine to substantially pure Form I Olanzapine comprising:
a) dissolving crude Olanzapine in a solvent, b) adding water to precipitate the product, and c) recovering substantially pure Olanzapine Form I by filtering the precipitate and drying the said precipitate.
[0018] The solvent used for dissolving crude olanzapine is DMSO [dimethyl sulphoxide]. Other solvents that have been used are: DMF [dimethylformamide] & THF [tetrahydrofuran].
[0019] The temperature at which water is added is 40° C.-50° C., more preferably at 50° C. An alcoholic solvent is added to the crude olanzapine solution at a temperature of 40° C.-50° C., prior to the addition of water. The alcoholic solvents used are methanol and ethanol. The reaction product is isolated by known techniques such as filtration or centrifugation. The pure Form 1 olanzapine is recovered by isolating and drying the precipitate. Drying of the product is carried out at a temperature of 50° C.-70° C.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The compound 2-methyl-4-(4-methyl-1-piperazinyl)-10H-thieno[2,3-b][1,5]benzodiazepine [olanzapine] is useful for treating psychotic patients and mild anxiety states.
[0021] As used herein “substantially pure” refers to Olanzapine associated with less than 5% Form II, and more preferably less than about 1% Form II. Further, “substantially pure” Form I will contain less than 0.5% related substances, wherein “related substances” refers to undesired chemical impurities or residual organic solvent.
[0022] As used herein the term “crude” refers to Olanzapine typically associated with undesired polymorph and/or greater than 5% undesired related substances. Such crude grade olanzapine may contain less than 1% undesired related substances.
[0023] Compound characterization methods include, for example x-ray powder pattern analysis, differential scanning calorimetry (DSC), and Infrared spectroscopy.
[0024] The materials for the present invention can be purchased or prepared by a variety of procedures well known to those skilled in the art. Crude Olanzapine can be prepared as described in U.S. Pat. No. 5,229,382, herein incorporated by reference in its entirety.
[0025] The process for converting crude olanzapine to substantially pure Form I olanzapine involves:
a) dissolving crude olanzapine in a solvent, b) adding water to the said solution to form a precipitate, and c) recovering substantially pure Form I olanzapine by filtering the precipitate and then drying the precipitate.
[0029] Crude olanzapine is dissolved initially in a water-miscible organic solvent. It is preferable to use solvents in which olanzapine is readily soluble such as dimethyl sulpholide (DMSO) to minimize solvent handling. The same objective can be achieved using the other solvents mentioned herein. The solution can be prepared by stirring and/or gentle heating. The solvent can be selected from a group consisting of dimethyl sulfoxide, dimethylformammide, tetrahydrofuran, either singly or in combination.
[0030] To this solution, water is added to precipitate the product. Since some exothermicity [40-50C] may be observed, it is preferable to add water slowly while maintaining the temperature of the reaction mass. Once all the product has been precipitated, the reaction mass is cooled, and the product recovered by known isolation techniques such as filtration or centrifugation. The filtered material is then subjected to drying [50°-70° C.] to obtain substantially pure Form I olanzapine.
[0031] As a preferred embodiment of the present invention, an alcoholic solvent such as methanol or ethanol, either singly or in combination is added at a temperature 40° C.-50° C., prior to adding water.
[0032] Drying can be done either under vacuum or by fluidization. The fluidization method for drying is more efficient for removing water, and dried until the outlet temperature reaches 50° C.-70° C.
[0033] The following examples are provided for the purposes of illustration and are not to be construed as limiting the scope of the claimed invention.
EXAMPLE 1
Preparation of Olanzapine Form-I using DMSO, Methanol and Water
[0034] 35 Kilos of crude Olanzapine was dissolved in 105 liters of dimethyl sulphoxide, and maintained at 50° C. for 30 minutes. The solution was then filtered through a hyflo bed to remove the insolubles. Additionally 35 liters of dimethyl sulphbxide was charged into the reactor, and press the washings through filter into another reactor.
[0035] The filtrate was cooled to 40° C., and 350 liters methanol was added slowly while maintaining the temperature between 40 and 50° C. This was followed by slow addition of 105 liters of water while maintaining the temperature between 40 and 50° C. to precipitate Olanzapine completely from the solution. The reaction mass was then cooled to 0-5° C., maintained for 3 hours at the same temperature, filtered and then dried at 60° C.-70° C. in a fluidized bed drier to obtain 25 kilos of final product. The product was identified as substantially pure Form I of Olanzapine by powder X-ray analysis.
EXAMPLE 2
Preparation of Olanzapine Form-I Using Dimethylformamide, Methanol and Water
[0036] 25 grams of crude olanzapine was dissolved in 125 ml of dimethyl formamide, and heated to 50-55° C. for 30 minutes, to dissolve the crude material. 1 gram activated carbon was added at 50-52° C. and heating was continued. The solution was then filtered through a hyflo bed to remove the insolubles. Now, 25 ml of dimethylformamide was charged into the flask, and the washings were pressed through filter.
[0037] The filtrate was cooled, and 375 ml methanol was added slowly while maintaining the temperature between 49 and 54° C. This was followed by slow addition of 75 ml of water while maintaining the temperature between 40 and 50° C. The reaction mass is now cooled to precipitate olanzapine completely from the solution. The reaction mass was then cooled to 0-5° C., maintained for 1.5 hours at the same temperature, and filtered and washed with water [25 ml] and dried at 50° C.-55° C. in a fluidized bed drier until moisture content was below 0.3% to obtain 22 grams of final product. The product was identified as substantially pure Form I of Olanzapine by powder X-ray analysis.
EXAMPLE 3
Preparation of Olanzapine Form-I Using THF, Methanol and Water
[0038] 25 grams of crude olanzapine was dissolved in 75 mL of tetrahydrofuran, and heated to 40-45° C. for 30 minutes, to dissolve the crude material. 1.0 gm Activated carbon was added at 50-52° C. and heating was continued. The solution was then filtered through a hyflo bed to remove the insolubles. Now, 25 mL of tetrahydrofuran was charged into the flask, and the washings were pressed through filter.
[0039] The filtrate was cooled, and 375 ml methanol was added slowly while maintaining the temperature between 43 and 47° C. This was followed by slow addition of 75 ml of water while maintaining the temperature between 37 and 42° C. the reaction mass is now cooled to precipitate Olanzapine completely from the solution. The reaction mass was then cooled to 0-5° C., maintained for 1.5 hours at the same temperature, and filtered and washed with water [25 ml] and dried at 50° C.-55° C. in a fluidized bed drier until moisture content was below 0.3% to obtain 20 grams of final product. The product was identified as substantially pure Form I of Olanzapine by powder X-ray analysis.
[0040] The present invention is not to be limited in scope by the specific embodiments and examples, which are intended as illustrations of a number of aspects of the invention and any embodiments which are functionally equivalent are within the scope of this invention. Those skilled in the art will know, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. | The invention is directed to a novel method for making crystalline Form I of Olanzapine, wherein crude olanzapine is dissolved in a water-miscible solvent in which it is freely soluble, from which substantially pure polymorphic Form I of Olanzapine is recovered by precipitation. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation of International Application Serial No. PCT/DE95/00625, filed May 9, 1995.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an optoelectronic unit, having a base plate which carries an optoelectronic component with at least one optically active zone, a lens body having at least one lens associated with the optically active zone, and a spacing device being an integral component of the lens body.
In the production of optoelectronic units or modules, the precise optical coupling of the optically active zone of the optoelectronic component (such as a laser diode) to some further optical element (such as a fiber-optical waveguide) is problematic, especially if a plurality of optically active zones (such as a diode array) are to be coupled.
Published European Patent Application 0 506 438 A1, corresponding to U.S. Pat. No. 5,260,587, discloses a unit with an optoelectronic component in the form of a so-called LED array with a plurality of light-emitting diodes spaced apart in a line as the optically active zones and with a lens carrier which carries a number of individual lenses (lens array) corresponding in number and spacing to the diodes. The assembly and adjustment of the known unit is comparatively complicated and expensive, because of the lack of adjusting devices on the unit itself.
For the sake of easier assembly, Published European Patent Application 0 421 118 A1 describes a carrier body for a glassed-in lens that is fixed relative to a body which carries a laser diode. To that end, one flat side of the carrier body, after being adjusted, can be soldered to metallized small glass blocks that are secured to both sides of the body which carries the laser diode.
German Published, Non-Prosecuted Patent Application DE 43 42 844 A1, corresponding to U.S. application Ser. No. 08/661,076, filed Jun. 10, 1996, discloses a carrier that jointly carries an optoelectronic component with a laser diode array, and lenses that have to be positioned and fixed individually. Additional, separate lenses can be inserted into indentations in the carrier and form a mechanical stop for the component.
An optoelectronic unit which is known from Published European Patent Application 0 529 947 A1 includes as its first part a base plate (termination plate) which has a solder-coated contact spot for at least one optoelectronic component with an optically active zone, and reference points in the form of first alignment indentations. A component placed on the contact spot is automatically exactly positioned relative to the contact spot and therefore to the alignment indentations, upon reflux of the solder, utilizing the surface tension of the solder. An optical fiber to be coupled extends in a groove of a second plate and ends at the end region toward the base plate. An indentation is provided in the end region, preceding the end of the optical fiber, and a separate spherical lens can be inserted into it. Further alignment indentations are formed in the end region, cooperating with the first alignment indentations and forming receptacle spaces. Separate alignment balls can be inserted into the receptacle spaces and provide for positioning and mutual alignment of the two plates in the XYZ directions. The positioning of the optical fiber in the Z direction (axial direction) and the adjustment and positioning of the lens are not described in further detail and must be carried out separately. The known unit has comparatively many individual parts that must each be manufactured precisely, that involve tolerance and that have to be manipulated individually.
Published European Patent Application 0 117 606 A1, corresponding to U.S. Pat. No. 4,767,172, describes a collector for a light-emitting diode row in which each light-emitting diode is assigned a central lens with a concentric parabolic mirror surface, in order to shape light emitted by the light-emitting diode into a parallel beam. The collector is braced through a spacing device on a base plate that carries the individual light-emitting diodes. Therefore the conditions of coupling and beam formation depend not only on the structural height of the light-emitting diodes but also on the tolerances of the seam heights between the light-emitting diodes and the base plate on one hand, and the spacing device and the base plate on the other hand. In the described use of the collector in an electrophotographic recording device, such tolerances are acceptable. However, when light is coupled into an optical fiber, for instance, tolerances that are lower by at least one order of magnitude must be assured.
German Published, Non-Prosecuted Patent Application DE 38 30 119 A1 describes a unit of the type referred to at the outset, in which an optoelectronic component in the form of a laser chip with at least one optically active zone is fixed on a base plate. A lens body has a plane side surface toward the zone and an opposite, convex side surface having a curvature which serves as an aspherical lens. The region between the curvature and the plane side surface necessarily dictates a considerable spacing between the laser and the convex side surface acting as a lens, and that spacing is disadvantageous to the coupling efficiency. Moreover, a material that serves to prevent reflections has to be disposed between the plane side surface and the laser. The laser mirror surface can become stressed and damaged from contact with that material, particularly when there are frequent temperature change cycles.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an optoelectronic unit, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type, which is technically simple, which requires a minimal adjustment effort and expense, which has very high coupling efficiency and which in particular has a plurality of cooperating optically active zones and lenses.
With the foregoing and other objects in view there is provided, in accordance with the invention, an optoelectronic unit, comprising a base plate; an optoelectronic component carried by the base plate and having at least one optically active zone; and a lens body having at least one lens associated with the at least one optically active zone, the lens body having an integral spacing device resting directly against the optoelectronic component for establishing a desired clearance distance between the at least one optically active zone and the at least one lens.
The unit according to the invention makes do with a considerably reduced number of individual parts that have to be manipulated and joined, since the spacing device is an integral component of the lens body. Merely by precise lens body production, the incident tolerances, which determine the optical quality of the unit with respect to the spacing between the optically active zone or zones and the lens or lenses, are advantageously reduced considerably. The unit according to the invention can moreover advantageously dispense with an additional part as a carrier for the lens body. A further advantage of the invention is that the surface structuring (alignment aids) of the base plate and precise positioning of the optoelectronic component with regard to the alignment aids, which are necessary in Published European Patent Application 0 529 947 A1, are not needed.
In accordance with another feature of the invention, the spacing device is in the form of studlike protuberances, having a height which is dimensioned in accordance with the desired spacing between the optically active zone and the lens.
In accordance with a further feature of the invention, the protuberances are lenticular in shape, so that in each case exact contact or stop points are defined.
In accordance with an added feature of the invention, the spacing device is in the form of protuberances in the lens body material, which is a preferred improvement from a production standpoint.
In accordance with an additional feature of the invention, the highest points of the protuberances are located in the same plane as the optical axis of the lens. As a result, the contact regions between the protuberances and the component are adequately spaced apart from the foot region of the component, so that there is enough free space for residues of joining media (such as adhesive or solder) below the protuberances. If the optically active zone is located on the upper long edge of the component, then the above-described embodiment of the invention assures precise spacing adjustment even if the component has been separated by being broken apart at rated breaking points. In that case, defective or irregular breakage surfaces running from the rated braking point to the foot region do not have a disruptive effect.
In accordance with yet another feature of the invention, the lens body is fixed on the base plate and is dimensioned in its height in such a way that the lens is aimed at the height of the optically active zone. This provides a further reduction in the number of degrees of freedom and therefore in the effort and expense for adjustment.
In accordance with yet a further feature of the invention, in an optoelectronic component with a plurality of optically active zones disposed in one row and with a lens body with a corresponding number of lenses disposed in a row, the spacing device is disposed in line with the lenses.
In accordance with yet an added feature of the invention, wherein the optoelectronic component has a plurality of optically active zones (surface-active two-dimensional array) disposed in a plane, and the lens body has a corresponding array of associated lenses (two-dimensional lens array), at least three defined bearing regions for the spacing device are provided on the surface of the optoelectronic component.
In accordance with a concomitant feature of the invention, the bearing regions are surrounded by annular, preferably raised, markings. This provides especially precise, easily assembled positioning of the lens body.
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 optoelectronic unit, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are respective diagrammatic, plan and sectional views of a first exemplary embodiment of the invention, wherein FIG. 2 is taken along a line II--II of FIG. 1, in the direction of the arrows; and
FIGS. 3 and 4 are respective plan and sectional views of a further exemplary embodiment of the invention, wherein FIG. 4 is taken along a line IV--IV of FIG. 3, in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIGS. 1 and 2 thereof, there is seen a unit that includes a ceramic base plate 1 which carries an optoelectronic component 2. The component 2 has a front edge 3 with many optically active zones 4a, 4b, 4c, 4d, 4e, constructed as laser diodes (laser diode array), which in fact can be seen as horizontal lines when suitably enlarged, because of their structuring. The laser diodes are connected by non-illustrated lower surface contacting of the component 2 and by individual contact spots 5a-5d and bonding wires 6a-6d to conductor tracks 7a-7d for individual triggering and are aligned in one row 8. The optically active zone 4e is not contacted.
A lens body 10 which is formed in one piece from an elongated strip of glass has a number of refractive or diffractive lenses 12a-12d that are disposed in a row 11 and correspond in number to the number of contacted optically active zones 4a-4d. The lenses each have respective optical axes 14a-14d. The lens body 10 is constructed in one piece and formed of lens body material 16. The lens body material 16 is recessed in line with the row 11 of the lenses 12a-12d, forming studlike protuberances 18, 19. Each of the protuberances 18, 19 has a highest point 20, 21 located in the same plane E with the optical axes 14a-14d of the lenses. Heights H or h of the protuberances relative to a back side 24 of the lens body 10 or to the lenses 12a-12d, are dimensioned in such a way that a spacing of the highest points 20, 21 from the highest points of the lenses 12a-12d corresponds to a desired spacing b between the optically active zones 4a-4d and the lenses 12a-12d. The lens body 10 has a lower surface 26 that is fixed to the base plate 1 as well. The optical axes 14a-14d of the lenses 12a-12d have a height a relative to the base plate 2 which is dimensioned in such a way that the optical axes 14a-14d are aligned with the optically active zones 4a, as is seen in FIG. 2.
Since the protuberances 18, 19 each directly strike a side surface 32 of the optoelectronic component 2 with their highest points 20, 21, a comparatively little-tolerance-affected adjustment of the spacing b between the zone 4a and the lens 12a is assured. The contact between the protuberances and the component takes place at the edge 3 of the component 2, so that a lower foot region 35 of the component 2 may have adhesive and/or solder residues without impairing the spacing adjustment.
The assembly of the unit is carried out by first mounting the component 2 on the base plate 1. After electrical contacting of the contact spots 5a-5d, the lens carrier 10 is put in place in such a way that the highest points 20, 21 of the protuberances 18, 19 rest on the component 2, and the lens carrier 10 rests with its lower surface 26 smoothly on the surface of the base plate. Thus the height a of the lens, the axial spacing b, and all of the angular positions are defined. The only still-existing degree of freedom is in the direction of an arrow A and can be defined passively, that is without operating the optoelectronic component. To that end, this purpose is especially advantageously served by the strip of the optically active zone 4e, relative to which the highest point 21 of the protuberance 19 can be aligned comparatively easily. The fixation of the lens carrier can be carried out by adhesive bonding or soldering. In the case of soldering, the soldering surfaces may be coated with a solderable metal that can be applied in structured fashion by planar methods.
FIGS. 3 and 4 show a further exemplary embodiment of an optoelectronic unit with an optoelectronic component 40 having contact spots 41 for individual electrical contacting of light-sensitive optically active zones 42a-42p, which are constructed as a two-dimensional (X-Y) 4*4 matrix of a surface-active photodiode array. A lens body 44 which is provided parallel to the X-Y plane of the optically active zones 42a-42p has a corresponding two-dimensional configuration of lenses 45a-45p in a 4*4 matrix (lens array). In every corner of the lens body 44, a studlike protuberance 46a-46d is provided as a spacing device. Each protuberance has a defined bearing region 48a-48d on a surface 49 of the component 40. The protuberances 46a-46d may preferably be constructed to be lenticular in shape, resulting in essentially point-type contacts with the bearing regions 48a-48d. As already explained in detail in conjunction with the first exemplary embodiment, the height or the respective highest points (highest points 50a and 50b of the protuberances 46a and 46b can be seen in FIG. 4) are dimensioned in accordance with a desired spacing B between the respective optically active zone (such as 42f) and the lens associated therewith (such as 45f). The bearing regions 48a-48d are each surrounded by annular markings 52a-52d. The markings rise above the surface 49 of the component 40 and serve both as a positional marking for the positioning of the studlike protuberances 48a-48d during assembly and for automatic positional fixation. To that end, the height of the markings is chosen in such a way that the protuberances lock in place in them. The lens carrier can be fixed in that position, for instance by adhesive bonding. An alternative fixation method is metallizing of the protuberances, through the use of which the lens body 44 can be soldered to the component 40. Given exact positioning of the markings, in this embodiment of the invention, adjustment can be dispensed with entirely.
The lens carrier can be formed of glass or silicon. In addition to planar structuring methods combined with etching techniques, lens carriers can also be manufactured in one piece of glass, in the form of pressed-glass parts. | An optoelectronic unit includes a base plate, an optoelectronic component carried by the base plate and having at least one optically active zone, and a lens body having at least one lens associated with the at least one optically active zone. The lens body has an integral spacing device resting directly against the optoelectronic component for establishing a desired clearance distance between the at least one optically active zone and the at least one lens. | 6 |
This is a continuation in part of application Ser. No. 540,071 filed Oct. 7, 1983, now U.S. Pat. No. 4,475,970.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to means for aligning an applicator wheel on a tape splicer of the type which splices a pre-determined length of recording tape into a cassette. In splicers of this general type the process is started with a cassette which contains two rotatably mounted hubs connected together by a relatively short length of leader tape. To load the cassette with recording tape, the leader is cut intermediate the two hubs and the forward end of a length of recording tape is spliced onto the leader. The tape is very rapidly wound into the cassette and when the end of the tape is reached the other end of leader is moved into abutting relationship with the trailing end of the recording tape and spliced. In each case, the splice is made by first abutting the recording tape and the leader and overlaying a short length of adhesive which connects the two lengths of tape together. In the embodiment disclosed in this application, the splicing tape is applied in short lengths by means of a rotatably mounted applicator wheel which reciprocates down into and up out of tape splicing contact with the abutted ends of the leader and recording tape.
The applicator wheel described in this application is made of a hard plastic material and is provided with notches in each corner. After each reciprocation, a blade is moved laterally into the notch, cutting the tape before the next downward movement of the applicator wheel occurs.
The applicator wheel is controlled during its downward movement by a ratchet and pawl. However, the upward movement of the applicator wheel out of contact with the tapes is not controlled by the ratchet. Due to the very rapid downward and upward movement of the applicator wheel, and the sudden halt to the upward movement of the applicator wheel, the wheel can become misaligned. If the wheel is jarred out of alignment, the blade will not cut the tape by passing through the notch in the corner of the applicator wheel but will instead cut into the applicator wheel itself, damaging or destroying the wheel and bending or breaking the blade. Furthermore, since the tape is not properly cut, the next splice is not made, resulting in an improperly wound cassette which must be rejected as defective.
SUMMARY OF THE INVENTION
Therefore it is an object of the invention to provide aligning means for cooperating with an applicator wheel to place the applicator wheel in proper alignment for the tape on the applicator wheel surface being cut and the next application of tape.
It is another object of the present invention to provide an integrally formed ratchet and body, the ratchet being used to positively rotate the applicator wheel into tape applying position and the body aligning the applicator wheel into proper tape cutting and applying position after each application of tape.
It is another object of this invention to provide a method of feeding and applying splicing tape to two adjacent ends, which method includes aligning the applicator wheel during each reciprocation thereof into exact alignment with a splice bed.
These and other objects and advantages of the invention are achieved by providing an apparatus for feeding and applying splicing tape to two adjacent tape ends positioned on a planar splice bed. The apparatus comprises a splicing tape applicator wheel mounted for rotation about a central axis and having a plurality of planar peripheral faces. Each face of the applicator wheel defines a splicing tape carrying surface. A source of splicing tape is provided and reciprocating means move successive tape carrying surfaces of the applicator wheel perpendicularly into and out of contact with two tape ends to be spliced. Motion converting means cooperate with the reciprocating means and the applicator wheel to convert perpendicular movement of the applicator wheel into unison rotation of the applicator wheel, thereby moving a next successive tape carrying surface into position for application of the splicing tape. Aligning means according to the present invention cooperate with the applicator wheel and the motion converting means for aligning successive planar surfaces of said applicator wheel into proper alignment with the planar splice bed after each application of splicing tape and before the next application. The alignment means also ensures that the blade cutter which cuts the tape on the applicator wheel into proper length segments passes through a notch in the corner of the applicator wheel, rather than impacting the applicator wheel itself. According to the embodiment of the invention described in this application, the alignment means includes stop means cooperating with the motion converting means to stop the unison perpendicular and rotational movement of the applicator wheel. The alignment means also comprises a stop means engagement member mounted for unison perpendicular rotational movement with the applicator wheel and positioned to engage the stop means at the termination of each upward reciprocation of the applicator wheel to reposition successive planar sides of the applicator wheel in preparation for the next downward movement thereof into tape-applying position.
According to a preferred embodiment of the invention the stop means engagement member comprises a body having a plurality of outwardly projecting shoulders, at least some of the shoulders adapted to engage the stop means and thereby align the applicator wheel. Preferably, the body is integrally formed with a ratchet which is mounted for unison perpendicular and rotational movement with the applicator wheel and which is rotated during the downward movement of the applicator wheel by a pawl.
According to the method of the invention, a splicing tape applicator wheel is provided having a plurality of planar peripheral faces. The applicator wheel is mounted for rotation about a central axis and is provided a source of splicing tape for being applied to successive tape carrying surfaces on the applicator wheel. The applicator wheel is reciprocated perpendicularly into and out of contact with the two tape ends to be spliced on a planar splice bed for applying a length of splicing tape from said tape carrying surface. The perpendicular movement of the applicator wheel is converted into unison rotation of the applicator wheel, thereby moving a next succesive tape carrying surface into tape applying position. During each reciprocation of the applicator wheel, the applicator wheel is aligned into exact alignment with the splice bed.
DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be explained in the following Description of the Preferred Embodiment when taken in conjunction with the following drawings, in which:
FIG. 1 is a perspective view of a tape winder on which the aligning means according to the present invention is used;
FIG. 2 is a perspective view of a tape splicer according to the present invention;
FIG. 3 is an enlarged view of the tape applicator wheel according to the present invention;
FIG. 4 is a view opposite that in FIG. 2 of the tape splicer according to the present invention;
FIG. 5 is an enlarged perspective view of the integrally formed ratchet and body according to the present invention;
FIG. 6 is a cross sectional view of the ratchet and body taken substantially alongs lines 6--6 of FIG. 5;
FIG. 7 shows the applicator wheel at the upper extent of its movement ready to begin its downward stroke towards the splice bed;
FIG. 8 shows the applicator wheel being rotated downwardly into contact with the splicing bed; and. FIG. 9 shows the applicator wheel in its downward movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, an audio tape cassette winder is shown and generally designated at broad reference numeral 10. Winder 10 comprises a console 11 within which are mounted the major electrical, pneumatic and mechanical operating parts. Console 11 has a front cover 12 which supports a rotatably driven audio tape supply reel 14 onto which is would a supply of magnetic tape 16; a tape leader extractor assembly 17; a cassette supply tray 19 which holds a plurality of cassettes "C"; cassette winding spindle 21; a defective cassette rejector assembly 22; and a stacking trough 24 for finished cassettes. A pair of vacuum take-up columns 25 and 26 selectively exert a vacuum force on tape 16 to positively control tape tension as it is unwound from the supply reel 14 and wound onto cassette "C" by cassette winding spindle 21. A control panel 28 enables the operator to manipulate various functions of winder 10. A tape splicing apparatus 30 is mounted on front panel 12 and dispenses adhesive splicing tape "T" from a supply spool 31.
Supply reel 14 may be wound with unrecorded audio tape which is then used to produce "blank" cassettes to be used for later recording. Alternatively, supply reel 14 may be wound with tape containing a series of identical recordings ("albums") of music, speach or other audio signals. A low frequency "Q" signal is recorded onto the audio tape between each album and indicates the end of one album and the beginning of the next. Therefore, in loading cassettes with pre-recorded tape, a "Q" signal sensor is provided which stops the movement of the tape and permits the tape to be severed between the albums. The various electrical, pneumatic and mechanical components used to drive the supply reel sense the presence of each "Q" signal, extract the leader from each cassette and prepare the leader for splicing; wind each cassette with a pre-determined amount of audio tape and eject the cassette to make room for the next one, are all part of the prior art and are not the invention per se of this application.
Patents examplary of the prior art referred to above included U.S. Pat. Nos. 3,717,314 and 3,753,834.
The splicer 30 is operable for splicing a wide variety of tapes, sheets, films and the like. Referring now to FIG. 2, splicer 30 is mounted in a stationary position on front panel 12 of winder 10 by means of a base, referred to as a splicer support block 50. A splice block 51 is mounted on splicer support block 50 for reciprocating up and down motion along two vertically extending splice block guide rails 52, carried by the upper end of splicer support block 50.
Reciprocating up and down motion of splice block 51 is effected by a two-way pneumatic splice cylinder 54 which is mounted to the splicer support block 50. A splice piston rod 58 is slidably positioned in splice cylinder 54 and connected to a piston (not shown) for movement in response to air pressure within splice cylinder 54. Splice cylinder 54 is a two-way cylinder and is provided with a down piston supply tube 60 and an up piston supply tube 61. Splice piston rod 58 is secured by the end remote from splice cylinder 54 to a piston rod mount 65 and is removable by loosening two screws 64a.
By introducing compressed air through down piston supply tube 60 into splice cylinder 54, piston rod 58 is extended outwardly from within cylinder 54, causing splice block 51 to move downwardly along guide rails 52. Introducing compressed air from up piston supply tube 61 into splice cylinder 54 causes piston rod 58 to be retracted within splice cylinder 54, and the attached splice block 51 to be moved upwardly.
Splice block 51 is assisted in its return to the upper position by splice block return assist spring 67, the upper end of which is attached to the stationary splicer support block 50 and the lower end of which is attached to splice block 51. Spring 67 also reduces the force of the downward movement of splice block 51 under the combined influence of gravity and splice cylinder 54.
A spool 31 of splicing tape "T" is carried by a splicing tape spool mount 68 connected to and moving in unison with splice block 51.
A guide bearing mount 80 is also positioned on the movable splice block 51 and carries a guide bearing 81. Adhesive splicing tape from splicing tape spool 31 is properly positioned for application by guide bearing 81 around which the splicing tape passes.
Referring now to FIG. 3, an applicator wheel 85 is integrally formed with a cylindrical mounting sleeve 86 and a concentrically formed, square ratchet mount bushing 87 having a screw receiving bore 88 therein. Applicator wheel 85 is mounted to splice block 50.
Referring to FIG. 4, a ratchet 90 having a square bore 90A is mounted on ratchet mount bushing 87. Since ratchet mount bushing 87 is square, the ratchet 90 and applicator wheel 85 always rotate in unison. Ratchet 90 is rotated by a pawl 100 pivotally mounted on splicer support block 50. Pawl 100 is biased by a spring 101 to return to its starting position after each reciprocation.
Referring now to FIG. 3, applicator wheel 85 -a polygon in this case- is substantially square. Each corner is truncated to provide a flat corner surface 103 into which is formed a cutter blade access slot 104. In the description that follows, the four sides of applicator wheel 85 will be arbitrarily referred to as 85a, 85b, 85c and 85d, respectively. Each of the four sides 85a-d comprise planar tape carrying surfaces. On each tape carrying surface 85a-d is formed a pair of ports 106a, 106b, 106c and 106d, respectively. Ports 106a-d are formed in the body of applicator wheel 85 so that they each define a radius.
Referring now to FIG. 4, tape "T" is applied to applicator wheel 85 in a continuous length. Therefore, the tape must be cut into appropriate length sections. This is accomplished by means of a reciprocating cutter blade assembly. Reciprocating movement is provided by a tape cutter cylinder 120 which is supplied with pressurized air by a cutting cylinder air supply tube 122. Referring to FIG. 6, tape cutter cylinder 120 moves a tape cutter piston rod through a slot 124 formed in splice block 51. A blade carrier 125 carries a cutter blade 127. As is best shown in FIG. 4, cutter blade 127 slides into one of the blade access slots 104 aligned therewith, cutting splicing tape "T" into a segment approximately the same length as each of the tape carrying surfaces 85a-d of applicator wheel 85. In the particular embodiment shown in FIG. 4, the tape cutter cylinder 120 is a one-way cylinder with the tape cutter piston rod being returned to its normal retracted position by a spring (not shown).
The two tape ends to be spliced are held in position by means of a splicing bed 130, the precise construction of which may vary considerably from one type of winder to another. The two tapes to be spliced may be two lengths of audio or video recording tape, a length of leader to either audio or video recording tape, or any other of a wide variety of combinations of leader to tape, film or other substances. For purposes of illustration a length of leader tape "L" is shown positioned on splicing bed 130 in abutting relation to a length of audio recording tape "A". As is shown in FIG. 10, the tapes "L" and "A" very nearly abut at a point directly beneath applicator wheel 85 in splicing tape "T" receiving position.
Referring now to FIG. 4, aligning means according to the present invention are shown in position on the splicer 30. Alignment means includes a stop means which comprises a stationary wall 91 carried by the stationary splicer support block 50. The stationary wall 91 defines a downwardly facing free surface 92. The alignment means also includes a stop means engagement member, which comprises a body in the form of a star wheel 95. Star wheel 95 is shown in FIG. 5 and is integrally formed with ratchet 90 and includes a central bore 96 which communicates with bore 90a of ratchet 90 and four outwardly extending shoulders in the form of fingers 96a through 96d. As will be observed in FIG. 5, each of the fingers 96a-d are eccentric to the axis of star wheel 95. Adjacent fingers, for example 96a and 96b are perpendicular to each other. Opposite fingers, for example, 96a and 96c, are parallel to each other.
Star wheel 95 and ratchet 90 are mounted on splice block 51 by means of a shaft 97 which extends through bores 96 and 90a. Shaft 97 mates with the ratchet mount bushing 87. Star wheel 95 and ratchet 90 therefore rotate in unison with applicator wheel 85.
Referring now to FIG. 7, the downwardly facing free surface defines two separate parallel planes 92a and 92b. The lateral distance between the two planes 92a and 92b is designed to mate exactly with any two opposite fingers of star wheel 95, for example 96b and 96d as is shown in FIG. 7. Since star wheel 95, ratchet 90 and applicator wheel 85 rotate in unison, the position of applicator wheel 85 can be very precisely set.
The position shown in FIG. 7 constitutes both the starting and ending point for each reciprocation of splicer 30. In operation, a pulse of compressed air through down piston supply tube 60 propels splice block 51 downwardly. One of the teeth of ratchet 90 catches on pawl 100. Pawl 100 rotates ratchet 90 as splice block 51 continues downwardly. As is shown in FIG. 8, ratchet 90, star wheel 95 and applicator wheel 85 all begin to rotate in unison. At its lowermost position splice block 51 has descended towards the splicing bed 130 and applicator wheel 85, having a layer of tape "T" thereon, impacts splice bed 130 and applies the tape "T" to the abutting ends of tapes "A" and "L". At this point, the surface of applicator wheel 85 should be parallel and flush with splice block 130.
Because of the speed at which winder 10 operates, the splicing process must take place very quickly. Therefore, a pulse of compressed air through up piston supply tube 61 rapidly moves splice block 51 back to its upper position. This upward movement is aided by spring 67.
During its upward movement, neither the applicator wheel 85, ratchet 90 or star wheel 95 is under any type of positive control. Therefore, the rapid movement upwardly may cause applicator wheel 85 to rotate slightly out of alignment. As the ratchet 90 moves upwardly, pawl 100 rides over one of its curved teeth and may increase the possibility of moving applicator wheel 85 out of alignment. If applicator wheel 85 is out of alignment when it reaches its uppermost position, the impact of fingers 96b and 96d on walls 92b and 92a restore proper alignment so that when blade 127 moves forward it passes cleanly through one of the slots 104, cutting tape "T" rather than impacting the applicator wheel 85 itself. This process also reorients the surfaces of applicator wheel 85 in their proper parallel and perpendicular relation to splicing bed 130.
An apparatus and method for aligning the applicator wheel of a splicing apparatus is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of a preferred embodiment of the apparatus and method according to the present invention is provided for the purpose of illustration only and not for the purpose of limitation--the invention being defined by the claims. | An integrally formed ratchet (90) and star wheel (95) is disclosed which rotates in unison with a tape applicator wheel (85). Eccentrically formed fingers (96a-d) cooperate with a downwardly facing wall to align and position applicator wheel (85) into correct position after each reciprocation of the splicer (30). Correct alignment is essential because a cutter blade 127 cuts the tape on the applicator wheel into pre-determined lengths by passing through a notch (104) in applicator wheel (85). Misalignment of the applicator wheel (85) may cause blade (127) to impact the applicator wheel (85) itself, damaging or destroying it. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved process for improving the yields of fibrous materials, such as wood pulp, and of increasing the viscosity of the delignified pulp, during an oxygen-alkali delignification or bleaching treatment. In the process, conducted at relatively low consistency, there are present small amounts of ammonia or a compound which will release ammonia under the alkaline conditions of the oxygen-alkali delignification.
Current interest in the paper industry has emphasized the desirability of delignifying wood pulp and other cellulosic fibrous materials using oxygen-alkali treatments. Such processes are desirable because they avoid the use of the traditional chlorination bleaching which uses a more expensive chemical and introduces complications due to the need to remove chlorine-containing by-products from the effluent streams. This requires expensive chemical recovery systems so as to abate stream and environmental pollution problems. A number of oxygen-alkali delignification processes have been presented, such as those of Richter U.S. Pat. No 1,860,432; Graangard et al. U.S. Pat. Nos. 2,926,114 and 3,024,158; Gaschke et al. U.S. Pat. No. 3,274,049; Meylan et al. U.S. Pat. No. 3,384,533; Watanabe U.S. Pat. No. 3,251,730; Rerolle et al. U.S. Pat. No. 3,423,282; Farley U.S. Pat. No. 3,661,699; and French patents 1,130,248 and 1,387,853. A more recent process which has been found to be particularly advantageous is that of Roymoulik et al. U.S. Pat. No. 3,832,276.
The Roymoulik et al. patent process is a highly satisfactory process. However, the paper industry continues to strive to improve pulp yields and to improve the quality of the pulp. It is known, for example, that oxygen-alkali delignification or bleaching methods tend to reduce the pulp viscosity. To counteract this problem, and to strive for optimum yields, various additives have been suggested in the oxygen-alkali treatments, such as magnesium salts, chelating agents and sequestering agents, have been employed in the systems in order to reduce the cellulose degradation which causes the unwanted reduction in pulp viscosities.
Yield loss during delignification or bleaching is not unique to oxygen-alkali delignification processes. It is encountered in many pulp treatments of cellulosic materials. With the increasing costs of the source of cellulosic materials, such as tree logs, the reduction of yield losses becomes of increasing importance to the paper industry. The search for means of reducing yield losses and viscosity losses has been going on for many years, even going back prior to the advent of oxygen-alkali delignification treatments.
One such suggested means of preventing viscosity reduction due to cellulose depolymerization or degradation is Heald U.S. Pat. No. 3,368,935. That patent is directed to a sulfite pulping process where urea is employed in the cooking liquor to control pH and prevent depolymerization of the cellulose. Sulfite cooking liquors are, however, an entirely different system from an oxygen-alkali bleaching system. The reaction mechanisms in the two processes are entirely different.
Baudisch U.S. Pat. NO. 2,271,218 describes a method of producing textile fibers by treating corn straw in a solution of alkali and urea. The process is a two-stage pulping process in which corn straw is treated with alkali and urea in the first stage and defiberized mechanically in the second stage. Such a treatment is quite different from an oxygen-alkali delignification treatment.
Liebergott et al. U.S. Pat. No. 3,740,311 describes a process for the delignification of wood pulp in which the pulp is treated at a relatively high consistency with ammonia and oxygen. In the process, ammonia is the sole source of alkalinity. Gaschke et al. U.S. Pat. No. 3,274,049 is similar to the Liebergott patent and differs in that it is directed to the treatment of bagasse, but it also employs ammonia as the sole source of alkalinity.
A publication by Lyman C. Aldrich, "Cellulose Degradation Inhibitors for the Chlorination Stage," TAPPI, Vol. 51, No. 3, pp. 71A-74A (March 1968) describes the use of urea and ammonium hydroxide (actually ammonium chloride, which is formed by the instantaneous reaction with ammonium hydroxide on the chlorine-containing acidic treatment liquor) during chlorine bleaching to inhibit cellulose degradation. While the addition of urea and ammonium hydroxide improves pulp viscosity to some extent, it also produces pulps having higher permanganate numbers, reflecting a higher lignin content than the controls. Thus, in the chlorination bleaching treatment of the Aldrich publication, the addition of urea and ammonium hydroxide at levels of additive above 0.25% actually reduced the amount of delignification. This is a serious disadvantage in a process whose sole purpose is to remove lignin from the pulp and so that if any subsequent chemical treatment is involved, such as the use of chlorine dioxide in a subsequent treatment of the pulp, that treatment can be minimized. In the acidic chlorination conditions employed by Aldrich, the nitrogenous compounds react with the chlorine in the bleaching solutions to form chloro derivatives of the nitrogen compound, thus wasting bleaching chemical. Thus, the addition of urea or ammonia serves no useful purpose insofar as delignification is involved.
A paper by Tobar, "Sulfamic Acid in the Chlorination and Hypochlorite Bleaching of Pulp," TAPPI, Vol. 47, No. 11, pp. 688-691, and Tobar U.S. Pat. No. 3,308,012, describe the use of urea and ammonium chloride as cellulose stabilizers during alkaline hypochlorite bleaching. On page 691 of the publication, Tobar states that in a hypochlorite bleaching system, the addition of urea or ammonium chloride produced both a loss in brightness and a loss in pulp viscosity, thereby showing that these agents in such a system actually produce undesirable results.
Gudivaka et al., "Inhibitors in Pulp Bleaching", Indian Pulp and Paper, pp. 447-452, (January 1971) describe the use of urea, ammonia and sulfamic acid in the bleaching of pulp by chlorine or hypochlorite. Such a system is, of course, quite different chemically from oxygen-alkali bleaching system. The results obtained by the authors were inconclusive.
Viscosity represents a measurement of the average degree of polymerization of the cellulose in the pulp sample, i.e., the average chain length of the cellulose. Thus, decreases in viscosity values represent the extent of depolymerization or degradation caused by the bleaching process. Excessive degradation is to be avoided since it provides undesirable physical properties in any paper made from the pulp.
Kappa No. is determined by the potassium permanganate consumed by a sample of pulp and represents a measurement of its retained lignin content. The higher the Kappa No., the less bleached and delignified is the pulp. By comparing Kappa Nos. of samples before and after bleaching treatment, one can obtain an evaluation of the extent of delignification which has taken place.
It is, therefore, an object of the present invention to provide an improved process for the delignification or bleaching of pulp by the oxygen-alkali process.
It is another object of the present invention to provide a method of delignifying wood pulp which will reduce yield losses and provide a pulp of inmproved viscosity.
Further objects will be apparent to those skilled in the art from the present description, taken in conjunction with the appended drawing, which is a graph comparing the shrinkage or yield loss in the oxygen-alkali treatment of wood pulp with various concentrations of ammonia in the pulp.
GENERAL DESCRIPTION OF THE INVENTION
We have now discovered that unexpectedly improved pulp yields and higher pulp viscosities can be obtained in the oxygen-alkali delignification of pulp by introducing into the alkaline pulp at least about 0.1% by weight (based on oven-dried pulp) of ammonia or a compound which will release ammonia under the alkaline conditions of the process. In the alkaline conditions contemplated, the alkali solution, containing pulp, shall have a pH of between about 9 and 13. In the case of ammonia, amounts of up to about 3% by weight of oven-dried pulp have been found to provide excellent results and amounts above that provide no advantage and result in loss in economy. Preferred amounts of ammonia are between about 0.4% and 1% by weight with the optimum amount being about 0.6%. In the case of urea, and compounds releasing ammonia, amounts up to about 6% by weight provide satisfactory results and amounts in excess of this provide no economical advantage. When urea is employed as the compound resulting in ammonia, the preferred amount is from about 1% to 4% by weight of oven-dried pulp.
In the process, temperatures of between about 200° and 260° F. are desirable with the preferred temperature range being between about 210° and 220° F. The pressure of elemental oxygen in the system is desirably between about 30 and 300 psig. with the preferred partial pressure range being between about 120 and 130 psig. The amount of oxygen employed is desirably between about 1 and 10% based on oven-dried pulp. Air can be used as the source of oxygen, but this requires longer reaction times and the use of higher pressures.
The amount of alkali, such as sodium and potassium hydroxides, or carbonates, or mixtures thereof, employed is sufficient to provide a pH range of between about 9 and 13, preferred between about 11.5 and 12.5. The amounts of sodium or potassium hydroxides generally employed are between about 0.5 and 8 grams per liter, preferably about 2 to 4 grams per liter.
As presently contemplated, the process can be conducted in a time interval of from about 1 to 120 minutes, but usually 20 to 40 minutes is the most satisfactory time period.
The consistency of the pulp is lower than that employed in most prior art bleaching or delignification processes and the desirable range is between about 1% and 10% based on oven-dried pulp, with the preferable range being between about 3% and 5%.
In addition to ammonia, per se, ammonium salts such as the chloride, carbonate sulfite, nitrate or sulfate may be employed. Also, ammonia-releasing compounds may be employed, such as urea, sodium cyanate, hydrazine and substituted hydrazines such as alkyl substituted hydrazines, cyanuric acid, primary amides such as methyl and propyl amide, hydroxylamine, sodium or magnesium nitrides, sulfamic acid, etc.
The oxygen-alkali delignification treatment may desirably be conducted in accordance with the process and apparatus disclosed in Roymoulik et al. U.S. Pat. No. 3,832,276. However, it is not necessary to employ these conditions. The alkaline pulp, containing the source of ammonia, is desirably mixed with oxygen in a high-shear mixing device so as to bring the oxygen into intimate contact with the alkaline pulp. High-shear, high-speed mixing devices, such as the Lightnin' type mixer, are highly suitable for this purpose. Desirably, the alkaline aqueous pulp is briefly subjected to a high-pressure oxygen pre-treatment and thereafter the pressure is gradually reduced during the delignification process.
The wood chips or pulp may first be impregnated with a source of ammonia before being exposed to the alkaline solution and oxygen.
As shown in the accompanying drawing, shrinkage or reduction in yield varies with the concentration of ammonia in the process. As shown, the yield loss is minimized at a concentration of approximately 0.6% ammonia. The data for the graph were obtained by employing the procedure of Example 1 hereinbelow.
DETAILED DESCRIPTION OF THE INVENTION
In order to disclose more clearly the nature of the present invention, the following examples illustrating the invention are given. It should be understood, however, that this is done solely by way of example and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims. In the examples which follow, and throughout the specification, the quantities of material are expressed in terms of parts by weight, unless otherwise specified.
EXAMPLE 1
Kraft hardwood pulp was subjected to oxygen-alkali bleaching, using various concentrations of urea. In the runs, the pulp consistency was approximately 2% by weight of oven-dried pulp. The alkaline delignification solution contained 4 grams per liter of sodium hydroxide. The delignification was carried out at a temperature of 205° F. in a pressure reactor having intimately mixed with the alkaline pulp, oxygen at an initial pressure of 100 psig. That pressure was maintained for approximately 10 minutes followed by venting to 36 psig. pressure, followed by gradual reduction to zero psig. over a period of 42 minutes. The experiments were repeated at each concentration of urea for between 4 and 7 repetitions. The results are set forth in Table 1 below.
Table 1______________________________________ Average Values Kappa Viscosity Yield % No. ofExperiment No. cp, at 0.5% on OD Pulp Runs______________________________________Starting Pulp 19.1 33.0 -- --Control 11.0 23.0 95.3 60.5% Urea 11.2 24.9 96.7 51.0% Urea 10.8 25.9 96.2 42.0% Urea 11.3 26.2 96.8 74.0% Urea 11.6 26.5 96.6 4______________________________________
EXAMPLE 2
The experiment of Example 1 was repeated employing various concentrations of ammonia, based on weight of oven-dried pulp, in place of the urea. Six runs were conducted for each concentration of ammonia. The results are shown below in Table 2.
Table 2______________________________________ Average Values Kappa Viscosity Yield % BrightnessExperiment No. cp, at 0.5% on OD Pulp %, Elrepho______________________________________Starting Pulp 19.1 33.0 -- 26.3Control 11.0 23.0 95.3 45.20.3% Ammonia 10.5 26.3 96.7 46.80.6% Ammonia 11.0 25.7 97.0 46.41.0% Ammonia 10.5 26.3 96.7 46.1______________________________________
EXAMPLE 3
A pilot plant run was conducted employing 0.6% ammonia in an oxygen-alkali system treating hardwood dissolving pulp of a consistency of 3% based on weight of oven-dried pulp. The pilot plant run was conducted in two parts. In one part referred to as "Conventional", the pulp, having a consistency of 3% based on oven-dried pulp, containing 1.8 grams per liter of sodium hydroxide, was mixed intimately with elemental oxygen to provide an initial pressure of 100 psig. and the pulp was maintained at a temperature of 205° F. for 10 minutes. Thereafter, the system was vented to 36 psig. pressure, the pressure was then gradually reduced to zero psig. over a period of 42 minutes. In the second portion of the pilot plant run conducted under what is referred to as "Split Flow" whereby the initial pulp consistency was 4.7% based on oven-dried pulp, containing 1.2 grams per liter of sodium hydroxide and the pulp treated at 230° F. at an initial oxygen pressure of 100 psig. After 16 minutes the temperature was reduced to 205° F., the consistency reduced to 3% by the addition of water, and the pressure reduced to 36 psig. and over 42 minutes the pressure was gradually reduced to zero psig. These pilot plant runs were conducted continuously for periods of 8 to 12 hours at the rate of 1 to 1.5 tons per day production of delignified pulp. The results are shown below in Table 3.
Table 3______________________________________Pilot Plant Trials UsingAmmonia-Kraft Dissolving Pulp Average Flow Permanganate Permanganate Viscosity ViscosityTreatment No. Start No. Final Start Final______________________________________Split FlowControl 5.4 2.9 32.8 12.70.6%Ammonia 5.5 3.3 33.8 21.7ConventionalControl 6.6 4.1 33.4 13.10.6%Ammonia 6.5 4.7 40.4 26.4______________________________________
As will be apparent to those skilled in the art from the present description, in the foregoing examples the ammonia and the urea may be replaced by appropriate amounts of other compounds releasing ammonia, such as ammonium chloride, carbonate, sulfite, nitrate or sulfate, sodium cyanate, hydrazine, cyanuric acid, methylamide, hydroxylamine, sulfamic acid, and sodium or magnesium nitrides, etc.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. | An process for increasing the yields of wood pulp and improving the viscosity of the pulp during oxygen-alkali delignification is provided whereby, in a wood pulp at a consistency of about 1-10%, there are present, in the pulp to be delignified, small amounts of ammonia or a compound which releases ammonia under the alkaline conditions of the process. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a new and improved concrete road barrier having a low profile to achieve unprecedented visibility for drivers and outer sidewalls facing toward the road which angle outwardly from the barrier base so as to reduce the ramp and roll tendencies of vehicles impacting on the barrier.
2. Description of the Prior Art
Along most highways, there are hazards that present substantial danger to drivers of automobiles if they should happen to leave the highway. To help prevent such accidents, road barriers are often provided along the sides and in the median of a highway to channel the traffic onto appropriate lanes. These barriers are commonly made of concrete, and they slope gradually inwardly from the bottom to the top.
The use of road barriers has several important purposes. First, as noted above, the barriers are intended to channel vehicles hitting the barriers back into the adjacent traffic lanes. Second, the barriers are intended to help prevent vehicles from traveling entirely off the road or into the lanes of opposing traffic. Third, the barriers are intended to be stable and relatively immovable. It is also desirable that the barriers be easily assembled, and that they be weather resistant.
It is recognized that the physical size of many barriers is controlled to a great extent by norms of highway construction. Thus, most modern traffic lanes are designed to be about 12 feet wide. These dimensions, in turn, have caused portable concrete barriers to have a maximum width of about two feet; and they are generally composed of segments about 10 to 30 feet long. The barrier segments are commonly connected end-to-end by lengths of channel iron or angle iron fastened along the sides close to the lower surface of the barriers.
The mass of a barrier is important from the standpoint of resisting movement due to vehicle collisions and redirecting the colliding vehicles, when they strike the barrier. In general, barriers are most effective in handling passenger cars and vehicles of comparable size, especially when they impact the barriers at speeds of 60 mph and lower and at angles between the barrier's longitudinal axis and the vehicle's velocity vector less than about 25 degrees. Large trucks pose a much more difficult problem, since they are capable of simply smashing through barriers. In general, the mass of barriers becomes increasingly important with increasing vehicle size and speed.
The most commonly used barrier at the present time, the "CMB" (concrete median barrier) is a structural concrete barrier which is about two feet wide at its base and tapers inwardly to a height of 32 inches. The barrier at its top is typically about 6 inches wide. The inclined sidewalls of the barrier originally were purposely designed to enable a vehicle to ramp along and up the sidewalls so as to avoid metal damage to the vehicle. While the ramping ability has been considered to be a generally desirable feature, it may give rise to serious problems especially at high vehicle speeds. At these speeds, a vehicle has an increased tendency to climb a barrier and ultimately roll over.
Another problem with existing barriers lies in their height. The height of existing barriers, commonly about 32 inches, is often above or just below the eye level of persons in passenger vehicles -- i.e., about 30 to 36 inches above the road surface. Thus, barriers along a road may interfere with visibility of traffic and potential hazards or other obstacles. Blocking of vision by barriers lying between a highway and an access road or entrance ramp can be a particular problem, where the access road or ramp lies on a different plane than the highway.
A further problem with existing barriers involves the cost, attachment difficulties, and maintenance characteristic of current hardware used to join segments of concrete road barriers together.
Accordingly, a need persists for a more economic road barrier which can further reduce the risks of highway travel. Of particular interest are improved visibility and the restriction of vehicles to their proper traffic lanes with improved control and with reduced tendencies to scale barriers and to roll over.
SUMMARY OF THE INVENTION
The present invention in a broad aspect comprises an elongated, concrete road barrier for channelling or controlling the access of traffic that reduces obstruction to vision and the rolling and ramping tendencies of impacting vehicles. The road barrier lies substantially parallel to the direction of traffic movement and is comprised of one or more segments of structural reinforced concrete which (1) measures no more than 24 inches in height, and (2) have outer sidewalls facing the road which angle outwardly from the barrier base. The invention in another aspect comprises a system for interconnecting abutting ends of segments to form a contiguous concrete barrier. The system preferably comprises connectors which are insertable through apertures in the ends of a segment through recesses proximate the ends of the segment. The system also preferably comprises connectors which enable the barrier segments to be laterally articulate.
A further distinctive feature of the barrier of this invention is its large mass relative to existing barriers, even though it is shorter than existing barriers. The new concrete road barrier, for example, weighs up to about 70 percent more than the existing popular "CMB" which is two feet wide at its base and weighs between about 300 and 350 pounds per linear foot. The new barriers, when two feet wide at their base, weigh between about 500 and 600 pounds per linear foot. The additional mass renders the barriers effectively more stable when placed on the ground, thus making them particularly suited to temporary use in construction zones. In addition, the concrete barriers or barrier segments may be affixed to the ground for permanent use along a finished road. The barriers may also be cast in place.
Several advantages over known road barriers emanate from this invention's structural features. One such advantage lies in the low profile of the new road barriers, which markedly reduces obstructions to viewing traffic and other potential hazards in or around the road.
Additional advantages emanate from the outward angling from the barrier base of the sidewalls facing a road traffic lane. The upwardly outward angle of the sidewall helps to make vehicle collisions safer by reducing deflection of the barrier and consequently the rolling and ramping of impacting vehicles. Rolling is especially minimized by the new road barrier, because the barrier usually impacts the wheels of vehicles at or above the center of the wheel hub.
As stated earlier, the control of large trucks and trailers presents an especially difficult problem for road barriers. In that regard, it is contemplated that the barriers of the invention with their greater mass and unique sidewall angles will prove considerably more effective than current conventional barriers in dealing with this problem. Thus, it is expected that large trucks and tractor-trailers will be able to impact the new barriers at higher angles without smashing through or climbing the barriers.
The improved visibility and channeling of traffic provided by the new road barrier is particularly valuable along an access lane lying on a lower plane than the highway into which it feeds traffic. The new road barrier reduces view obstruction between a vehicle on such an access lane merging with highway traffic and the main lane traffic, thereby providing greater road safety.
The safety features of this road barrier are also particularly helpful for improving visibility across the lanes of busy urban intersections, where large volumes of traffic intensify the hazards posed by obstructing the view of fast-flowing vehicles and other obstacles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG 1 is a perspective partial cutaway view of a preferred embodiment of the present invention showing the connection of two reinforced concrete barrier segments using a pair of connecting bolts.
FIG. 1A is a cross-sectional view of a reinforced concrete barrier segment and connecting bolts taken along the section lines 1A--1A of FIG. 1.
FIG. 2, 2A, 2B, and 2C depict exemplary configurations of reinforcing steel bars which may be used to strengthen the concrete barriers of this invention.
FIG. 3 is an exploded perspective view of an alternative method of connecting barrier segments using channel iron and anchor bolts with threaded inserts.
FIGS. 4 and 4A show an alternative method of connecting barrier segments using at least two reinforcing steel segments imbedded in each barrier segment, a connecting pin and a plurality of bolts set in the end of at least one of the barrier segments.
FIG. 5 is an exploded, partial cutaway, perspective view of an alternative method of connecting barrier segments using an I-beam section fixedly connected to both segments using dowels or anchor bolts with threaded inserts.
FIG. 6 is a partial cutaway, perspective view of an alternative method of connecting barrier segments using a steel-T type connection.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the present invention is depicted by FIGS. 1, 1A, 2, 2A, 2B, and 2C. Barrier segments 10 are comprised of concrete reinforced by exemplary steel reinforcing bars 14 and includes two ends with apertures 12. Each end of barrier 10 is provided with two threaded bolts 16 inserted through trough 18 into aperture 12 and secured by nut 20. The opposite end of bolt 16 is similarly threaded and similarly extends through aperture 12 and into a trough 18 in an adjacent barrier. Water caught in trough 18 may drain through weep hole 22.
FIGS. 2, 2A, 2B and 2C depict exemplary configurations that reinforcing steel bars 14 in the concrete segment 10 may take. Steel reinforcement is required throughout the barrier segment including both ends, where loads on the connecting bolts cause high load concentration.
In highway construction zones, the concrete barrier segments are typically merely set on the ground. In this mode, the segments may be relocated and are often preformed to include apertures along the base of the barrier segment 24 to permit forklift tines or similar lifting apparatus to move each segment.
Also, however, the barrier segments may be affixed subterraneously by dowels, bolts or other methods in such a way that the barrier is prevented from deflecting significantly. If the barrier segments are anchored to the underlying surface to form a permanent barrier, the troughs 18 may be filled with mortar or other suitable material, thereby helping to protect the bolts 16 or other suitable connectors.
Alternatively, a barrier may be constructed by casting larger sections in place along the designated roadway. Casting may be accomplished using slip forms or conventional wooden forms. As with the preformed segments described above, these larger segments may either be affixed subterraneously by dowels, bolts, and so on, or merely rest on the surface. Additionally, through tie-ins of reinforcing steel, or use of a preformed groove or keyway the cast-in-place sections may be made permanently attached to the surface.
As shown especially in FIG. 1A, the barrier sidewalls are angled outwardly from the barrier base. Such an angle r acts to direct the primary thrust of a barrier on a colliding vehicle wheel preferably at or above the center of the wheel hub. In this regard, the wheel diameters of vehicles currently range from about 22 inches for compact automobiles to about 42 inches for large trucks. Thus, a 22-inch tall barrier of the invention will normally be capable of engaging almost all vehicle wheels above the center of the wheels. It is contemplated, however, that those barriers may function at heights as low as twelve inches, even though this height is below the hub center of some autos and large trucks. The visibility advantages provided by the low profile barrier may
be recognized with barriers of heights up to 24 inches.
FIGS. 3 through 6 depict alternate arrangements for the connection of barrier segments to achieve the road barrier of the present invention. Referring to FIG. 3, the road barrier of this invention comprises an end-to-end assembly of concrete barrier segments. The segments are connected by means of a section of channel iron 26 which is fixedly attached at either end by means of anchor bolts 28 which are inserted through holes in the channel iron into threaded bolt inserts 30 in each barrier segment 10.
FIGS. 4 and 4A show an alternative method of connecting barrier segments using at least two reinforcing steel segments 32 imbedded in each barrier segment 10, a connecting pin 34 and a plurality of bolts 36 set in the end of at least one of the barrier segments. FIG. 4 is an exploded perspective view of the arrangement showing each of said reinforcing steel segments 32 having been bent to form a protruding eye. FIG. 4A shows the completed connection with the connecting pin placed through each protruding eye. The connection has been stiffened using bolts 36, preset into the end of at least one barrier segment 10, and backed out against the adjacent barrier segment.
FIG. 5 depicts an alternative method for connecting barrier segments to achieve the road barrier of this invention using an I-beam section 38 fixedly connected to both barrier segments 10 using dowels or anchors 40 which are inserted through holes in the I-beam section 38 and into each barrier segment 10.
FIG. 6 shows an alternative method for connecting barrier segments to achieve the road barrier of this invention in which the inner walls and ends of the segments 10 may be joined by a steel T connector 42 as by means of dowels 44 located on each end of the horizontal portion of the steel T connector 42.
The structural concrete used in the invention may typically have conventional compressive strengths of about 2,000 to 6,000 psi and more typically between about 3,000 and 5,000 psi after 28 days of curing. The concrete segments may also be advantageously formed of concrete, pre-stressed with steel cables in accordance with a conventional methods.
The outward angling of at least one sidewall of the segment has an added benefit in simplifying the process for making concrete barriers, which are generally pre-formed. Conventional barriers having upwardly inward sloping walls require their forms to be overturned; whereas the concrete barriers of this invention may simply be lifted out of their forms.
As noted earlier, the height of the new concrete road barrier may be up to and including about 24 inches. A barrier height of between about 16 and about 20 inches is particularly preferred.
Lengths suitable for concrete road barriers of the invention are widely variable, but the length of each barrier segment is preferably between about 5 and about 30 feet and most preferably between 10 and 20 feet. The suitability of any given length will depend on several factors, including the geometry of the road, and contractor's preferences. The barrier width may also vary widely. The top or base may each measure from about 20 inches to about 30 inches in width, and preferably about 26 inches wide. If less than 20 inches wide, the concrete barriers should be bolted or otherwise permanently affixed to the ground. The top should always be wider than the bottom as explained earlier.
The outer sidewalls of each concrete barrier facing the roadway should be disposed at an angle of between about 60 and about 89 degrees from the transverse axis of the barrier base. This angle is preferably between about 80 and about 88 degrees, and most preferably between about 87 and about 88 degrees. The steeper angles, among other factors, provide for greater mass.
Abutting ends of each concrete barrier may be connected by a number of economic, easily installed and removed devices. As shown in the drawing, the barrier ends are preferably connected as shown in FIG. 1 by bolts 16 having threaded ends which are inserted through aligned apertures 12 in the abutting ends of the barriers. The bolts 16 are secured within each barrier by corresponding nuts 20 which are screwed onto the ends of the bolts within the barriers. As shown in the drawing, a trough or other suitable recess -8 is provided near each end of each barrier, and the bolt apertures 12 extend from the end of the barrier into the recess 18. The recesses are configured to enable the bolts to be inserted into the recesses and thence through the apertures. Sufficient clearance is provided in the apertures to enable the barriers to be adjusted in position -- as, for example, to follow around a curve in a highway. The barrier is thereby made laterally articulate. Each recess is preferably spaced from its respective end of its barrier so as to avoid adversely affecting the strength of the barrier, while at the same time enabling the use of strong but readily usable bolts. Reinforcing bars 14 are preferably positioned in the barriers in the vicinity of the recesses to provide adequate strength to the barriers. The bars may take various configurations; several shapes are shown in FIGS. 2-2C.
The bolts for connecting the concrete barriers must be sufficiently large to withstand substantial load. A preferable length has been found to be about 26 inches, with a diameter of about 11/4 inches. Other examples of suitable connective devices include horizontal reinforced steel bar connections with anchor bolts, angle irons, and steel channels as practiced in the art.
The barriers of this invention may be combined with other types of barriers and guard rails. Those sections of roadways which would more appropriately and safely be protected by other barriers such as energy absorbing terminals or crash cushions to guard against head-on collisions.
Compliance tests of the new barrier design were conducted in accordance with guidelines presented in NCHRP Report 230. The tests employed two vehicles -- a 1984 Sierra 2500 GMC pickup, and a 1981 Honda Civic. The GMC pickup weighed about 4500 pounds and the Honda Civic weighed about 1965 pounds, both being their gross static weights.
A series of reinforced concrete barrier segments similar to the design shown in FIGS. 1 and 1A were connected end-to-end using pairs of A36 11/4" steel bolts. Each segment was 20 inches high and 20 feet long. Each segment was also two inches wider at its top than at its bottom -- i.e., 28 inches versus 26 inches.
Each test vehicle was towed into the barrier using a steel cable guidance and reverse tow system. A steel cable for guiding the test vehicle was stretched along the path, anchored at each end, and threaded through an attachment to the front wheel of the test vehicle. Another steel cable was connected to the test vehicle, passed around a pulley near the impact point, through a pulley on the tow vehicle, and then anchored to the ground such that the tow vehicle moved away from the test site. A 2 to 1 speed ratio between the test vehicle and the tow vehicle existed under this system. The test vehicles were released to be free-wheeling and unrestrained just prior to impact with the barrier.
The GM pickup struck the barrier at a speed of about 44.4 mi/h. (71.4 km/h) and at an angle of about 26.1 degrees. The Honda Civic struck the barrier at a speed of about 45.7 mi/h (73.5 km/h) and at an angle of about 21.3 degrees. In each instance the left front of the vehicle made initial impact.
Each test vehicle was instrumented with transducers, accelerometers and pressure sensitive contact switches to measure such factors as roll, pitch and yaw rates; longitudinal, lateral and vertical acceleration levels; and impact times and velocities. Three high-speed cameras were used to photograph the tests from positions above, behind and in front of the test vehicles.
The barrier received moderate damage from the GM pickup, and only minimal cosmetic damage from the Honda Civic. Each vehicle was redirected by the barrier, and did not penetrate or go over the barrier. There were no detached elements or debris in either instance to show potential for penetration of the occupant compartment or to present undue hazard to other traffic. Each vehicle remained upright and stable with the barrier during impact and after exiting the test installation. Neither vehicle climbed the barrier as would have been the tendency with the CMB barrier. In the case of the GM pickup, the barrier had a maximum lateral movement of about 5 inches (12.7 cm) at the center joint. In the case of the Honda Civic, there was no measurable lateral movement of the barrier.
Many variations and modifications may be made to the longitudinal road barrier described herein without departing from the relevant principles of the invention. Accordingly, it should be readily understood by persons skilled in the art that the scope of this invention is not limited to the specific applications provided in this disclosure but is intended to encompass any embodiment that falls within the scope and spirit of the appended claims. | A low profile road barrier that minimizes obstruction to vision and the ramping and rolling of automobiles which may be comprised of one or more interconnected concrete barrier segments stationed along the road or cast in place. The road barrier usually lies substantially parallel to the direction of traffic, may be up to about 24 inches in height and has a sidewall facing toward the road which angles outwardly from the barrier base. Abutting ends of contiguous segments are interconnected by economic, easily installed and removed devices, which preferably comprise bolts with two threaded ends insertable through apertures in the segment ends secured by corresponding nuts. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to a wind power installation comprising a rotor and a generator driven by the rotor for generating electric power. At least one rotor blade is mounted in a rotor hub so as to be displaceable about its longitudinal axis. The wind power installation comprises an auxiliary generator driven by the rotor for generating electric power for at least one consumer.
A wind power installation having a multi-stage generator is known from DE 102 33 589 A1, the entire contents of which is incorporated hereby by reference. Different generator stages which are selectively connected or disconnected are provided in the wind power installation for different wind speeds. The multiple stages of the generator are intended to make effective use of a wide range of different wind strengths for generating electricity.
An adjusting apparatus for rotor blades is known from DE 196 44 705, the entire contents of which is incorporated hereby by reference. In adjusting the rotor blades, same are brought into an angled position, the so-called flag position, at which the wind power installation comes to a standstill. The adjusting apparatus comprises an auxiliary generator which is installed in fixed inter-connection with the nacelle/rotor and which derives power from the rotational motion of the rotor relative the nacelle. The rotor blades are rotated directly into the flag position by the power thus derived.
An apparatus for adjusting the angle of attack of a rotor blade having an emergency current circuit is known from DE 100 09 472 C2, the entire contents of which is incorporated hereby by reference. The emergency current circuit comprises a permanent magnet generator which connects to the motors for adjusting the angle of attack such that same is set into the flag position after the emergency current circuit switches on. A high velocity to the rotor blades is hereby also achieved upon a high rotational speed to the rotor shaft.
A wind power installation providing contactless power transmission from a non-rotating part of the wind power installation to the rotor is known from DE 101 53 644 C2, the entire contents of which is incorporated hereby by reference. For this purpose, an asynchronous machine is integrated into the wind power installation, the stator of which is connected to the non-rotating part of the wind power installation and the rotor of which is arranged at the rotating part.
A control apparatus for a wind power installation is known from DE 368 799, the entire contents of which is incorporated hereby by reference, in which a self-excited and separately-excited generator are operated together with accumulators such that voltage is maintained automatically and the fluctuating power consumptions of the connected consumers are covered.
Known from EP 1 286 049 A2, the entire contents of which is incorporated hereby by reference, is a wind power installation having a stabilizing device which actively stabilizes the rotor in a low-load rotational position (park position). Additionally known is its own energy supply means, in particular in the form of an auxiliary wind power installation mounted on the machine gondola of the wind power installation.
Modern wind power installations frequently have an adjusting device, the so-called pitch drive, which can adjust the rotor blade about its longitudinal axis, thereby enabling an adjustment to different wind velocities.
If it becomes necessary to shut down such a wind power installation, the pitch drive brings the rotor blades into their flag position; i.e., the rotor blades are essentially positioned at right angles (90°) to their normal orientation. In this position, the rotor can be kept in a permanent standstill by a holding brake or by different stabilizing means. However, the rotor is frequently not kept at a standstill by a brake, instead the rotor spins in the wind; i.e., it rotates as thereby also does the drive train including the generator connected to the rotor, whereby the generator is disconnected from the power system. This condition is known as spinning mode. In this case, depending on wind velocity and direction, an irregular rotational speed of a few revolutions per minute commences, compared to the rotational speed in normal operation of the wind power installation being substantially higher, for example in the range of 15-20 revolutions per minute.
It is generally required for the rotor blades to be able to be set into the flag position also in the event of a power outage. For this purpose, energy stores are usually provided, for example accumulators or condensers for electrical pitch drives and accumulators for hydraulic pitch drives, which provide the power necessary for a one-time adjustment of the rotor blades into the flag position. Energy stores are frequently dimensioned such that they are depleted following this one-time displacement process and are not recharged until resumption of normal operation. DE 200 20 232 U1 proposes the use of an auxiliary generator in order to reliably rotate the rotor blades into the flag position.
For temporarily supplying the controller of the wind power installation in the case of power failure, a commercial, uninterruptible power supply (UPS) based on accumulators is usually provided, same being configured so as to supply the controller of the wind power installation with power for a short period of time so that, for example, a status signal can be sent via a remote monitoring system indicating that the operating system has been properly shut down and/or the controller switched off.
Required in the case of ocean (off-shore) wind power installations is that the wind power installations also be capable of supplying essential components with emergency power for several days or weeks in the event of longer power supply system outages. For this purpose, it is common to provide for a diesel generator, which must be supplied with an accordingly large quantity of diesel. Substantial maintenance costs are necessary to ensure a faultless state to the diesel and the diesel generator; among other things, the diesel must be continually or at least regularly recycled and replaced at specific intervals. The expenditure for this is substantial, in addition working with diesel fuel off-shore leads to environmental endangerment.
It is an object of the present invention to provide an emergency power supply in the event of power failure which can be produced at low expense, requires low maintenance in normal operation, and represents no danger to the environment.
BRIEF SUMMARY OF THE INVENTION
The wind power installation according to the invention comprises a rotor and a generator driven by same for generating electricity which is intended in particular to be supplied to a power system. At least one rotor blade rotatable about its longitudinal axis is mounted in a rotor hub. A rotor-driven auxiliary generator for generating electricity for at least one consumer is furthermore provided. According to the invention, the auxiliary generator is designed for a rotational speed of the rotor set for a rotor blade adjusted into the flag position. This rotational speed is lower than the rotational speed in normal operation. Particularly at the rotational speed in spinning mode, the auxiliary generator generates electricity for the consumer(s). The invention is based on the recognition that when the wind power installation is spinning, the low rotational speed given for operating the auxiliary generator can be utilized in this manner to sustainably and reliably ensure an emergency power supply. In particular in the case of off-shore wind power installations which must also be designed for a power outage lasting several days or weeks, the auxiliary generator affords a reliable power supply. In order for the wind power installation to be sustained in operating mode, the auxiliary generator provides a controller for the rotor blade adjustment and at least one motor for adjusting the angle of attack of the rotor blade. In this design, the auxiliary generator also enables the control of the angle of attack of at least one rotor blade in spinning mode so as to result in controlled or regulated operation of the wind power installation in spinning mode. The angle of attack of the rotor blade is controlled by the controller in order to obtain a rotational speed for which the auxiliary generator is designed. The controller controls and/or regulates the angle of attack of at least one rotor blade so as to operate the auxiliary generator at a low rotational speed on a sustained basis. Preferably, each rotor blade is provided with a motor for adjusting the angle of attack, wherein each of the motors are supplied by the auxiliary generator. This design enables the angle of attack of all rotor blades to also be adjusted in spinning mode and thus ensures a regulated spinning mode under different conditions.
In a further preferred design, the auxiliary generator supplies a controller for the angle of the machine gondola (azimuth angle) and an azimuth drive for adjusting the angle of the machine gondola. In this design, the auxiliary generator enables the orientation of the machine gondola and thus the rotor in the wind during spinning mode. By so doing, also wind power installations which have been shut down can actively follow changing wind directions so that the wind power installation receives less load, even in strong wind.
One preferred development provides for switching means for switching on the auxiliary generator for actuation by the rotor during a network power supply outage. Said switching means are preferably of mechanical, hydraulic, pneumatic and/or electrical configuration. In one feasible design, a mechanical coupler is provided as the switching means which is opened in normal operation of the wind power installation and closes automatically in the event of power failure, wherein the coupler preferably closes in time-delayed manner such that the delay allows for the rotational speed to already be decreased by the wind-rotated rotor blades.
In another design, the coupler is opened electrically and/or hydraulically and closed by spring action. It is alternatively conceivable to provide a switching means operating under centrifugal force which opens upon the exceeding of a first predefined rotational speed and closes upon falling below a second predefined rotational speed. The first predefined rotational speed can hereby be the same as or different from the second predefined rotational speed.
One feasible design of the wind power installation according to the invention provides for a brake which is applied prior to the auxiliary generator switching on until a rotational speed specified for the auxiliary generator is reached.
In one feasible design, the auxiliary generator is driven continuously by the rotor and electrical switching means do not produce an electrical connection with the consumers until the rotational speed specified for the auxiliary generator is reached.
In continuation of the afore-mentioned design, the switching means comprises a contactor which is open during normal operation and which closes upon power failure preferably in a time-delayed manner. The switching means furthermore comprises an additional rectifier, converter and/or inverter which converts the power generated by the auxiliary generator in the manner as required by the consumer to be supplied and provides it as direct or alternating current.
In a likewise preferred design, the auxiliary generator is coupled to the rotor by means of a drive, wherein the drive preferably has a transmission ratio in order to power the auxiliary generator for generating electricity at a number of revolutions per minute to the rotor of the wind power installation which is less than 15 revolutions per minute. For example, the transmission ratio is configured to have a range of rotational speed for the auxiliary generator of from two to eight revolutions per minute. It is further preferred for the auxiliary generator to be configured such that at a transmission ratio for a rotational speed of from four to six revolutions per minute, a sufficient provision of electricity will thereby ensue. Future wind power installations having very large diameters can also generate power with the auxiliary generator at significantly lower rotational speeds.
The auxiliary generator is preferably of a self-excited or permanently-excited configuration. Alternatively, a generator with separate excitation can be used for which the excitation power is provided by an energy store, for example an accumulator. Additionally, a practical continuation provides for at least one accumulator in the wind power installation which ensures an uninterruptible power supply, wherein the accumulator is supplied by the auxiliary generator and in particular recharged in the event of power failure. It is likewise conceivable to configure the generator such that the switching means can operate same as an auxiliary generator.
The object according to the invention is likewise achieved by a method for controlling a wind power installation. The wind power installation comprises at least one rotor blade, the angle of attack of which is adjustable about its longitudinal axis. The method is characterized by a mode of operation in which the rotor blade rotates at a slower rotational speed compared to its regular operation. The rotor preferably has, as mentioned above, a rotational speed of less revolutions per minute, while the rotational speed during normal operation is from 15 to 20 revolutions per minute. The auxiliary generator configured for this range of rotational speed generates electricity applicable for controlling the angle of attack of the rotor blade. The controller sets the angle of attack of the rotor blade such that the wind power installation is driven at the reduced rotational speed mode of operation on a sustained basis. The auxiliary generator hereby supplies the controller and a drive for adjusting of the rotor blades. The angle of attack adjustment can hereby be regulated or controlled.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
The following will make reference to the figures in describing the present invention in greater detail.
FIG. 1 a schematic view of the drive train of a wind power installation according to the invention, and
FIG. 2 a block diagram comprising the essential components of the wind power installation to be supplied by the auxiliary generator.
DETAILED DESCRIPTION OF THE INVENTION
While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated
FIG. 1 shows a schematic view of a drive train for a wind power installation comprising a rotor blade 1 mounted displaceably in a rotor hub 2 . The rotor shaft 3 leads to a drive 4 , the output shaft of which forms the generator shaft 5 for the generator 6 . In normal operation, the wind power installation has a rotational speed of, for example, approximately 15-20 revolutions per minute which the drive 4 converts into the appropriate rotational speed for the generator 6 . Of course, gearless drive trains also exist.
An automatic coupler 9 connected to a generator shaft 7 of an auxiliary generator 8 is provided on an output shaft of the generator 6 .
The drive train shown works as follows: when power is lost, the rotor blades are rotated into the flag position by an auxiliary motor which is fed by a generator or an energy store (not shown). The wind power installation thereby switches over to spinning mode in which the rotor has a rotational speed of approximately four to six revolutions per minute. Upon the approximate approaching of the rotational speed, the coupler 9 closes so that the auxiliary generator 8 can be driven by the rotor. The electricity provided by the auxiliary generator 8 , on an order of magnitude of some kilowatts, suffices to supply the essential components of the wind power installation in the event of power loss such as, for example, the controller, wind sensors, pitch and azimuth systems, hydraulic systems, signaling devices, obstruction lights for ships and aircraft and the like. As will be described in the following, the power provided by the auxiliary generator 8 even allows a control or regulation of the spinning mode.
FIG. 2 shows the connections of the wind power installation in a block diagram. In normal operation, the electricity generated at generator 6 is supplied to the power system through the closed switch 17 . The electrical consumers, for example the controller 13 , the signaling devices and obstruction light 14 , as well as the azimuth system 15 and the pitch system 16 are supplied with electricity from the power system—from generator 6 respectively.
When the wind power installation needs to be disconnected from the power system, for example due to a power supply outage, the switch 17 opens. In this event, the uninterruptible power supply 12 assumes the supplying of the consumers for a short period of time, the controller 13 and the signaling devices and obstruction light 14 in particular. In addition, the pitch drives, which are an integral part of the pitch system 16 , set the rotor blades into the flag position. The power necessary for this is taken from energy stores which are likewise an integral part of the pitch system 16 . The adjusting of the rotor blades into the flag position reduces the rotational speed of the rotor. At an appropriate rotational speed, switch 18 is thrown and the electricity generated by the auxiliary generator 8 is converted into the appropriate alternating current for the consumers by means of converter 11 . The uninterruptible power supply 12 can hereby be recharged, the controller 13 can resume operation as necessary and assume control tasks, furthermore the signaling devices and obstruction light 14 can be operated. With the normally closed switch 19 , supply of the azimuth system 15 and the pitch system 16 continues.
Of course, a converter 11 can be omitted when the components 12 . . . 16 of the wind power installation are capable of being operated directly by the power generated by the auxiliary generator 8 .
The auxiliary generator 8 ensures at least the supply of the controller 13 of the wind power installation and the pitch system 16 as well as the supply of at least one pitch drive so that at least one rotor blade in the wind power installation can be set to a position other than the flag position. In the case of spinning mode control, the rotor blade is adjusted such that the rotational speed of the rotor is within a range which effects an especially favorable rotational speed for the generator shaft 7 for operating of the auxiliary generator 8 , for example 400-500 revolutions per minute. This allows a control of the spinning mode and the achieving of a constant provision of energy.
The auxiliary generator 8 can supply power to at least the controller 13 of the wind power installation and the azimuth system, the wind sensors, the azimuth drives and—if provided—the hydraulic system. The wind direction is determined in particular by the wind sensors so that the controller 13 receives an input variable as to which direction the wind power installation needs to track. The hydraulic system needs to be supplied with power if the wind power installation is equipped with azimuth brakes which need to be hydraulically ventilated upon tracking of the wind power installation. It is hereby possible to track and set the wind power installation in blowing wind such that as little load as possible acts upon it. In particular, the wind power installation is positioned such that the rotor points toward the wind.
When a calm sets in, supply from the auxiliary generator 8 is no longer possible. In this case, another supplying of the controller 13 and the signaling devices and obstruction light 14 is needed, which is assumed by the uninterruptible power supply 12 . Operation of the azimuth system 15 and the pitch system 16 is then unnecessary and these components are disconnected from the supply by the opening of switch 19 .
The controller 13 is connected with the remaining components of the wind power installation by means of (not shown) control lines, a local communication network or other connecting means in order to control them and to receive their performance data and measurement readings.
Safety guidelines for modern wind power installations stipulate that wind power installations which have been shut down upon power failure be capable of weathering storms of a certain intensity with changing wind direction without damage. When the wind power installation can actively follow changing wind direction, it can then be configured for the dimensioned load at substantial material savings to the various different components and there is greater probability that the wind power installation will weather extreme wind conditions undamaged.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | A wind power installation with a rotor, a generator for generating electric power, at least one rotatably mounted rotor blade displaceable about its longitudinal axis for adjusting the angle of attack, and an auxiliary generator for generating electric power for at least one consumer, characterized in that the auxiliary generator produces electricity for a controller for the rotor blade adjustment and for a drive for adjusting the angle of attack of at least one rotor blade at a lower range of rotational speed in comparison to the rotational speed in normal operation, wherein the controller for the angle of attack is controlled or regulated for sustained operation in the range of the rotational speed. | 5 |
[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 61/301,959 filed on Feb. 5, 2010, which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] Convenience beverage vending is a multi-billion dollar major industry world-wide. Today, market share is totally dominated by beverages sold in plastic bottles and aluminum cans. It is estimated that less than 15% of such beverage containers are currently recycled, leading to huge environmental waste
[0003] In addition, most convenience beverages are predominately water, and consequently, there is a significant embedded energy in their bottling, transportation and distribution into the vending machines themselves.
[0004] There is a need for a new type of beverage vending that addresses the selection limitations and environmental concerns related to existing beverage vending machines.
SUMMARY
[0005] A convenience beverage vending machine and methods of dispensing convenience beverages are described. An embedded computer interface that allows customers to vend a wide variety of convenience beverages into their own re-usable containers is utilized. This vending machine is connected to a municipal water source and drain, in a similar fashion to a standard drinking fountain. This allows the bulk of the beverage contents to be supplied to the machine in a highly concentrated form, and mixed into a custom beverage in the machine, rather than transporting the water to the vending site. The municipal water entering the machine goes through a multi-stage filtration process that is custom tailored to the water quality at a specific location site.
[0006] The vending machine vends beverages that may be made from hot, cold or carbonated water, and everything from plain filtered water, to standard soft drinks, to fully custom beverages that are designed by the customer. Beverage ingredients may be stocked in the machine in one of two ways, both in highly concentrated forms. Beverage ingredients may be in the form of liquid syrups, either in industry standard “bag-in-box” format, cartridges, or in syrup tanks. Beverage ingredients may be in powder form and may appear in bulk powder containers and or low volume containers. Each machine holds a plurality of separate ingredients. Some of these may be standard beverages and the remainder may be separate ingredients including, but not limited to: multiple types of real fruit syrup concentrates, regular and low calorie sweetener syrups, multiple types of flavored nutritional supplements, and multiple types of flavor neutral nutritional supplements.
[0007] A human agent or user may approach the invention and present identification. The machine identifies the user as a customer and pulls up that customer's account. Further, the machine may locate a customer based on a global positioning system (GPS) or a proximity sensor and sign the customer in via a mobile device application. If desired, the user may add funds through the machine interface with physical currency or bill the amount necessary, for example, to a credit card. The machine may also pull up a list of that user's favorite or recently vended beverages. The user can then simply order from this list, order plain filtered water, a standard soft drink, favorite or top selling recipes recommended by the machine, or design a totally new custom beverage. In designing a new custom beverage, the user may select flavor types (which may be blended) and their relative flavor intensity. For example, the user could select 30% pomegranate and 70% blueberry, and then vary the intensity from light, like a flavor hinted water, to heavy, like a fruit juice. The user may also select additional sweetener, from a more standard sugar based sweetener, like cane/agave syrup, or a low calorie sweetener, like stevia/citrus extract. Again, the user may select a combination of these in various percentages, and then vary the intensity from lightly sweet to very sweet. Next, the user may optionally select a nutritional supplement mix, like immune boost, energy boost, multi-vitamin, etc., select their relative percentages, and then vary the amount, maybe according to body weight. For example, a child may use less nutritional supplement than an adult. After making all these selections, the beverage is automatically mixed and dispensed into the user's own container. If the user likes the drink, it may be saved to the user's account and stored in the database for future vending or editing to adjust the recipe. In another example, a customer may access a social media outlet, such as provided by Facebook, Inc. headquartered in Palo Alto, Calif., and “drink share” recipes. For example, a customer may access a social media outlet (e.g., Facebook®) via an electronic application such as an iPhone® application, Android® application and/or other electronic application, and “drink share” custom drink recipes. A customer may then choose to have a local machine vend a shared drink recipe discovered from the social media outlet experience. The local machine may be able to vend the requested shared drink recipe by accessing a remote database via an internet connection. For example, a customer may discover a shared drink recipe during a social media outlet experience and save it to a personal account. The personal account may be saved in a remote database, which the machines are able to access and subsequently vend a drink as requested by the customer.
[0008] A custom mix ratio beverage may also be created. Unlike a standard soda machine, which vends the syrup and water base in a fixed ratio simultaneously, the microprocessor control allows any combination of all of the multiple ingredients stocked in the machine to be mixed in variable proportion to each other, and to the base water. Standard soda fountain mix ratios may be pre-programmed so that standard soft drinks may be vended, or completely custom beverages designed by the individual users may also be vended.
[0009] An automatic cleaning cycle, incorporated into a novel vending cycle may also be incorporated. In a standard soda fountain, soda syrup/water mix drips slightly at the end of each vending operation. This causes the dispense area to be sticky and hence, it requires frequent cleaning. A mixing manifold may be incorporated that is first cleaned with an automatic clean cycle. This purges any drips that may have leaked into the manifold during the period between vending cycles. The mixing manifold multi-path solenoid valve on the end that is normally open to the machine drain is connected to the drain. The clean cycle is effectuated with hot water at approximately 190° F. and/or with a cleaning solution such as bleach.
[0010] The vending machine may also be equipped to provide for automated cleaning of valves. Solenoid valves and standard soda fountain dispensing valves alike can become sticky over time, and may fail to open or close correctly. In a standard soda fountain machine, the machine parts are frequently disassembled and cleaned and then reassembled. One embodiment of the vending machine utilizes a periodic valve cleaning cycle which may be executed via software or through manual control at certain defined intervals based upon events such as elapsed time, or number of vends of given syrup types.
[0011] The vending machine may also provide a unique billing/customer interface that enables the individual customer to create unique beverages and store their favorite recipes in the machine central database. Each machine may be connected via the internet to the main database. As each individual machine may be stocked with different ingredients, the user interface may display drink possibilities that can be made in the specific machine that the customer is using. The system may also enable features such as “parental controls.” This feature may be enabled in machines deployed in schools, where parents may set limits on the number and type of beverages their children can vend, and may put limits on types of beverages or specific ingredients, such as sugar. The parent may also require a specific nutritional supplement in each beverage. In addition, customers may name drinks and submit them to be tried and rated by other customers, and the database may display the top rated/top selling recipes in the machine. The system may also enable features such as “own/operator controls.” For example, the machine may incorporate lockout times. For example, the machine may be programmed to lock the machine to students during class times, while remaining open to teachers and/or staff.
[0012] The vending machine may also be able to vend beverages into containers of all different sizes, colors and translucencies. Often opaque containers are difficult to see through during beverage filling causing overfilling and spills. If the user knows the bottle/container size, they can select the appropriate size/amount of total beverage, and the microprocessor may adjust the quantities of all ingredients automatically and fill the container accurately, without overflowing the container. If the user makes a mistake, and does not know the size of the container, a manual or microprocessor controlled cycle may be activated to circumvent overfilling.
[0013] The vending machine may also provide the user with a safe experience. Since the machine may be used to vend hot, cold or carbonated beverages, there is a risk that some customer may vend a hot drink into an unsuitable container, such as a stainless steel bottle that is not insulated, potentially causing burns. For this reason, the vending machine may incorporate a temperature sensor. If the temperature on the surface of the bottle exceeds a safe level, the user may be alerted and the vending process halted.
[0014] Dispense area sanitation may also be incorporated in the vending machine. Traditional soda fountains utilize a dispense nozzle which is activated by pushing a disposable cup up against the dispense valve lever. If users were to use their own containers with this type of dispense mechanism, bacteria may be transmitted to the dispense lever and consequently between successive customers. In one embodiment of the vending machine, a recessed dispense tube may be utilized which is shielded so it cannot come in contact with users bottles, and the entire dispense area may be flooded with an anti-bacterial Ultra-Violet sterilization light.
[0015] 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 or essential 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.
BRIEF DESCRIPTION OF THE CONTENTS
[0016] The detailed description is described with reference to accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items.
[0017] FIG. 1 is a schematic of an implementation of the plumbing system in the vending machine apparatus.
[0018] FIG. 2 is a schematic on an implementation of the electrical system in the vending machine apparatus.
[0019] FIG. 3 is a depiction of an implementation showing the locations of components in the vending machine apparatus.
[0020] FIG. 4 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0021] FIG. 5 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0022] FIG. 6 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0023] FIG. 7 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0024] FIG. 8 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0025] FIG. 9 is a depiction of an interface presented to the human agent to effectuate the dispense of a custom beverage.
[0026] FIG. 10 is a flow chart depicting the control process relating to beverage vending in an implementation.
DETAILED DESCRIPTION
[0027] Referring to the drawings. FIG. 1 shows an implementation of the vending machine apparatus that may include a touch screen display 100 . However, other implementations may include many other means for the delivery and/or reception of information to and from a user such as a keyboard, monitor, human interface device, or visual display. In an implementation, a personal computer (PC) containing a processor or processors and memory 101 may communicate with the touch screen display 100 to receive and transmit information related to the information acquired by the display 100 and/or delivered by the PC 101 . Other implementations may include other means for the delivery or reception of information to a component interacting with the user.
[0028] The PC 101 may convert received information to a format and/or language for communication with two Programmable Logic Controllers (PLCs) 103 , 104 . Other implementations may include a means to directly and/or indirectly communicate the user's input with one or more controller devices.
[0029] The PC 101 may communicate with two PLCs 103 , 104 via an Ethernet router 102 . The PLCs 103 , 104 may send and receive information to and from the PC 101 which is directly related to the information retrieved from a user and/or the operation of said PLCs 103 , 104 . Other implementations may include single or multiple control devices and/or methods capable of directly or indirectly effectuating the user's desire. In one example, the user may select an option presented on the touch screen display 100 which may then be transmitted to the PC 101 . PC 101 may then interpret the user's input and convert the input to a format and/or language intelligible to the PLCs 103 , 104 . The PC 101 may then transmit information necessary to accomplish the desire of the user to the PLCs 103 , 104 via an Ethernet router 102 .
[0030] In an implementation the PLC 103 controls a relay 105 connected to a solenoid valve 124 to effectuate the controlled flow of fluid and/or gas through the solenoid manifold 113 . Alternative implementations may include single or multiple relays of varying types including solid state relays, polarized relays, latching relays, reed relays, or other means to control or directly influence the actuation of a valve or the flow of fluid. Other implementations may also include single or multiple valves actuated by pneumatic, hydraulic, electrical, and/or other mechanical means. For example, the user's input after being communicated to the PLC 103 via the PC 101 and/or Ethernet router 102 may be effectuated by the activation of a relay 105 which activates a solenoid valve 124 allowing fluid to pass for an amount of time directly related to the user's input. Further, the user's input after being communicated to the PLC 103 via the PC 101 and/or Ethernet router 102 may be effectuated by the activation of a relay 105 which activates the solenoid valve 124 allowing fluid to pass for an amount of volume based on feedback from one or more flow sensors directly related to the user's input.
[0031] As illustrated in FIG. 1 , an implementation utilizes a fluid system to effectuate the transportation, filtration, alteration and manipulation of one or more fluids and its properties. Water entering the vending machine apparatus passes through a normally closed safety solenoid valve 106 . Valve 106 allows for the flow of fluid into the vending machine to be terminated at any time. An Ozone generator may be connected to the fluid path exiting valve 106 via a T-connection. Flow from the fluid path exiting valve 106 may be prevented from entering the Ozone generator via a check valve. In this implementation, the water passes through a water softening filter 107 to reduce magnesium, calcium, and other dissolved minerals to levels desirable and palatable for human consumption. After the softener 107 , fluid passes through two activated carbon filters 108 orientated in series. The fluid then passes through an ultraviolet (UV) filter 109 before continuing to other components of the fluid system.
[0032] In summary, an implementation may use a four stage filtration process consisting of a softener 107 , activated carbon filters 108 , and a UV filter 109 to effectuate the delivery of water that is palatable and suitable for human consumption. However, other implementations may include varying quantities and types of purification and/or particulate filters necessary to effectuate the delivery of water that is palatable and suitable for human consumption. An implementation may include other means to reduce scale and/or water hardness such as a scale filter. Alternative implementations may omit the use of filtration in the fluid system.
[0033] The inlet fluid path may be divided to flow to several components. One component may be a solenoid valve 110 for controlling the flow of fluid to a hot tank or water heater 111 . Another implementation may use one or more pneumatic, electric, hydraulic, and/or mechanical valves located before and/or after a heater tank to effectuate the flow of fluid to and from a heater tank.
[0034] The flow of fluid into the heater tank 111 may be directly controlled by the actuation of a solenoid valve 110 . Fluid flow to and from the heater tank 111 passes through the inlet port and outlet port respectively. The outlet port may be directly connected to a fluid path that remains at atmospheric pressure at all times. Other implementations may utilize means to effectuate the heating of water such as a pressurized hot tank, instant water heater, or various other heat addition techniques.
[0035] The temperature of hot water may range from about 100° F. to 212° F. This hot fluid then follows a fluid path to a one way valve 112 which prohibits the backflow of fluid toward or into the heater tank 111 . After the one way valve 112 , the hot fluid passes through three manifolds 113 , orientated with one in series and two in parallel, a fluid flow meter, and a 3-way normally open solenoid valve 115 . At this point the hot fluid is diverted to a fluid path connected to the dispensing nozzle 116 or to a fluid path connected to a drain line 117 . Another implementation may include one or more fluid paths which the hot fluid would follow directly and/or indirectly to the dispensing nozzle and/or drain. Yet other implementation may include means necessary to guide hot fluids from a source to a destination in the fluid system resulting in the dispensing and/or draining of said fluid.
[0036] Fluid may also enter a fluid treatment apparatus 118 which possesses the ability to cool and/or carbonate incoming fluid. This vending machine also possesses the ability to cool one or multiple incoming fluids all of which pass through unique fluid paths. Other implementations may include one or more apparatuses to effectuate the cooling and/or carbonating of fluid in the invention.
[0037] Fluid paths exiting the vending machine, such as a path dedicated to chilled fluid flow through a one way valve 112 to prevent backflow, and then to a dedicated solenoid valve 124 located on a manifold 113 may be incorporated. Each fluid path then follows a path similar to that of the hot fluid after entering a manifold.
[0038] Drain valves may be utilized to ensure the ability to drain fluid held by the present invention. Valves may be of a myriad of designs including but not limited to shut-off valves and solenoid valves. FIG. 1 illustrates an implementation of drain valves with a main line drain valve 129 , a hot tank drain valve 130 , a carbonated fluid drain valve 131 , and an ice bath drain valve 132 . Also an ice bath overflow fluid path or drain line 133 could be utilized to maintain on optimal fluid level in said ice bath as a component of the chiller 118 .
[0039] The temperature of the chilled product may range from about 60° F. to 32° F. For example, fluid may enter a combination water chiller, carbonator, and syrup chiller designed for soda-fountain style machines 118 . Fluid exiting from the chilled water path then follows a path connected to a one way valve 124 and then to a normally closed solenoid valve located on a manifold. When the solenoid is activated, the chilled water flows through the manifolds 113 , flow meter 114 , and 3-way solenoid 115 directly to dispense. Other implementations may incorporate the use of one or more fluid paths and/or valves to control the flow of fluid from a fluid treatment device such as a water chiller and effectuate the dispense or disposal of said fluid. Carbonated fluid exiting the fluid treatment apparatus may follow a fluid path directly or indirectly connected to the dispense nozzle and the fluid path may be regulated by a device such as a needle valve 134 or through the use of an inline compensator or similar device. In another example, syrup may traverse a syrup chilling line and flow through a manifold 113 , flow meter 114 , and 3-way solenoid 115 to a dispensing nozzle.
[0040] One implementation utilizes a pressurized carbon dioxide (CO 2 ) tank 119 with outlet pressure regulated to supply a combination chiller/carbonator 118 , product pump 120 , and direct line with CO 2 gas. Other implementations may incorporate various other components requiring pressurized gas for pneumatic actuation, carbonation, direct use, and/or other applications requiring pressurized gas.
[0041] Gas entering a product pump 120 effectuates the operation of the pump and the flow of the product through a fluid path which bisects the product pump 120 . For example, CO 2 gas actuates a pneumatic turbine pump which delivers positive pressure to incoming fluid thus causing the fluid to traverse an outflow fluid path. CO 2 gas may also follow a fluid path terminating at a one way valve 112 connected to a dedicated, normally closed, solenoid valve on a manifold 113 . The flow through the fluid path may be regulated by a component such as a needle valve 135 . The path then continues along a route similar to the chilled fluid as described previously. In other implementations gas may follow various routes terminating at a flow controlling component, such as a solenoid valve, pneumatic valve and/or mechanical valve effectuating the dispense or disposal of the gas. In other implementation, CO 2 gas may enter a carbonation tank under pressure where it dissolves into the co-occupying fluid.
[0042] Pneumatically driven product pumps 120 may effectuate the transmission of product fluid from one or more containers to dispense or disposal along a fluid path similar to the chilled fluid as described previously. Alternative implementations may utilize other means for the transmission of product fluid to dispense or disposal via one or more fluid transmission methods such as electric pumps, pneumatic pumps, positive displacement pumps, hydraulic pumps, positive head, and any combination or isolated use thereof.
[0043] One implementation may utilize a combination of solenoid manifolds 113 to control the flow of fluid from unique and separate inflow paths to a common outflow path. For example, a six line manifold may contain six normally closed solenoid valves, each preventing a given fluid from entering the manifold. When a given solenoid valve is energized, fluid that was previously blocked by the solenoid flows through the manifold. Multiple solenoid valves 112 may actuate during overlapping time intervals allowing one or more fluids to enter the manifold through unique fluid paths and depart through a common path. Other means may also be used to achieve the controlled flow of single and/or multiple fluids through a common exit may also be utilized.
[0044] In another implementation, the vending machine may utilize a normally open 3-way solenoid valve 115 to control the flow of fluid to the dispense nozzle 116 . The solenoid functions such that all fluid passing through an inlet departs through one of two unique outlet paths. When the 3-way solenoid 115 is energized all fluid passing through an inlet departs through an outlet path connected to the dispense nozzle 116 . Other implementations may utilize methods such as a normally closed solenoid or other means by which to control the dispensing of a fluid.
[0045] A sink 121 may be located beneath the dispense nozzle 116 to capture disposed fluid and channels said fluid to a drain 117 . Other implementations may use various methods to capture disposed fluid and pass said fluid to a drain.
[0046] An ultra violet (UV) sanitization light 125 may be utilized to effectuate the sanitization of the sink, dispense nozzle and or the dispense area.
[0047] Fluids may be transmitted to disposal exit through a drain pipe 117 . Other implementations may use methods such as a reservoir with a submersible pump to expel disposed fluid from the invention.
[0048] An inductive float switch 128 may detect the presence of fluid at the base of the invention. Other implementations may use other fluid level sensing means.
[0049] A magnetic stripe card reader 122 may effectuate the transfer of funds from the consumer as payment for products delivered by the invention. For example, consumer approaches the invention and utilizes a VISA® credit card to purchase a beverage from the vending machine Other means may also be used to effectuate a payment, such as a cash and coin machine or other payment accepting device.
[0050] A near field radio frequency identification (RFID) reader 123 may effectuate the recognition of a known customer and enable the invention to respond to that customer in a personalized manner. For example, a customer approaches the machine and presents an RFID tag to the reader 123 which accepts an identification number from the customer's tag and transmits the information to a program which retrieves and utilizes information associated with the customer's identification number. The RFID tag may be a proximity card, a passive RFID tag, an active RFID tag, a Near Field Communications device, or any another RFID technology and/or frequency communication device suitable for effectuating the recognition of a known customer and enable the invention to respond to that customer in a personalized manner. Other implementations may use methods such as a user name, password, magnetic stripe card, smart card, and/or any similar method to effectuate the identification of known customers.
[0051] Single or multiple LED lights 126 may be used to illuminate a beverage container located below the dispense nozzle 116 and or for the purpose of illumination in the area where fluid is dispensed.
[0052] A camera 127 may be used to capture images of the path of fluid out of the dispense nozzle 116 . The captured images may be still images and/or video images of the path of fluid out of the dispense nozzle 116 .
[0053] The beverage selection and customization process may utilize a touch screen display 100 to effectuate communication between the vending machine and a user. Such communication enables the user to directly control the composition of a dispensed beverage. For example, FIG. 4 exemplifies an initial display image that an implementation may utilize. The user's identity becomes known to the invention at a “sign in” event. Preceding this event, an implementation may display an image as shown in FIG. 5 .
[0054] An implementation may use display images such as shown in FIG. 4-9 for the beverage customization process. For example, a user utilizes a display image such as shown in FIG. 5 to select a desired drink volume. In one implementation, a beverage volume may range from about six fluid ounces to about sixty four fluid ounces or any similar volume related to a personal beverage container. The user then has option to select a main fluid type such as regular cold water, carbonated water, and hot water. However, other implementations may include main fluid types other than water such as a solution of water and ethanol alcohol. After that, a display screen, such as shown in FIG. 7 , may be used to allow the user to select one or multiple supplemental fluids to add to the beverage. For example, the user selects kiwi, mango and orange fruit juice concentrates to be added to the custom beverage. The user then has the option to customize the ratio in which the supplemental fluids are added. The user may designate that the final combination of supplemental fluid contain 47% kiwi, 28% orange, and 25% mango fruit juice concentrates.
[0055] Other implementations may include similar but different means for the user to customize the specific supplemental fluid to be added. Other implementations may also include similar but different means for the user to customize the ratio in which the specific supplemental fluids are added. For example, a user may choose to create a beverage from multiple supplemental fluids at an infinite variety of ratios with the sum total equaling one or 100%. The arbitrary value of 100% may be associated with a value directly related to the user's desired flavor strength. If a user chooses five supplemental fluids at a flavor strength of “heavy,” where heavy flavoring is known to be equal to one fluid ounce, then the five supplemental fluids may be combined at an infinite variety of ratios with the volume equal to a constant of one fluid ounce. Still other implementations may utilize means other than a total volume approach to enable a user to customize the mix ratios of supplemental fluids. Another implementation may be to set supplement volumes to static volumes or “shots.” The shots may be of the same volume for an 8 oz drink and a 32 oz drink. A user may select one shot or more than one. Such other approaches may include setting the summation of supplemental fluid taste, viscosity, or other properties to meet the desire of the user.
[0056] After selecting supplemental fluids in a unique combination as per the user's desire, nutritional supplements may be added to the beverage through a display image as shown in FIG. 7 . Nutritional supplements in liquid, powder, or other form may be added to the beverage or the total fluid volume dispensed in a fixed quantity, mass, or in a quantity proportional to a property of the beverage or the user's desire. For example, the user may choose a twenty fluid ounce beverage with a nutritional supplement. The total mass of supplement dispensed may be a fixed mass such as one gram. In another implementation, the mass of nutritional supplement may be proportional to the user's desired supplementation or proportional to the volume of the twenty ounce beverage. The user may also have the option of adding a sweetener to the custom beverage. The sweetener may consist of ingredients such as cane sugar, Stevia, agave sugar, or other sweeteners. These sweeteners may be added to the custom beverage in a manner similar to that described for the nutritional supplements.
[0057] The total mass of sweetener dispensed may be directly proportional to the beverage volume and the strength of sweetness desired by the user. Other implementations may include similar means to enable a user to customize the sweetness of a custom beverage. The user may also be presented with a display image as shown in FIG. 8 that informs the user of the final composition of the customized beverage that the user created through the drink customization process.
[0058] At this point in the beverage customization process, the user has the option to confirm the purchase and/or final composition of the custom beverage. The user may also be presented with a display screen, as shown in FIG. 9 , that presents various information to the user. This information may include advertisements which are presented to the user. These advertisements may be generic and/or targeted to the specific user. The display screen may also present social media interaction options. For example, users may choose to share their drink with their friends as their Facebook® status. Also, the final screen may allow the user to initiate the vending by pressing a button or through similar means of actuation.
[0059] A cleaning cycle may be utilized to ensure proper sanitization and performance. In one implementation, the vending machine may utilize an automated cycle to effectuate the cleaning and sterilization of one or more fluid paths. This cleaning may be effectuated by the circulation of hot water with a temperature of approximately 190° F. and/or a sanitizing fluid such as a bleach solution through one or more of the fluid paths. Another implementation may utilize ozone gas (O 3 ) to effectuate the sanitization of one or more fluid paths. Other implementations may utilize a similar cleaning cycle effectuated through manual means rather than automated. Also, various methods for determining the necessity of cleaning and sanitization may be incorporated in an implementation to initiate a cleaning cycle. Such methods may include the use of a flow characterization sensor to sense a change in the flow indicative of the necessity for a cleaning cycle. However, other implementations may utilize methods dictating a time interval between cleaning cycles and/or a means for manual determination of the necessity of a cleaning cycle.
[0060] A computing device which includes a process and memory, such as random access memory (RAM), may be utilized. The computing device may be used in combination with other components of an implementation including, but not limited, to a controller and display device. The computing device may operate in combination with connected devices to effectuate the dispense of a customized beverage. The computing device may also perform actions according to software operating in the device.
[0061] A means to clean and sanitize components exposed to a user interacting with the vending machine for the purpose of beverage vending may also be included. All surfaces exposed to the user are easily sanitized and cleaned. More specifically, areas of the vending machine exposed to fluid through the beverage vending process, hereinafter called the dispense area, are regularly sanitized through a sanitization cycle. In one implementation, the cycle may include an ultra violet (UV) sanitization light 125 to effectuate the sanitization of the dispense area. Other implementations may utilize hot fluid, such as water, at a temperature of approximately 190° F. and/or sanitization fluid such as a bleach solution to effectuate the cleaning of the dispense area. One implementation may activate a UV light after the vending cycle or at some other time for a period necessary to inhibit bacterial growth and that of potential pathogens in the dispense area. In another implementation, a surface in the dispense area may be immersed in sanitization solution to effectuate the removal of harmful bacteria from the dispense area.
[0062] A means to ensure the safe dispense of hot fluid where hot fluid is defined as fluid at a temperature of above 100° F. may also be incorporated. The safe method reduces the risk of burn and/or other related injury to a user. In one implementation, such a safe method is effectuated through the use of a temperature sensor that measures, directly and/or indirectly, the surface temperature of a container. The method may include means to terminate dispense of hot fluid and/or lower the surface temperature in the event that the surface temperature of the container reaches or exceeds a temperature threshold. For example, a user places a metallic container in the dispense area and effectuates dispense of hot fluid. After fluid enters the container, a temperature sensor indicates that the surface temperature exceeds 100° F. The present invention then halts dispense of hot fluid and dispenses cold fluid at a temperature of about 45° F. until the temperature sensor indicates that the surface temperature is below the temperature threshold of approximately 100° F. Other implementations may utilize similar but different methods of detecting unsafe temperature levels.
[0063] A method to determine the volume and/or size of a container into which fluid is dispensed may also be incorporated. One implementation utilizes an array of proximity sensors located in a pattern to allow for the computation and approximation of container size. For example, one implementation utilizes a various ultrasonic range finders may be arranged in a hemispherical pattern around the container bay to determine the dimensions of a container. An algorithm then transforms dimensional data received from the range finders and calculates approximate container volume. Other implementations may utilize means which determine or approximate container volume by measuring other properties, such as mass, without departing from the scope of the present invention.
[0064] A method to verify the presence of a container in the dispense area may also be incorporated. Such a method allows for the vending machine to terminate dispense of fluid in the event that there is no container present into which fluid will be dispensed. One implementation may use an ultrasonic range finder to verify the presence of an object in the dispense area. Other implementations may use various other means to verify the presence of a container into which fluid will be dispensed.
[0065] A method to encourage the alignment of a container opening and the dispensed fluid so as to ensure that dispensed fluid enters the container may be incorporated. One implementation utilizes dimensional sensors and a multi-dimensional actuator to position a dispense nozzle over and above the container opening. Other implementations may use various other methods including a combination of sensors and messages that inform the user of the status of alignment between the container opening and the dispense nozzle. Another implementation may present an image of the dispense nozzle and the container opening to a user and allow the user to effectuate dimensional adjustments to ensure the flow of dispensed fluid into the container.
[0066] A method to prevent the overfill or flow of fluid out of a container opening may be incorporated. Such an event may occur during the fluid dispense process. One implementation utilizes a dimensional sensor that measures the speed of fluid rise in a container. This implementation may then sense a change in speed of said fluid which may indicate that the container has reached maximum fluid capacity. For example, an ultrasonic range finder indicates that fluid is rising in a container at a velocity of V o . Then the sensor indicates that the current velocity, V c , of the fluid has decreased by a given factor, k, or V o =V c/k . This decrease in velocity further indicates, by implication, that the fluid is no longer rising in the container and has begun to flow out of the container opening.
[0067] A method to ensure that fluid passing through fluid paths as a component of a clean cycle does not enter a container located below a dispense nozzle may be incorporated. One implementation effectuates this method by incorporating a multi-directional valve which is connected to a drain and to a dispense nozzle. In the event of a clean cycle, the multi-directional nozzle is positioned to ensure that fluid does not flow into the dispense nozzle and instead flows into a drain or re-circulation loop that is part of the clean cycle. For example, before dispensing fluid, a fluid path is filled with hot water at a temperature of approximately 190° F. The fluid path is connected to a normally closed 3-way solenoid valve which controls the flow of fluid either to a dispense nozzle or to the drain. The 3-way solenoid is de-energized and thus all hot fluid entering said valve passes to a fluid path connected to the drain. This ensures that hot fluid does not enter a dispense nozzle. Other implementations may utilize other types of valves or methods to effectuate this method.
[0068] A method to store information on a customer identification device may also be incorporated. In one implementation, the device is a customer's near field radio frequency identification (RFID) tag. In other implementations the device may present itself as a personal communication or entertainment device such as an MP3 player or cell phone. Still other implementations may utilize various other devices capable of passing and storing information.
[0069] In one implementation, information containing information specific to the owner of the device is sent from the vending machine to the device for storage. This information is then stored for later use by a user and/or the vending machine For example, a customer possesses an RFID tag which stores information pertaining to the customer's account balance and beverage preferences. In the event that the customer utilizes the RFID device to identify himself to the vending machine, the information previously described is passed to the vending machine. The information is then utilized to effectuate the personalization and/or beverage vending experience of the customer. Other implementations may utilize stored information for other purposes relating to the customer experience.
[0070] A method which enables customers to create or modify an aspect of their account and/or view information pertaining to the vending machine through electronic means may be incorporated. In one implementation, this is effectuated through the utilization of an electronic application such as an iPhone® application, Android® application and/or other electronic application. For example, a customer uses an iPhone® application to create a custom beverage and add it to his account. The next time this customer identifies himself to an implementation, he may be given the option of dispensing the beverage created on the application. In another example, a customer utilizes an iPhone® application to view locations of the vending machines near that specific customer's location. Other implementations may utilize various other electronic means to effectuate this method. Such other electronic means may include a web site, a social media outlet (e.g., Facebook®) or other information conduit.
[0071] A method to present advertisements to one or more users within a given proximity may also be incorporated. The advertisements may be tailored to a specific user and/or intended for a general audience.
[0072] A method to store customer information in a database may also be incorporated. The database may be utilized by various implementations of the vending machine to share and retain information pertaining to a customer, beverage components, location and various other information that are utilized to effectuate the beverage customization, vending process, and/or customer experience. For example, a database contains information pertaining to volumes of beverage ingredients to ensure that the ingredients are replaced before they empty. In another implementation, the database contains information pertaining to an individual customer's name, beverage history, beverage preferences, affiliations, age, gender, location and other personal attributes. This information is passed from the database to an implementation in the event that a customer identifies himself. The information may be utilized to customize the customer experience and present the customer with known preferences.
[0073] FIG. 10 illustrates a process through which a controller may effectuate the dispense of a customized beverage. In an implementation, the process initializes upon the establishment of communication between all controlling devices 138 . The process continues with the confirmation of successful communion. If successful, the process continues and controller subroutines are activated 139 . Following this, the controller waits to receive data encompassing the information necessary to dispense a beverage 140 . When the information is received, the clean process 144 performs a pre-determined cleaning algorithm which may include the use of hot water to clean lines before dispense. The type of water 141 desired is selected and appropriate dispense volumes are calculated. Then a ratio of the total beverage volume is dispensed and a process determines whether or not syrup was requested. If syrup was requested a pour syrup 145 algorithm controls the dispense of the desired volume of single or multiple syrups. If syrup was not requested or upon completion of the pour syrup process 145 , the remaining beverage volume is dispensed. Following this event the post clean 142 process performs a cleaning algorithm to clean fluid paths and the controller or controllers wait to receive the data necessary to dispense another beverage. At any point in the process described above, a stop command 143 may interrupt the process immediately moving said process to the post clean 142 event.
[0074] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | Methods and apparatus describing a convenience beverage vending machine and its operation are described. An embedded computer interface allows consumers to create their own drinks or choose from a menu of drinks. Drinks are dispensed in a re-usable container. The beverages may be made from hot water, cold water or carbonated water that is mixed with various flavors of syrup, sweeteners and nutritional supplements. Identification may be presented and the computer recognizes the consumer and pulls up that consumer's account to determine funds available and previous drink selections and mixtures. The machine may incorporate an automatic cleaning cycle for both the valves and the dispense area. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to altered carbonyl reductases, genes thereof, vectors containing such genes, and transformants obtained by transformation with such vectors.
BACKGROUND ART
[0002] A method of asymmetrically reducing the carbonyl group of a carbonyl compound using a microorganism or an enzyme is known as one of the methods for producing optically active alcohols useful as starting materials or intermediates for the synthesis of pharmaceuticals or agricultural chemicals. Asymmetric enzymes reducing carbonyl compounds (hereinafter, carbonyl reductases) are useful in the production of various optically active alcohols.
[0003] The asymmetric reduction reactions using carbonyl reductases may suffer from deactivation of the enzyme or inhibition of the enzymatic reaction due to the presence of the substrate or generated products, the acid or alkali used in pH adjustment, the surfactant or organic solvent added to improve the properties of the reaction mixture, or the like. Accordingly, carbonyl reductases capable of avoiding the deactivation of the enzyme or inhibition of the enzyme reaction by the organic solvent or the like provide shortening of the reaction time and improvement in the reaction yield, and are thus more useful in the industrial production of optically active alcohols.
[0004] For example, there have been attempts to acquire organic solvent resistance by random mutation, and Patent Literature 1 and Non Patent Literature 1 describe reductases that are resistant to 2-propanol or dimethyl sulfoxide.
[0005] However, there are only a few enzymes resistant to dimethylformamide, an industrially highly useful organic solvent, and at present no reductase having practical levels of dimethylformamide resistance has been reported.
CITATION LIST
Patent Literature
[0006] Patent Literature 1: JP 2009-225773 A
Non Patent Literature
[0000]
Non Patent Literature 1: Chem Sus Chem, 1, 431-436 (2008)
SUMMARY OF INVENTION
Technical Problem
[0008] Many of pharmaceutical intermediates such as ezetimibe and montelukast have higher solubility in dimethylformamide than in 2-propanol and dimethyl sulfoxide. If a dimethylformamide-resistant enzyme can be used in the production of such a compound, the properties of the reaction mixture can be improved, and thus higher productivity can be expected than in the case of using other organic solvents.
[0009] An object of the present invention is therefore to modify a wild-type enzyme that is less reactive in the presence of dimethylformamide to provide altered carbonyl reductases having better reactivity in the presence of the organic solvent than the wild-type enzyme, and/or to provide transformants producing such reductases.
Solution to Problem
[0010] The present inventors have found altered carbonyl reductases having better reactivity in the presence of an organic solvent than the wild-type enzyme, from among a mutant enzyme library prepared by randomly mutating the wild-type enzyme gene, thereby arriving at completion of the present invention.
[0011] Specifically, the present invention relates to a polypeptide having the following properties (a) to (c):
[0012] (a) the polypeptide has an amino acid sequence having at least 78% sequence identity to the amino acid sequence of SEQ ID NO:1 in the sequence listing;
[0013] (b) the polypeptide reduces 2-pentanone into 2-pentanol; and
[0014] (c) the polypeptide has higher reactivity to a carbonyl compound in the presence of an organic solvent and/or higher thermal stability than a carbonyl reductase having the amino acid sequence of SEQ ID NO:1 in the sequence listing.
[0015] Preferably, the organic solvent is dimethylformamide.
[0016] Preferably, the polypeptide contains an amino acid substitution, relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing, at one or more positions selected from the group consisting of positions 2, 22, 25, 39, 42, 45, 51, 56, 71, 87, 90, 102, 109, 124, 135, 138, 155, 159, 175, 177, 183, 190, 195, 212, 220, 226, 228, 236, 238, 250, 254, 257, 259, 265, 267, 270, 279, 298, 300, 301, and 331.
[0017] Preferably, the amino acid substitution is one or more of the following amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0018] substitutions at position 2 with isoleucine, at position 22 with arginine, at position 25 with phenylalanine, at position 39 with arginine, at position 42 with arginine, at position 45 with aspartic acid, at position 51 with alanine, at position 56 with lysine, at position 71 with asparagine or arginine, at position 87 with isoleucine, at position 90 with glycine, at position 102 with isoleucine, at position 109 with glycine, at position 124 with leucine, at position 135 with alanine, at position 138 with asparagine, at position 155 with leucine or arginine, at position 159 with phenylalanine, at position 175 with aspartic acid, at position 177 with phenylalanine, at position 183 with threonine, at position 190 with serine, at position 195 with leucine, at position 212 with phenylalanine, threonine, or tyrosine, at position 220 with valine, at position 226 with glycine, at position 228 with valine, at position 236 with asparagine, at position 238 with isoleucine, at position 250 with proline, at position 254 with asparagine, at position 257 with serine, at position 259 with glutamic acid, at position 265 with lysine, at position 267 with proline, at position 270 with methionine, at position 279 with arginine, at position 298 with proline, at position 300 with aspartic acid, at position 301 with cysteine, and at position 331 with phenylalanine.
[0019] Preferably, the amino acid substitution is one or more of the following amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0020] substitutions at position 2 with isoleucine, at position 45 with aspartic acid, at position 71 with asparagine or arginine, at position 102 with isoleucine, at position 124 with leucine, at position 175 with aspartic acid, at position 177 with phenylalanine, at position 183 with threonine, at position 195 with leucine, at position 220 with valine, at position 226 with glycine, at position 236 with asparagine, at position 238 with isoleucine, at position 257 with serine, at position 259 with glutamic acid, at position 265 with lysine, at position 267 with proline, at position 270 with methionine, at position 300 with aspartic acid, and at position 301 with cysteine, and the polypeptide has better stability to the organic solvent than the carbonyl reductase having the amino acid sequence of SEQ ID NO:1 in the sequence listing.
[0021] Preferably, the amino acid substitution is selected from the following amino acid substitutions (1) to (35) relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0022] (1) an amino acid substitution at position 71 with asparagine and at position 195 with leucine;
[0023] (2) an amino acid substitution at position 71 with arginine and at position 259 with glutamic acid;
[0024] (3) an amino acid substitution at position 71 with arginine and at position 270 with methionine;
[0025] (4) an amino acid substitution at position 71 with arginine and at position 300 with aspartic acid;
[0026] (5) an amino acid substitution at position 102 with isoleucine and at position 270 with methionine;
[0027] (6) an amino acid substitution at position 177 with phenylalanine and at position 220 with valine;
[0028] (7) an amino acid substitution at position 226 with glycine and at position 270 with methionine;
[0029] (8) an amino acid substitution at position 257 with serine and at position 259 with glutamic acid;
[0030] (9) an amino acid substitution at position 257 with serine and at position 270 with methionine;
[0031] (10) an amino acid substitution at position 259 with glutamic acid and at position 270 with methionine;
[0032] (11) an amino acid substitution at position 259 with glutamic acid and at position 300 with aspartic acid;
[0033] (12) an amino acid substitution at position 267 with proline and at position 270 with methionine;
[0034] (13) an amino acid substitution at position 270 with methionine and at position 300 with aspartic acid;
[0035] (14) an amino acid substitution at position 2 with isoleucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0036] (15) an amino acid substitution at position 45 with aspartic acid, at position 175 with aspartic acid, and at position 183 with threonine;
[0037] (16) an amino acid substitution at position 102 with isoleucine, at position 226 with glycine, and at position 267 with proline;
[0038] (17) an amino acid substitution at position 124 with leucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0039] (18) an amino acid substitution at position 177 with phenylalanine, at position 259 with glutamic acid, and at position 270 with methionine;
[0040] (19) an amino acid substitution at position 220 with valine, at position 259 with glutamic acid, and at position 270 with methionine;
[0041] (20) an amino acid substitution at position 236 with asparagine, at position 259 with glutamic acid, and at position 270 with methionine;
[0042] (21) an amino acid substitution at position 238 with isoleucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0043] (22) an amino acid substitution at position 257 with serine, at position 259 with glutamic acid, and at position 270 with methionine;
[0044] (23) an amino acid substitution at position 257 with serine, at position 259 with glutamic acid, and at position 300 with aspartic acid;
[0045] (24) an amino acid substitution at position 259 with glutamic acid, at position 265 with lysine, and at position 270 with methionine;
[0046] (25) an amino acid substitution at position 259 with glutamic acid, at position 270 with methionine, and at position 300 with aspartic acid;
[0047] (26) an amino acid substitution at position 259 with glutamic acid, at position 270 with methionine, and at position 301 with cysteine;
[0048] (27) an amino acid substitution at position 2 with isoleucine and at position 238 with isoleucine;
[0049] (28) an amino acid substitution at position 71 with asparagine and at position 195 with leucine;
[0050] (29) an amino acid substitution at position 109 with glycine and at position 331 with phenylalanine;
[0051] (30) an amino acid substitution at position 124 with leucine and at position 236 with asparagine;
[0052] (31) an amino acid substitution at position 159 with phenylalanine and at position 259 with glutamic acid;
[0053] (32) an amino acid substitution at position 42 with arginine, at position 155 with arginine, and at position 279 with arginine;
[0054] (33) an amino acid substitution at position 45 with aspartic acid, at position 175 with aspartic acid, and at position 183 with threonine;
[0055] (34) an amino acid substitution at position 155 with leucine, at position 250 with proline, and at position 298 with proline; and
[0056] (35) an amino acid substitution at position 56 with lysine, at position 138 with asparagine, at position 190 with serine, and at position 254 with asparagine.
[0057] Preferably, the amino acid substitution is one or more of the following amino acid substitutions:
[0058] substitutions at position 22 with arginine, at position 39 with arginine, at position 51 with alanine, at position 87 with isoleucine, at position 90 with glycine, at position 259 with glutamic acid, and at position 270 with methionine, and
[0059] the polypeptide has better resistance to reaction inhibition by the organic solvent than the carbonyl reductase having the amino acid sequence of SEQ ID NO:1 in the sequence listing.
[0060] Preferably, the amino acid substitution is one or more of the following amino acid substitutions (1) to (7) relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0061] (1) an amino acid substitution at position 22 with arginine;
[0062] (2) an amino acid substitution at position 22 with arginine and at position 87 with isoleucine;
[0063] (3) an amino acid substitution at position 39 with arginine;
[0064] (4) an amino acid substitution at position 39 with arginine and at position 51 with alanine;
[0065] (5) an amino acid substitution at position 51 with alanine;
[0066] (6) an amino acid substitution at position 87 with isoleucine; and
[0067] (7) an amino acid substitution at position 90 with glycine.
[0068] The present invention also relates to a polynucleotide encoding the polypeptide.
[0069] The present invention also relates to a vector containing the polynucleotide.
[0070] Preferably, the vector further contains a polynucleotide that encodes a polypeptide capable of regenerating a reduced coenzyme.
[0071] Preferably, the polypeptide capable of regenerating a reduced coenzyme is glucose dehydrogenase.
[0072] The present invention also relates to a transformant obtained by transformation of a host cell with the vector.
[0073] Preferably, the host cell is Escherichia coli.
[0074] The present invention also relates to a method for producing an alcohol compound, including allowing the polypeptide, or the transformant and/or a treated product thereof to act on a carbonyl compound.
[0075] Preferably, the carbonyl compound is an unsymmetrical ketone, and the alcohol compound is an optically active alcohol.
[0076] Preferably, the carbonyl compound is an unsymmetrical ketone represented by the following formula (1):
[0000]
[0000] wherein R 1 and R 2 are each a hydrogen atom, a halogen atom, an optionally substituted alkyl group, an optionally substituted aralkyl group, an optionally substituted aryl group, an optionally substituted alkoxy group, an amino group, or a nitro group, or R 1 and R 2 may be joined together to form a ring, provided that R 1 and R 2 have different structures, and the alcohol compound is an optically active alcohol represented by the following formula (2):
[0000]
[0000] wherein R 1 and R 2 are the same as described above, and * represents an asymmetric carbon atom.
Advantageous Effects of Invention
[0077] The present invention provides altered carbonyl reductases having better reactivity in the presence of an organic solvent than the wild-type enzyme, genes thereof, vectors containing such genes, transformants obtained by transformation with such vectors, and methods for producing treated products of such transformants.
DESCRIPTION OF EMBODIMENTS
[0078] The polypeptide of the present invention characteristically has the following properties (a) to (c):
[0079] (a) the polypeptide has an amino acid sequence having at least 78% sequence identity to the amino acid sequence of SEQ ID NO:1 in the sequence listing;
[0080] (b) the polypeptide reduces 2-pentanone into 2-pentanol; and
[0081] (c) the polypeptide has higher reactivity to a carbonyl compound in the presence of an organic solvent and/or higher thermal stability than a carbonyl reductase having the amino acid sequence of SEQ ID NO:1 in the sequence listing.
[Nomenclature for Description of Mutations]
[0082] In the present specification, amino acids, peptides, and proteins are represented using abbreviations, as indicated below, approved by the IUPAC-IUB Commission on Biochemical Nomenclature (CBN). Further, the left and right ends of an amino acid sequence of a peptide or protein are, respectively, the N- and C-termini unless otherwise specified. For ease of reference, the following commonly used nomenclatures are adapted. One is the following nomenclature: “original amino acid; position; substituted amino acid”. For example, the substitution of tyrosine at position 64 with aspartic acid is designated as “Y64D”. Multiple mutations are separated by hyphens “-”. For example, “S41A-Y64D” represents mutations at positions 41 and 64 substituting serine with alanine and tyrosine with aspartic acid, respectively.
ABBREVIATIONS FOR AMINO ACIDS
[0083] A=Ala=alanine, C=Cys=cysteine,
D=Asp=aspartic acid, E=Glu=glutamic acid,
F=Phe=phenylalanine, G=Gly=glycine,
H=His=histidine, I=Ile=isoleucine,
K=Lys=lysine, L=Leu=leucine,
M=Met=methionine, N=Asn=asparagine,
P=Pro=proline, Q=Gln=glutamine,
R=Arg=arginine, S=Ser=serine,
T=Thr=threonine, V=Val=valine,
W=Trp=tryptophan, Y=Tyr=tyrosine
[Sequence Identity]
[0084] The “sequence identity” for polypeptides and polynucleotides refers to the value obtained by optimally aligning two polypeptides or polynucleotides to be compared, counting the number of positions of amino acids or nucleic acid bases (e.g., A, T, C, G, U or I) matched between both sequences, dividing the counted number by the total number of the compared bases, and multiplying the result of the division by 100.
[0085] The sequence identity can be calculated, for example, using the following sequence analysis tools: GCG Wisconsin Package (University of Wisconsin), the ExPASy World Wide Web molecular biology server (Swiss Institute of Bioinformatics), BLAST (U.S. National Center for Biotechnology Information), and GENETYX (GENETYX Corporation).
[0086] In the present invention, the wild-type enzyme before mutation is a polypeptide that has 335 amino acid residues represented by SEQ ID NO:1 in the sequence listing and is capable of reducing 2-pentanone into 2-pentanol.
[0087] Although the source of the polypeptide is not limited, the polypeptide is preferably a carbonyl reductase derived from a microorganism belonging to the family Saccharomycetaceae, more preferably the genus Vanderwaltozyma , still more preferably a microorganism belonging to the species Vanderwaltozyma polyspora , and particularly preferably from Vanderwaltozyma polyspora NBRC 0996. The microorganisms are available from the Incorporated Administrative Agency, National Institute of Technology and Evaluation, Department of Biotechnology, Biological Resource Center (NBRC: 2-5-8 Kazusakamatari, Kisarazu-shi, Chiba, 292-0818 JAPAN).
[0088] The wild-type enzyme in the present invention is encoded by the polynucleotide of SEQ ID NO:2 in the sequence listing. For example, the wild-type enzyme gene can be obtained from microorganisms belonging to the family Saccharomycetaceae, preferably the genus Vanderwaltozyma , more preferably the species Vanderwaltozyma polyspora , and still more preferably Vanderwaltozyma polyspora NBRC 0996 using common genetic engineering techniques described in, for example, Molecular Cloning 2nd Edition (Joseph Sambrook, Cold Spring Harbor Laboratory Press (1989)).
[0089] Specifically, the wild-type enzyme gene can be prepared by performing PCR using the genomic DNA of Vanderwaltozyma polyspora NBRC 0996 as described in (Reference Example 1) to amplify a polynucleotide encoding the amino acid sequence of SEQ ID NO:1 or the polynucleotide of SEQ ID NO:2.
[0090] The polypeptide of the present invention may be obtained by altering the amino acid sequence of SEQ ID NO: 1.
[0091] Examples of alterations of the amino acid sequence of SEQ ID NO:1 include substitutions, additions, insertions, and deletions. The sequence may include only one type of alteration (e.g. substitution) or two or more types of alterations (e.g. substitution and insertion). The term “amino acids” means, for example, 40, preferably 20, more preferably 10, and still more preferably 8, 5, 4, 3, or 2 amino acids.
[0092] Moreover, the sequence identity between the altered amino acid sequence and the amino acid sequence of SEQ ID NO:1 is at least 85%, preferably at least 90%, more preferably at least 92%, still more preferably at least 95%, at least 97%, at least 98%, at least 98.5%, or at least 99%.
[0093] Although a substitution, insertion, deletion, or addition of an amino acid may be introduced at any position in the amino acid sequence of SEQ ID NO:1 in the sequence listing, the polypeptide preferably contains an amino acid substitutions, relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing, at one or more positions selected from positions 2, 22, 25, 39, 42, 45, 51, 56, 71, 87, 90, 102, 109, 124, 135, 138, 155, 159, 175, 177, 183, 190, 195, 212, 220, 226, 228, 236, 238, 250, 254, 257, 259, 265, 267, 270, 279, 298, 300, 301, and 331.
[0094] More preferably, the polypeptide contains one or more of the following amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0095] substitutions at position 2 with isoleucine, at position 22 with arginine, at position 25 with phenylalanine, at position 39 with arginine, at position 42 with arginine, at position 45 with aspartic acid, at position 51 with alanine, at position 56 with lysine, at position 71 with asparagine or arginine, at position 87 with isoleucine, at position 90 with glycine, at position 102 with isoleucine, at position 109 with glycine, at position 124 with leucine, at position 135 with alanine, at position 138 with asparagine, at position 155 with leucine or arginine, at position 159 with phenylalanine, at position 175 with aspartic acid, at position 177 with phenylalanine, at position 183 with threonine, at position 190 with serine, at position 195 with leucine, at position 212 with phenylalanine, threonine, or tyrosine, at position 220 with valine, at position 226 with glycine, at position 228 with valine, at position 236 with asparagine, at position 238 with isoleucine, at position 250 with proline, at position 254 with asparagine, at position 257 with serine, at position 259 with glutamic acid, at position 265 with lysine, at position 267 with proline, at position 270 with methionine, at position 279 with arginine, at position 298 with proline, at position 300 with aspartic acid, at position 301 with cysteine, and at position 331 with phenylalanine.
[0096] Moreover, from the standpoint of enhancing the stability to an organic solvent, the polypeptide of the present invention preferably contains one or more of the following amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0097] substitutions at position 2 with isoleucine, at position 45 with aspartic acid, at position 71 with asparagine or arginine, at position 102 with isoleucine, at position 124 with leucine, at position 175 with aspartic acid, at position 177 with phenylalanine, at position 183 with threonine, at position 195 with leucine, at position 220 with valine, at position 226 with glycine, at position 236 with asparagine, at position 238 with isoleucine, at position 257 with serine, at position 259 with glutamic acid, at position 265 with lysine, at position 267 with proline, at position 270 with methionine, at position 300 with aspartic acid, and at position 301 with cysteine.
[0098] Further, the polypeptide of the present invention more preferably contains an amino acid substitution selected from the following amino acid substitutions (1) to (35) relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0099] (1) an amino acid substitution at position 71 with asparagine and at position 195 with leucine;
[0100] (2) an amino acid substitution at position 71 with arginine and at position 259 with glutamic acid;
[0101] (3) an amino acid substitution at position 71 with arginine and at position 270 with methionine;
[0102] (4) an amino acid substitution at position 71 with arginine and at position 300 with aspartic acid;
[0103] (5) an amino acid substitution at position 102 with isoleucine and at position 270 with methionine;
[0104] (6) an amino acid substitution at position 177 with phenylalanine and at position 220 with valine;
[0105] (7) an amino acid substitution at position 226 with glycine and at position 270 with methionine;
[0106] (8) an amino acid substitution at position 257 with serine and at position 259 with glutamic acid;
[0107] (9) an amino acid substitution at position 257 with serine and at position 270 with methionine;
[0108] (10) an amino acid substitution at position 259 with glutamic acid and at position 270 with methionine;
[0109] (11) an amino acid substitution at position 259 with glutamic acid and at position 300 with aspartic acid;
[0110] (12) an amino acid substitution at position 267 with proline and at position 270 with methionine;
[0111] (13) an amino acid substitution at position 270 with methionine and at position 300 with aspartic acid;
[0112] (14) an amino acid substitution at position 2 with isoleucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0113] (15) an amino acid substitution at position 45 with aspartic acid, at position 175 with aspartic acid, and at position 183 with threonine;
[0114] (16) an amino acid substitution at position 102 with isoleucine, at position 226 with glycine, and at position 267 with proline;
[0115] (17) an amino acid substitution at position 124 with leucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0116] (18) an amino acid substitution at position 177 with phenylalanine, at position 259 with glutamic acid, and at position 270 with methionine;
[0117] (19) an amino acid substitution at position 220 with valine, at position 259 with glutamic acid, and at position 270 with methionine;
[0118] (20) an amino acid substitution at position 236 with asparagine, at position 259 with glutamic acid, and at position 270 with methionine;
[0119] (21) an amino acid substitution at position 238 with isoleucine, at position 259 with glutamic acid, and at position 270 with methionine;
[0120] (22) an amino acid substitution at position 257 with serine, at position 259 with glutamic acid, and at position 270 with methionine;
[0121] (23) an amino acid substitution at position 257 with serine, at position 259 with glutamic acid, and at position 300 with aspartic acid;
[0122] (24) an amino acid substitution at position 259 with glutamic acid, at position 265 with lysine, and at position 270 with methionine;
[0123] (25) an amino acid substitution at position 259 with glutamic acid, at position 270 with methionine, and at position 300 with aspartic acid;
[0124] (26) an amino acid substitution at position 259 with glutamic acid, at position 270 with methionine, and at position 301 with cysteine;
[0125] (27) an amino acid substitution at position 2 with isoleucine and at position 238 with isoleucine;
[0126] (28) an amino acid substitution at position 71 with asparagine and at position 195 with leucine;
[0127] (29) an amino acid substitution at position 109 with glycine and at position 331 with phenylalanine;
[0128] (30) an amino acid substitution at position 124 with leucine and at position 236 with asparagine;
[0129] (31) an amino acid substitution at position 159 with phenylalanine and at position 259 with glutamic acid;
[0130] (32) an amino acid substitution at position 42 with arginine, at position 155 with arginine, and at position 279 with arginine;
[0131] (33) an amino acid substitution at position 45 with aspartic acid, at position 175 with aspartic acid, and at position 183 with threonine;
[0132] (34) an amino acid substitution at position 155 with leucine, at position 250 with proline, and at position 298 with proline; and
[0133] (35) an amino acid substitution at position 56 with lysine, at position 138 with asparagine, at position 190 with serine, and at position 254 with asparagine.
[0134] Moreover, from the standpoint of enhancing the resistance to the reaction inhibition by an organic solvent, the polypeptide of the present invention preferably contains one or more of the following amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0135] substitutions at position 22 with arginine, at position 39 with arginine, at position 51 with alanine, at position 87 with isoleucine, at position 90 with glycine, at position 259 with glutamic acid, and at position 270 with methionine.
[0136] Further, the polypeptide more preferably contains any of the following amino acid substitutions (1) to (7) relative to the amino acid sequence of SEQ ID NO:1 in the sequence listing:
[0137] (1) an amino acid substitution at position 22 with arginine;
[0138] (2) an amino acid substitution at position 22 with arginine and at position 87 with isoleucine;
[0139] (3) an amino acid substitution at position 39 with arginine;
[0140] (4) an amino acid substitution at position 39 with arginine and at position 51 with alanine;
[0141] (5) an amino acid substitution at position 51 with alanine;
[0142] (6) an amino acid substitution at position 87 with isoleucine; and
[0143] (7) an amino acid substitution at position 90 with glycine.
[0144] The organic solvent is, for example, preferably dimethylformamide, dimethyl sulfoxide, 2-propanol, ethyl acetate, toluene, methanol, ethanol, n-butanol, hexane, acetonitrile, propyl acetate, butyl acetate, acetone, dimethoxypropane, t-methyl butyl ether, diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran, dimethylacetamide, diglyme, ethylene glycol, dimethoxyethane, carbon tetrachloride, methylene chloride, ethylcellosolve, cellosolve acetate, 1,3-dimethyl-2-imidazolidinone, or hexamethylphosphoric triamide, and is more preferably dimethylformamide, dimethyl sulfoxide, 2-propanol, ethyl acetate, toluene, butyl acetate, or 1,3-dimethyl-2-imidazolidinone, and still more preferably dimethylformamide, dimethyl sulfoxide, or 2-propanol.
[0145] The enzyme of the present invention has high reactivity to a carbonyl compound even in the presence of an organic solvent. The term “in the presence of an organic solvent” may mean a miscible mixture of a liquid containing the enzyme and an organic solvent, or a heterogeneous mixture of a liquid containing the enzyme and an organic solvent, which may be mixed by physical stirring.
[0146] The “enzyme having high reactivity in the presence of an organic solvent” means that the enzyme has higher activity for 2-pentanone reduction in the presence of an organic solvent or after it is held in the presence of the organic solvent for a certain period of time than the wild-type enzyme of SEQ ID NO:1 in the sequence listing. It is preferably an enzyme having high stability to an organic solvent or having high resistance to the reaction inhibition by an organic solvent.
[0147] What is meant by “having better stability to an organic solvent” is that, specifically, when the residual activity toward 2-pentanone or 2-hexanone of the enzyme after incubation with an organic solvent is measured by the method described later in Example 4 or 5, the enzyme has a higher residual′ activity than the wild-type enzyme by at least 1%, preferably by at least 5%, more preferably by at least 10%, and still more preferably by at least 20%.
[0148] Moreover, what is meant by “having better resistance to the reaction inhibition by an organic solvent” is that, specifically, when the relative activity toward 2-hexanone in the presence of an organic solvent is measured by the method described later in Example 31, the enzyme has a higher relative activity than the wild-type enzyme by at least 1%, preferably by at least 5%, more preferably by at least 7%, still more preferably by at least 10%, and most preferably by at least 20%.
[0149] The stability of the enzyme to an organic solvent can be evaluated, for example, as follows.
[Method for Evaluation of Stability of Enzyme to Organic Solvent]
[0150] A buffer (preferably a 0.01 to 1M phosphate buffer with a pH of 5 to 8) containing an organic solvent with a given concentration (e.g. 0.5% to 50%) is added to a cell-free extract containing the enzyme, and the mixture is incubated at a given temperature (e.g. 4 to 40° C.). If the mixture of the organic solvent and the buffer is heterogeneous, the resultant mixture is incubated with shaking or stirring. A sample without the organic solvent and a treated mixture with the organic solvent are each sampled after 0.1 to 48 hours, and then diluted with a 0.1M potassium phosphate aqueous solution (pH 7.0). Using the diluted solutions, the activity of the enzyme is measured as described in [Method for evaluation of carbonyl compound reducing ability] below. The relative activity can be calculated by the following equation.
[0000] Relative activity (%)=[enzyme activity in the presence of solvent]/[enzyme activity in the absence of solvent]×100
[0151] The altered carbonyl reductase having better stability to an organic solvent than the carbonyl reductase of SEQ ID NO:1 in the sequence listing refers to an enzyme having a higher residual activity as evaluated as above than the wild-type by at least 1%, preferably by at least 5%, more preferably by at least 10%, and most preferably by at least 20%.
[Method for Evaluation of Carbonyl Compound Reducing Ability]
[0152] The progress of the reduction reaction can be easily evaluated by reacting at 30° C. a 100 mM potassium phosphate buffer (pH 6.5) with a reaction mixture containing 0.25 mM NADPH or reduced nicotinamide adenine dinucleotide (hereinafter, NADH), 1 to 50 mM of a carbonyl compound to be evaluated for reduction activity (e.g., 2-pentanone, 2-hexanone, 2,3-butanedione), and the polypeptide of the present invention; and measuring the decrease in the absorbance at a wavelength of 340 nm associated with a reduction in the amount of NADPH or NADH. If the absorbance decreases, the polypeptide of the present invention is determined to have an ability to reduce the target carbonyl compound. It is considered that a higher rate of decrease in absorbance indicates a higher ability to reduce the target carbonyl compound. The reducing ability of the polypeptide can also be expressed numerically, and 1 U of reduction activity is defined as the amount of enzyme catalyzing the consumption of 1 μmol of NADPH per minute.
[0153] Moreover, the resistance to the reaction inhibition by an organic solvent can be determined, for example, as follows.
[Method 1 for Evaluation of Resistance to Reaction Inhibition by Organic Solvent]
[0154] The conversion ratio from a carbonyl compound to an alcohol is determined by reacting a 100 mM potassium phosphate buffer (pH 6.5) with a reaction mixture containing 3 mM NADPH or reduced nicotinamide adenine dinucleotide (hereinafter, NADH), 1% of a carbonyl compound to be evaluated for reduction activity (e.g., 2-pentanone, 2-hexanone, 2,3-butadione), 0.01 to 60% (v/v) of an organic solvent or no organic solvent, and the polypeptide of the present invention at 30° C. for 0.01 to 5 hours; and analyzing the reaction product by, for example, gas chromatography.
[0155] The relative activity can be calculated by the following equation.
[0000] Relative activity (%)=[conversion ratio in the presence of organic solvent]/[conversion ratio in the absence of organic solvent]×100
[0156] As used herein, the altered carbonyl reductase having better resistance to the reaction inhibition by an organic solvent than the carbonyl reductase of SEQ ID NO:1 in the sequence listing means that it has a higher residual activity as evaluated as above than the wild-type by at least 1%, preferably by at least 5%, more preferably by at least 7%, still more preferably by at least 10%, and most preferably by at least 20%. Also, the enzyme of the present invention has higher thermal stability than the carbonyl reductase of SEQ ID NO:1 in the sequence listing.
[0157] The altered carbonyl reductase of the present invention can be searched as follows.
[0158] DNA fragments in which one or more base sequence substitutions, insertions, deletions, and/or additions are introduced into the base sequence (wild-type enzyme gene) of SEQ ID NO:2 in the sequence listing can be obtained by using error-prone PCR (Leung et al., Technique 1, 11-15 (1989)) or a kit based on the same principle. For example, using the wild-type enzyme gene as a template, T at position 240 can be substituted by C by usual techniques, so that the Nde I recognition site can be destroyed without a change in the amino acid sequence of the wild-type enzyme (SEQ ID NO:3 in the sequence listing). Using the resulting sequence as a template, a pair of primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing) and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing), and Diversify PCR Random Mutagenesis Kit (from Clontech), multiple kinds of double-stranded DNAs (mutant enzyme genes) can be obtained in which a mutation is introduced randomly into the full length of the gene encoding the wild-type enzyme, a Nde I recognition site is added to the initiation codon, and a Sal I recognition site is added immediately after the termination codon. Amplified fragments of the DNAs are digested with Nde I and Sal I, and then inserted between the Nde I recognition site and the Sal I recognition site downstream from the lac promoter in the plasmid pUCN18 (a plasmid obtained by changing T at position 185 in pUC18 (from Takara Bio, Inc.) to A to destroy the Nde I site, and further changing GC at positions 471 and 472 to TG to introduce a new Nde I site by PCR). The resulting plasmid is used to transform Escherichia coli HB101 (hereinafter, E. coli HB101). The transformed E. coli is applied to an LB medium plate containing 100 μg/mL ampicillin to obtain a single colony of E. coli . Moreover, using mutant enzyme genes prepared as above in place of the wild-type gene, mutations can be further introduced by the same procedures to prepare a mutant enzyme library.
[0159] From the library, altered carbonyl reductases according to the present invention can be selected. The selection method is not particularly limited, but the following method is preferred.
[Selection Method 1 by Plate Evaluation of Enzyme Having Better Stability to Organic Solvent]
[0160] Recombinant bacteria from the mutant enzyme library and a recombinant bacterium producing the wild-type enzyme (e.g. E. coli HB101 (pNKP) in Reference Example 3) are each inoculated into an appropriate medium (e.g. 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin) and cultured with shaking at 37° C. for 24 hours. The cells in the obtained culture media are disrupted and centrifuged, followed by removing the precipitate to obtain a cell-free extract. A buffer (preferably a 0.01 to 1M phosphate buffer with a pH of 5 to 8) containing an organic solvent having an appropriate concentration (preferably dimethylformamide having a final concentration of 10 to 30%) is added to the cell-free extracts containing the respective enzymes, followed by incubation at an appropriate temperature (e.g. 4 to 40° C.). After incubation for about 0.1 to 48 hours, the treated cell-free extracts are dispensed into a 96-well plate (from AGC Techno Glass Co., Ltd.). A phosphate buffer (pH 5 to 7) containing NADPH (preferably 1.5 mM) and a carbonyl compound (preferably 10 mM 2,3-butanedione) is added and they are reacted at 10° C. to 40° C. NADPH fluorescence is measured with time using an UV transilluminator and recording system FAS-III (from Toyobo Co., Ltd.). At this time, an enzyme solution in which the reaction does not proceed shows the remaining NADPH fluorescence, while a cell-free extract in which the reaction has proceeded shows reduced fluorescence with the decrease in NADPH. Enzymes which show quenched fluorescence in a short time compared to the wild-type enzyme (control) are selected as enzymes having better stability to a chloride. Plasmids are extracted from the culture media containing the selected enzymes, and the base sequence of the altered carbonyl reductase genes is determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites can be identified.
[Selection Method 2 by Plate Evaluation of Enzyme Having Better Stability to Organic Solvent]
[0161] Recombinant bacteria from the mutant enzyme library and a bacterium producing the wild-type enzyme (e.g. E. coli HB101 (pNKP) in Reference Example 3) are each inoculated into an appropriate agar medium (e.g. an LB medium plate containing 100 μg/mL ampicillin) and cultured at 30° C. for 24 hours. The thus obtained colonies are transferred to a nylon membrane (Biodyne A, 0.45 μm), which is then immersed in a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer) containing an organic solvent (preferably 40% dimethylformamide) for 0.1 minutes to 24 hours. This buffer has preferably been heated to 40° C. to 80° C. Then the nylon membrane is immersed in a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer) containing NADP + (preferably 1 mM), nitroblue tetrazolium (preferably 200 μM), 1-methoxy-5-methylphenazinium methylsulfate (preferably 10 μM), and 2-propanol (e.g. 0.1 to 50%) at an appropriate temperature (e.g. 4 to 40° C.) for 0.1 minutes to 24 hours. Thereafter, the nylon membrane is washed with distilled water, whereby four-color stained colonies can be selected as recombinant bacteria with altered carbonyl reductases having better stability to an organic solvent.
[0162] These recombinant bacteria are each inoculated into an appropriate liquid medium (e.g. 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin) and cultured with shaking at 37° C. for 20 hours. The cells in the obtained culture media are collected by centrifugation and suspended in a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer). The suspension is disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract.
[0163] A mixture of a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer) and dimethylformamide is added to the cell-free extracts to give a final concentration of dimethylformamide of preferably 0.1 to 60%, followed by heating (preferably at 40° C. to 80° C. for 0.1 minutes to 24 hours) and then cooling with ice. The cooled mixtures are each mixed with a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer) containing NADP + (preferably 1 mM), nitroblue tetrazolium (preferably 200 μM), 1-methoxy-5-methylphenazinium methylsulfate (preferably 10 μM), and 2-propanol (e.g. 0.1 to 50%), and then transferred to a 96-well plate (from AGC Techno Glass Co., Ltd.) and observed. Stained samples can be selected as altered carbonyl reductases having better stability to an organic solvent.
[0164] Plasmids are extracted from the culture media of the selected recombinant bacteria, and the base sequence of the mutant RKP genes is determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites can be identified.
[Selection Method by Plate Evaluation of Enzyme Having Better Resistance to Reaction Inhibition by Organic Solvent]
[0165] Recombinant bacteria from the mutant enzyme library and a bacterium producing the wild-type enzyme (e.g. E. coli HB101 (pNKP) in Reference Example 3) are each inoculated into an appropriate agar medium (e.g. an LB medium plate containing 100 μg/mL ampicillin) and cultured at 30° C. for 24 hours. The thus obtained colonies are transferred to a nylon membrane (Biodyne A, 0.45 μm), which is then immersed into a buffer (preferably 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer) containing NADP + (preferably 1 mM), nitroblue tetrazolium (preferably 200 μM), 1-methoxy-5-methylphenazinium methylsulfate (preferably 10 μM), 2-propanol (e.g. 0.1 to 50%), and an organic solvent (preferably 0.1 to 80% dimethylformamide) at an appropriate temperature (e.g., 4 to 40° C.) for 0.1 minutes to 10 hours. Thereafter, the nylon membrane is washed with distilled water, and then stained colonies can be selected as candidates for recombinant bacteria with altered carbonyl reductases having better resistance to the reaction inhibition by an organic solvent.
[0166] These recombinant bacteria are each inoculated into an appropriate liquid medium (e.g. 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin) and cultured with shaking at 37° C. for 20 hours. The cells in the obtained culture media are disrupted and centrifuged, followed by removing the precipitate to obtain a cell-free extract. The cell-free extracts are each mixed with a buffer (preferably 0.1M phosphate buffer (pH 6.5)) containing NADPH (preferably 0.625M), a carbonyl compound (preferably 10 mM 2,3-butanedione), and an organic solvent (preferably 0.1 to 80% dimethylformamide) dissolved therein. The mixtures are dispensed into a 96-well plate (from Asahi Techno Glass), and NADPH fluorescence is measured with time using a Benchmark Plus microplate spectrophotometer (from BIO-RAD). An enzyme solution in which the reaction does not proceed shows the remaining NADPH fluorescence, while a cell-free extract in which the reaction has proceeded shows reduced fluorescence with the decrease in NADPH. Samples in which NADPH is consumed due to the reduction of the carbonyl compound and thus fluorescence is quenched in a short time are selected as recombinant bacteria with altered carbonyl reductases having even better resistance to the reaction inhibition by an organic solvent.
[0167] Plasmids are extracted from the culture media of the selected recombinant bacteria, and the base sequence of the mutant RKP genes is determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites can be identified.
[0168] Altered carbonyl reductases having combined properties of multiple mutations can be produced using site-directed mutagenesis by combining multiple mutations which can enhance reactivity to a carbonyl compound in the presence of an organic solvent and/or thermal stability.
[0169] The polynucleotide of the present invention may be any polynucleotide encoding the polypeptide of the present invention. Examples include a polynucleotide having a base sequence encoding the wild-type enzyme of SEQ ID NO:2 in the sequence listing, and polypeptides obtainable by modifying the polynucleotide.
[0170] The wild-type enzyme gene can be modified by known methods described in Current Protocols in Molecular Biology (Frederick M. Ausubel, Greene Publishing Associates and Wiley-Interscience (1989)) and the like. Specifically, polynucleotides in which the amino acid sequence of the wild-type enzyme is altered can be produced by substitution, addition, insertion, or deletion of one or more bases (e.g., 40, preferably 20, more preferably 10, still more preferably 5, 4, 3, or 2 bases) of the wild-type enzyme gene. Examples include mutagenesis methods based on PCR such as error-prone PCR (Leung et al., Technique 1, 11-15 (1989)), and methods using commercially available kits such as Diversify PCR Random Mutagenesis Kit (from Clontech), Transformer Mutagenesis Kit (from Clontech), EXOIII/Mung Bean Deletion Kit (from Stratagene), or QuickChange Site Directed Mutagenesis Kit (from Stratagene).
[0171] When a polynucleotide is produced by site-directed mutagenesis, the site-directed mutagenesis is carried out by, for example, the methods reported by Olfert Landt et al. (Gene, 96, 125-128 (1990)); Smith et al. (Genetic Engineering, 3, 1, Setlow, J. Plenum Press); Vlasuk et al. (Experimental Manipulation of Gene Expression, Inouye, M. Academic Press); and Hos. N. Hunt et al. (Gene, 77, 51 (1989)), or using commercially available kits such as QuikChange II Kit (from Stratagene). In the case of mutation at two positions, the target polynucleotide of the present invention can be obtained by repeating a method based on any of the above methods twice. Also in the case that the amino acids at other positions are substituted by other amino acids, the target polynucleotide of the present invention can be obtained in this manner.
[0172] The polynucleotide encoding the polypeptide of the present invention is preferably a polynucleotide that encodes a polypeptide having activity in reducing 2-pentanone to 2-pentanol and having higher reactivity to a carbonyl compound in the presence of an organic solvent than a carbonyl reductase having the amino acid sequence of SEQ ID NO:1 in the sequence listing, and that hybridizes under stringent conditions with a polynucleotide containing a base sequence complementary to a polynucleotide having the base sequence of SEQ ID NO:2 in the sequence listing.
[0173] The “polynucleotide that hybridizes under stringent conditions with a polynucleotide having a base sequence complementary to the polynucleotide of SEQ ID NO:2 in the sequence listing” means a polynucleotide obtained using as a probe a polynucleotide having a base sequence complementary to the base sequence of SEQ ID NO:2 in the sequence listing by colony hybridization, plaque hybridization, Southern hybridization or the like under stringent conditions.
[0174] The hybridization can be carried out in accordance with the methods described in Molecular Cloning 2nd Edition (Joseph Sambrook, Cold Spring Harbor Laboratory Press (1989)) and the like. The “polynucleotide that hybridizes under stringent conditions” may be, for example, a DNA obtained by hybridizing the polynucleotide derived from a colony or plaque fixed on a filter at 65° C. in the presence of 0.7 to 1.0M sodium chloride, and then washing the filter at 65° C. with 3×SSC solution (1 SSC solution contains 150 mM sodium chloride and 15 mM sodium citrate). The polynucleotide is more preferably obtained by washing with 1 SSC solution at 65° C., still more preferably with 0.7×SSC solution at 65° C., and even more preferably with 0.5×, 0.45×, 0.25×, 0.2×, or 0.15×SSC solution at 65° C.
[0175] The hybridization conditions are not particularly limited to those described above. Several factors, such as temperature and salt concentration, are thought to affect the stringency of hybridization, and those skilled in the art can select appropriate conditions for such factors to achieve optimal stringency.
[0176] The polynucleotide hybridizable under the above conditions may be, for example, preferably a polynucleotide having at least 78%, more preferably at least 84%, still more preferably at least 87%, and even more preferably at least 89%, at least 90%, at least 94%, at least 95%, or at least 97% sequence identity to the polynucleotide of SEQ ID NO:2. Any polynucleotide encoding a polypeptide that has the properties of the polypeptide of the present invention is included in the above polynucleotide.
[0177] A polypeptide-expressing vector can be constructed by inserting the polynucleotide encoding the polypeptide of the present invention into an expression vector.
[0178] The expression vector used in the above process may be any vector that can express the polypeptide encoded by the polynucleotide in an appropriate host organism. Examples of such vectors include plasmid vectors, phage vectors, and cosmid vectors. Also, shuttle vectors that enable gene exchange to occur between one host strain and another can also be used.
[0179] Such a vector for Escherichia coli , for example, usually contains a regulatory element such as a lacUV5 promoter, a trp promoter, a trc promoter, a tac promoter, a lpp promoter, a tufB promoter, a recA promoter, or a pL promoter and is suitable as an expression vector containing an expression unit operably linked to the DNA of the present invention. Examples include pUCN18 (see Reference Example 2), pSTV28 (from Takara Bio Inc.), and pUCNT (WO 94/03613).
[0180] The term “regulatory element” as used herein refers to a base sequence containing a functional promoter and any related transcription element(s) (e.g., an enhancer, CCAAT box, TATA box, SPI site, or the like).
[0181] The term “operably linked” as used herein means that various regulatory elements (e.g., a promoter, enhancer, and the like) regulating the expression of the gene are linked to the gene such that they can work in host cells. It is well known to ones having ordinary skill in the art that the type and kind of regulatory element may vary depending on the host.
[0182] Vectors, promoters and the like which can be used in various organisms are described in detail in “Biseibutsugaku Kiso Koza (Basic Courses in Microbiology) (8, Tadahiko ANDO, Kyoritsu Shuppan, 1987)”, and the like.
[0183] The vector may further contain a polynucleotide that encodes a polypeptide capable of regenerating a reduced coenzyme. Examples of the polypeptide capable of regenerating a reduced coenzyme include glucose dehydrogenase.
[0184] A transformant can be obtained by transforming a host cell with the vector. The transformant may also be obtained by introducing the polynucleotide that encodes the polypeptide of the present invention into the chromosome.
[0185] The host cell to be transformed with the vector may be any cell that can be transformed with the polypeptide-expressing vector containing the polynucleotide encoding the polypeptide, so as to express the polypeptide encoded by the introduced polynucleotide. Examples of microorganisms that can be used as the host cell include bacteria for which host-vector systems have been developed, such as those belonging to the genera Escherichia, Bacillus, Pseudomonas, Serratia, Brevibacterium, Corynebacterium, Streptococcus , and Lactobacillus ; actinomycetes for which host-vector systems have been developed, such as those belonging to the genera Rhodococcus and Streptomyces ; yeasts for which host-vector systems have been developed, such as those belonging to the genera Saccharomyces, Kluyveromyces, Schizosaccharomyces, Zygosaccharomyces, Yarrowia, Trichosporon, Rhodosporidium, Pichia , and Candida ; and molds for which host-vector systems have been developed, such as those belonging to the genera Neurospora, Aspergillus, Cephalosporium , and Trichoderma . Besides microorganisms, various host-vector systems have also been developed for plants and animals. In particular, systems for expressing a large amount of heterologous protein in an insect such as a silkworm (Nature, 315, 592-594 (1985)), or a plant such as a rape, corn, or potato have been developed, which can be suitably used. Among these, preferred in view of the efficiency in introduction and expression are bacteria, with E. coli being particularly preferred.
[0186] The vector of the present invention can be introduced into host microorganisms by known methods. For example, in the case that the polypeptide-expressing vector is any of plasmids of the present invention (pNKPm01 to pNKPm53 in Examples 2, 3, 6 to 15, 17 to 27, and 30) obtained by introducing a polynucleotide encoding an altered carbonyl reductase into the above expression vector pUCN18, and the host microorganism is E. coli , a transformant (e.g. E. coli HB101 (pNKPm50) in Example 27) can be obtained by engineering commercially available E. coli HB101 competent cells (from Takara Bio, Inc.) or the like according to the protocol provided with the cells to introduce the vector into the host cell.
[0187] Also, a transformant can be grown which is transformed to express both the polypeptide of the present invention and the polypeptide capable of regenerating a reduced coenzyme described later in the same cell. Specifically, a transformant can be obtained by incorporating the polynucleotide encoding the polypeptide of the present invention and the polynucleotide encoding a polypeptide capable of regenerating a reduced coenzyme into the same vector, and introducing the vector into the host cell. Or alternatively, it can be obtained by incorporating these two kinds of DNAs into the respective two vectors from different incompatibility groups, and introducing the vectors into the same host cell.
[0188] Examples of transformants that can be obtained as described above include a transformant obtained by introducing into E. coli HB101 competent cells (from Takara Bio, Inc.) both a recombinant vector (e.g. pNKPm01 in Example 2) obtained by introducing the nucleotide encoding the altered carbonyl reductase into the expression vector pUCN18, and a vector containing a polynucleotide encoding glucose dehydrogenase which is a polypeptide capable of regenerating a reduced coenzyme.
[0189] The polypeptide of the present invention or the transformant and/or a treated product thereof can be allowed to act on a carbonyl compound to produce an alcohol compound.
[0190] The carbonyl compound used as a substrate is not particularly limited. Among carbonyl compounds, unsymmetrical ketones are preferred because they are reduced into useful optically active alcohols.
[0191] Examples of such carbonyl group-containing compounds include unsymmetrical ketones represented by the following formula (1):
[0000]
[0000] wherein R 1 and R 2 are each a hydrogen atom, a halogen atom, an optionally substituted alkyl group, an optionally substituted aralkyl group, an optionally substituted aryl group, an optionally substituted alkoxy group, an amino group, or a nitro group, or R 1 and R 2 may be joined together to form a ring, provided that R 1 and R 2 have different structures. Examples of the products formed therefrom include optically active alcohols represented by the following formula (2):
[0000]
[0000] wherein R 1 and R 2 are the same as described above, and * represents an asymmetric carbon atom.
[0192] The R 1 and R 2 are each preferably a C1 to C14 alkyl group, a C6 to C14 aryl group, a C4 to C14 heteroaryl group, a C1 to C5 alkoxy group, a C2 to C5 alkoxycarboxyl group, a C1 to C5 linear or branched alkyl group, a C2 to C5 alkenyl group, a C5 to C10 cycloalkyl group, a C4 to C9 heterocycloalkyl group, a carboxyl group, a hydrogen atom, a halogen atom, a hydroxyl group, an amino group, or a nitro group.
[0193] The term “optionally substituted” means that the group may have a substituent. Examples of the substituent include halogen atoms and hydroxyl, carboxyl, amino, cyano, nitro, alkyl, aryl, aralkyl, and alkoxy groups. Examples of halogen atoms include fluorine, chlorine, bromine, and iodine atoms.
[0194] Specific example of the carbonyl compound include 2-pentanone, 2-hexanone, 2,3-butanedione, acetophenone, (S)-1-(4-fluoro-phenyl)-5-(2-oxo-4-phenyl-oxazolidin-3-yl)-pentane-1,5-dione, propiophenone, n-butyrophenone, valerophenone, hexanophenone, 1-phenyl-2-butanone, benzylacetone, 2,5-hexanedione, 2,3-hexanedione, 3,4-hexanedione, and phenoxy-2-propanone.
[0195] Examples of the alcohol compound produced using the polypeptide of the present invention include 2-pentanol, 2-hexanol, 2,3-butanediol, 3-hydroxy-2-butanone, 1-phenyl ethyl alcohol, [3-[(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one, 1-phenyl-1-propanol, 1-phenyl-1-butanol, 1-phenyl-1-pentanol, 1-phenyl-1-hexanol, 1-phenyl-2-butanol, 4-phenyl-2-butanol, 2,5-hexanediol, 5-hydroxy-2-hexanone, 2,3-hexanediol, 2-hydroxyhexan-3-one, 3-hydroxy-2-hexanone, 3,4-hexanediol, 4-hydroxy-3-hexanone, and 1-phenoxy-2-propanol.
[0196] When the carbonyl group-containing compound is reduced into an alcohol using the polypeptide of the present invention or the transformant expressing the polypeptide of the present invention and/or a treated product thereof, the following procedure may be followed. However, the procedure is not limited to the following procedure.
[0197] An appropriate solvent (e.g. 100 mM phosphate buffer (pH 6.5)), a carbonyl compound substrate (e.g. 2-pentanone or acetophenone), a coenzyme such as NADPH or oxidized nicotinamide adenine dinucleotide phosphate (hereinafter, NADP + ), and a cultured product of the transformant and/or a treated product or the like thereof are added, and then reacted with stirring while the pH is controlled.
[0198] The term “treated product” means a product still having the enzyme catalytic activity of the polypeptide, such as a crude extract, cultured cells, a freeze-dried organism, an acetone-dried organism, disrupted cells, or immobilized preparations thereof.
[0199] The reaction temperature is preferably 5° C. to 80° C., more preferably 10° C. to 60° C., and still more preferably 20° C. to 40° C. The pH of the reaction mixture is preferably 3 to 10, more preferably 4 to 9, and still more preferably 5 to 8. The reaction may be carried out either batchwise or in a continuous manner. In the case of the batchwise method, the reaction substrate may be introduced at a concentration of 0.01 to 100% (w/v), preferably 0.1 to 70% (w/v), and more preferably 0.5 to 50% (w/v) of the total reaction mixture. An additional amount of substrate may be further added during the reaction.
[0200] Moreover, in the reaction, an aqueous solvent may be used, or a mixture of an aqueous solvent and an organic solvent may be used. Examples of the organic solvent include dimethylformamide, dimethyl sulfoxide, 2-propanol, ethyl acetate, toluene, methanol, ethanol, n-butanol, hexane, acetonitrile, propyl acetate, butyl acetate, acetone, dimethoxypropane, t-methyl butyl ether, diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran, dimethylacetamide, diglyme, ethylene glycol, dimethoxyethane, carbon tetrachloride, methylene chloride, ethylcellosolve, cellosolve acetate, 1,3-dimethyl-2-imidazolidinone, and hexamethylphosphoric triamide. The concentration of the organic solvent in the reaction system is not particularly limited, but is preferably 1 to 95%, more preferably 5 to 90%, and still more preferably 10 to 80%.
[0201] The treated product or the like of the transformant refers to, for example, a cell-free extract, cultured cells, freeze-dried cells, acetone-dried cells, disrupted products thereof, or mixtures thereof. Moreover, they may be used after the polypeptide itself or directly the cells are immobilized by known means.
[0202] Moreover, in the reaction, a transformant producing both the polypeptide of the present invention and a polypeptide capable of regenerating a reduced coenzyme can be used to greatly reduce the amount of coenzyme used. The polypeptide capable of regenerating a reduced coenzyme is described in detail below.
[0203] When an alcohol compound is synthesized by reducing a carbonyl compound using the transformant capable of producing the polypeptide of the present invention, NADPH or NADH is required as a coenzyme. As described above, the reduction reaction can be carried out by adding a required amount of NADPH or NADH to the reaction system. However, the amount of expensive coenzyme can be greatly reduced by carrying out the reaction using the polypeptide of the present invention in combination with a coenzyme regeneration system that contains an enzyme capable of converting the coenzyme (NADP + or NAD + ) in oxidized form into reduced NADPH or NADH (hereinafter, such an ability is referred to as a reduced-coenzyme regeneration ability), and a substrate thereof. The enzyme having the reduced-coenzyme regeneration ability may be, for example, hydrogenase, formic acid dehydrogenase, carbonyl reductase, glucose-6-phosphate dehydrogenase, or glucose dehydrogenase. Suitable is glucose dehydrogenase.
[0204] The reaction may be carried out by adding the coenzyme regeneration system to an asymmetric reduction reaction system. However, when the catalyst used is a transformant obtained by transformation with both the polynucleotide encoding the enzyme of the present invention and a polynucleotide encoding the polypeptide capable of regenerating a reduced coenzyme, the reaction can be efficiently performed without separately preparing the enzyme capable of regenerating a reduced coenzyme and adding the prepared enzyme into the reaction system. Such a transformant can be obtained by the above-described method for preparing a transformant.
[0205] After the reaction, an alcohol can be recovered from the reaction mixture by any method, such as by extracting the alcohol directly from the reaction mixture or, if necessary, after separating cells and the like, with a solvent such as ethyl acetate, toluene, t-butyl methyl ether, hexane, or methylene chloride, followed by dehydration and then purification by distillation, recrystallization, silica gel column chromatography, or the like. A high purity alcohol compound can be easily obtained by this method.
EXAMPLES
[0206] The following examples illustrate the present invention in detail. They are, however, by no means limitative of the invention. The recombinant DNA technology procedures and the like used in the examples below are described in detail in the following textbooks: Molecular Cloning 2nd Edition (Joseph Sambrook, Cold Spring Harbor Laboratory Press (1989)), and Current Protocols in Molecular Biology (Frederick M. Ausubel, Greene Publishing Associates and Wiley-Interscience (1989)).
Reference Example 1
Acquisition of DNA Encoding Polypeptide (Wild-Type Enzyme) Having Activity for Carbonyl Compound Reduction Derived from Vanderwaltozyma polyspora NBRC 0996
[0207] A DNA encoding a polypeptide having activity for the reduction of a carbonyl compound (hereinafter, the polypeptide is referred to as RKP) was obtained by PCR from Vanderwaltozyma polyspora NBRC 0996.
[0000] [Preparation of Chromosomal DNA from Vanderwaltozyma polyspora NBRC 0996]
[0208] In a 500-ml Sakaguchi flask, 50 ml of a liquid medium (pH 7) containing 16 g of bacto-tryptone, 10 g of yeast extract, 5 g of sodium chloride, and 0.1 g of Adekanol LG-109 (from NOF Corporation) (each per liter) was prepared and steam sterilized at 120° C. for 20 minutes. The medium was inoculated with 5 ml of a culture of Vanderwaltozyma polyspora NBRC 0996 precultured in the same medium in advance, and the strain was cultured with shaking at 30° C. for 18 hours. A chromosomal DNA was extracted from the culture medium according to the method of Murray et al. (Nucl. Acids Res. 8, 4321 (1980)).
[PCR Reaction]
[0209] PCR was performed using primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing) and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing), and the chromosomal DNA of Vanderwaltozyma polyspora NBRC 0996 as a template.
[0210] As a result, a double-stranded DNA (RKP gene) was obtained which had a Nde I recognition site added to the initiation codon of the gene having the base sequence of SEQ ID No:2 in the sequence listing, and had a Sal I recognition site added immediately after the termination codon. PCR was further performed using the obtained DNA as a template, so that T at position 240 was changed to C by usual techniques. Thus, without a change in the amino acid sequence of the RKP enzyme encoded by the gene, a double-stranded DNA having the base sequence of SEQ ID NO:3 in the sequence listing in which the Nde I recognition site in the gene was destroyed (RKP gene with the Nde I site destroyed) was obtained. The PCR was carried out using PrimeSTAR HS DNA Polymerase (from Takara Bio, Inc.) as a DNA polymerase under reaction conditions as described in the manual.
Reference Example 2
Construction of Recombinant Vector pNKP
[0211] A recombinant vector pNKP was constructed by digesting with Nde I and Sal I the RKP gene with the Nde I site destroyed in Reference Example 1, and inserting the fragment between the Nde I recognition site and the Sal I recognition site downstream from the lac promoter in the plasmid pUCN18 (a plasmid obtained by changing T at position 185 in pUC18 (from Takara Bio, Inc.) to A to destroy the Nde I site, and further changing GC at positions 471 and 472 to TG to introduce a new Nde I site by PCR).
Reference Example 3
Production of Recombinant Organism that Expresses Polypeptide
[0212] Using the recombinant vector pNKP constructed in Reference Example 2, E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed to produce a recombinant organism E. coli HB101 (pNKP). Also, using the pUCN18, E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed to produce a recombinant organism E. coli HB101 (pUCN18).
Reference Example 4
Expression of DNA in Recombinant Organism
[0213] The two kinds of recombinant organisms obtained in Reference Example 3 ( E. coli HB101 (pUCN18), E. coli HB101 (pNKP)) were each inoculated into 5 ml of 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin and cultured with shaking at 37° C. for 24 hours. The cells in the culture media obtained above were collected by centrifugation and suspended in 5 ml of 100 mM phosphate buffer (pH 6.5). The suspension was disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract. The activity for acetophenone reduction of the thus obtained cell-free extracts was measured. The activity for acetophenone reduction was calculated from the rate of decrease in the absorbance at a wavelength of 340 nm as determined by adding 10 mM acetophenone, 0.25 mM coenzyme NADPH, and the cell-free extract to 100 mM phosphate buffer (pH 6.5) and reacting them at 30° C. for 1 minute. The enzyme activity oxidizing 1 μmol of NADPH to NADP per minute under these reaction conditions was defined as 1 U. The acetophenone-reducing activities of the recombinant organisms are described below. E. coli HB101 (pUCN18) showed an acetophenone-reducing activity of 0.1 U/mg or lower, while E. coli HB101 (pNKP) which expressed RKP showed an acetophenone-reducing activity of 5 U/mg. As described above, the recombinant organisms obtained in Reference Example 3 were found to have activity for acetophenone reduction and to express RKP.
Reference Example 5
Stability of Wild-Type Enzyme RKP to Organic Solvent
[0214] A cell-free extract of the wild-type enzyme was obtained in the same manner as in Reference Example 4. To the cell-free extract was added dimethylformamide at a final concentration of 30, 40 or 50%, and they were adjusted to a pH of 6.5 using sulfuric acid or sodium hydroxide and then incubated at 30° C. for 3 hours. A cell-free extract to which nothing was added was also similarly incubated as a control. The cell-free extracts were diluted after 3 hours. The 2-pentanone-reducing activity of these cell-free extracts was measured in the same manner as in Reference Example 4. The relative activity with the addition of the solvent was calculated by the equation below and used as an indicator of stability to various compounds. The results are shown in Table 1.
[0000] Relative activity (%)=[enzyme activity after just 3 hours (with solvent)]/[enzyme activity after just 3 hours (without solvent)]×100
[0000]
TABLE 1
Relative activity
Solvent added
Concentration
(%)
No solvent
100
Dimethylformamide
30%
64
40%
9
50%
0
Dimethyl sulfoxide
40%
91
50%
58
[0215] The wild-type enzyme showed lower stability to dimethylformamide than to dimethyl sulfoxide.
Reference Example 6
Stability of Wild-Type Enzyme RKP to Organic Solvent
[0216] A cell-free extract of the wild-type enzyme was obtained in the same manner as in Reference Example 4. To the cell-free extract was added dimethylformamide at a final concentration of 30%, and they were adjusted to a pH of 6.5 using sulfuric acid or sodium hydroxide and then incubated at 30° C. for 2 hours. A cell-free extract to which nothing was added was also similarly incubated as a control. The cell-free extracts were diluted after 2 hours. The 2-hexanone-reducing activity of these cell-free extracts was measured. The rate of decrease in the absorbance at a wavelength of 340 nm was determined by adding 10 mM 2-hexanone, 0.25 mM coenzyme NADPH, and the cell-free extract to 100 mM phosphate buffer (pH 6.5) and reacting them at 30° C. for 1 minute. The 2-hexanone-reducing activity was calculated from the rate of decrease. The relative activity with the addition of the solvent was calculated by the equation below and used as an indicator of stability to various compounds. The activity (relative activity) of the wild-type enzyme with the solvent was 8% of that without the solvent.
[0000] Relative activity (%)=[enzyme activity after just 2 hours (with solvent)]/[enzyme activity after just 2 hours (without solvent)]×100
Reference Example 7
Inhibition of Reaction of Wild-Type Enzyme RKP by Organic Solvent
[0217] A cell-free extract of the wild-type enzyme was obtained in the same manner as in Reference Example 4. To the cell-free extract was added dimethylformamide at a final concentration of 30%, and they were adjusted to a pH of 6.5 using sulfuric acid or sodium hydroxide and then incubated at 30° C. for 2 hours. A cell-free extract to which nothing was added was also similarly incubated as a control. The cell-free extracts were diluted after 2 hours. The 2-hexanone-reducing activity of these cell-free extracts was measured. A reaction was carried out by adding 30% dimethylformamide, 10 mM 2-hexanone, 0.25 mM coenzyme NADPH, and the cell-free extract to 100 mM phosphate buffer (pH 6.5). The rate of NADPH consumption was determined from the rate of decrease in NADPH fluorescence, whereby the 2-hexanone-reducing activity was calculated. The relative activity with the addition of the solvent was calculated by the equation below and used as an indicator of stability to various compounds. The activity (relative activity) of the wild-type enzyme with the solvent was 24% of that without the solvent.
[0000] Relative activity (%)=[enzyme activity (with solvent)]/[enzyme activity (without solvent)]×100
Example 1
Preparation 1 of Mutant Enzyme Library
[0218] DNA amplified fragments in which a mutation was introduced randomly into the full length of the RKP gene were obtained by error-prone PCR (Leung et al. Technique 1, 11-15 (1989)) using the plasmid pNKP containing the RKP gene prepared in Reference Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The amplified fragments were digested with the restriction enzymes Nde I and Sal I and then incorporated into a high expression vector pUCN18 treated with the same enzymes to prepare mutant-enzyme-expressing plasmids. With each plasmid, E. coli HB101 was transformed, and the transformant was applied to an LB medium plate containing 100 μg/mL ampicillin. The colonies grown in each case were formed of a recombinant E. coli containing a mutated RKP gene. The group of these recombinant bacteria is referred to as mutant enzyme library 1.
Example 2
Selection 1 of Altered Carbonyl Reductase
[0219] Altered carbonyl reductases having better stability to an organic solvent were selected from the mutant enzyme library 1. The recombinant bacteria in the mutant enzyme library 1 prepared in Example 1 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. To 60 μL of each of the obtained culture media was added 240 μL of phosphate buffer (pH 7.0) containing 10 mM EDTA·2Na and 1% Triton X-100, and the mixture was incubated at 37° C. for 1 hour. The treated media were centrifuged to give a supernatant as a cell-free extract. Phosphate buffer (pH 6.5) containing dimethylformamide at a final concentration of 10 to 30% was added to 200 μL of each of the cell-free extracts, followed by incubation at 30° C. for 2 hours (dimethylformamide treatment). The cell-free extracts treated with dimethylformamide were dispensed in an amount of 50 μL into a 96-well plate (from AGC Techno Glass Co., Ltd.), followed by adding 50 μL of phosphate buffer (pH 6.5) containing 6 mM NADPH, and 100 μL of phosphate buffer (pH 6.5) containing 133 mM 2,3-butanedione. The mixture was reacted at 30° C. NADPH fluorescence was measured with time using an UV transilluminator and recording system FAS-III (from Toyobo Co., Ltd.). An enzyme solution in which the reaction did not proceed showed the remaining NADPH fluorescence, while a cell-free extract in which the reaction had proceeded showed reduced fluorescence with the decrease in NADPH. Enzymes which showed quenched fluorescence in a short time compared to the control cell-free extract of E. coli HB101 (pNKP) (wild-type enzyme) were selected as enzymes having high reactivity in the presence of dimethylformamide, i.e., altered carbonyl reductases having better stability to an organic solvent. Plasmids were extracted from the culture media of the selected enzymes, and the base sequence of the mutant RKP genes was determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites were identified. The obtained altered carbonyl reductases having better stability to an organic solvent are shown in Table 2.
[0000]
TABLE 2
Plasmid
Mutation site
pNKPm01
T257S
pNKPm02
K259E
pNKPm03
S267P
pNKPm04
K270M
pNKPm05
N102I-E226G-S267P
pNKPm06
H71R-G300D
[0220] The six enzymes shown in Table 2 having better stability to an organic solvent were obtained.
Example 3
Selection 2 of Altered Carbonyl Reductase
[0221] Altered carbonyl reductases having better stability to an organic solvent were selected from the mutant enzyme library 1. The recombinant bacteria in the mutant enzyme library 1 prepared in Example 1 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each inoculated on an LB medium plate containing 100 μg/mL ampicillin. The thus obtained colonies were transferred to a nylon membrane (Biodyne A, 0.45 μm) heated to 40° C. The nylon membrane was immersed in 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer containing 30% dimethylformamide at 40° C. for 30 minutes. Then, the nylon membrane was immersed in 50 mM MOPS buffer containing 1 mM NADP + , 200 μM nitroblue tetrazolium, 10 μM 1-methoxy-5-methylphenazinium methylsulfate, and 10% (v/v) 2-propanol at room temperature for 30 minutes. Thereafter, the nylon membrane was washed with distilled water, and then stained colonies were selected as candidates for recombinant bacteria with altered carbonyl reductases having better stability to dimethylformamide. The candidate strains were each inoculated into 5 ml of 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin, and cultured for 20 hours. The cells in the obtained culture media were collected by centrifugation and suspended in 100 mM phosphate buffer (pH 6.5) in an amount of ⅙ of the amount of the culture medium. The suspension was disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract. To 20 μL of each of the cell-free extracts were added dimethylformamide at a final concentration of 20, 23, 26, or 30% and 50 mM MOPS buffer (pH 7.0) so that the total amount of the mixture was 40 μL, followed by heating at 40° C. for 30 minutes. After the mixture was cooled on ice for 1 minute, 200 μL of 50 mM MOPS buffer containing 1 mM NADP + , 200 μM nitroblue tetrazolium, 10 μM 1-methoxy-5-methylphenazinium methylsulfate, and 10% (v/v) 2-propanol was added. Each reaction mixture was transferred to a 96-well plate (from AGC Techno Glass Co., Ltd.) and observed for 1 hour. Stained samples were selected as recombinant bacteria with altered carbonyl reductases having better stability to dimethylformamide. Plasmids were extracted from the culture media of the selected recombinant bacteria, and the base sequence of the mutant RKP genes was determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites were identified. The obtained altered carbonyl reductases having better stability to an organic solvent are shown in Table 3.
[0000]
TABLE 3
Plasmid
Mutation site
pNKPm01
T257S
pNKPm02
K259E
pNKPm03
S267P
pNKPm04
K270M
pNKPm05
N102I-E226G-S267P
pNKPm06
H71R-G300D
pNKPm07
H71N-F195L
pNKPm08
L177F-A220V
pNKPm09
N45D-N175D-I183T
pNKPm10
K22R
pNKPm11
Y25F
pNKPm12
T135A
pNKPm13
Q155L
pNKPm14
F195L
pNKPm15
S212F
pNKPm16
S212T
pNKPm17
S212Y
pNKPm18
E228V
pNKPm19
N265K
pNKPm20
R301C
pNKPm21
S2I-V238I
pNKPm22
E109G-K331F
pNKPm23
I124L-S236N
pNKPm24
I159F-K259E
pNKPm25
L177F-A220V
pNKPm26
K42R-Q155R-K279R
pNKPm28
Q155L-S250P-Q298P
pNKPm29
E56K-T138N-T190S-D254N
[0222] The 29 enzymes shown in Table 3 having better stability to an organic solvent were obtained. Six enzymes out of these enzymes were the same mutant enzymes as those obtained in Example 2.
Example 4
Evaluation 1 of Altered Carbonyl Reductase
[0223] The recombinant bacteria with the altered carbonyl reductases obtained in Example 2 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. The cells in the obtained culture media were collected by centrifugation and suspended in 100 mM phosphate buffer (pH 6.5) in an amount equal to to ⅕ of the amount of the culture medium. The suspension was disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract. To 60 μL of each of the cell-free extracts was added 60 μL of phosphate buffer (pH 7.0) containing dimethylformamide at a final concentration of 30, 40, or 50%, followed by incubation at 30° C. (dimethylformamide treatment). The extracts treated with dimethylformamide after just 3 hours were sampled, diluted, and measured for activity for 2-pentanone reduction as described in Reference Example 4. The residual activity was calculated by the equation below and used as an indicator of stability to dimethylformamide.
[0000] Relative activity (%)=[enzyme activity after just 3 hours (with solvent)]/[enzyme activity after just 3 hours (without solvent)]×100
[0224] The relative activities of the wild-type enzyme and the altered carbonyl reductases evaluated in the presence of 40% dimethylformamide are shown in Table 4.
[0000]
TABLE 4
Residual activity
Mutation site
(%)
Wild-type enzyme
7.9
T257S
20.2
K259E
29.4
N102I-E226G-S267P
25.6
K270M
36.2
H71R-G300D
17.8
[0225] The altered carbonyl reductases shown in Table 4 had better stability to an organic solvent than the wild-type enzyme.
Example 5
Evaluation 2 of Altered Carbonyl Reductase
[0226] The recombinant bacteria with the altered carbonyl reductases obtained in Example 3 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. The cells in the obtained culture media were collected by centrifugation and suspended in 100 mM phosphate buffer (pH 6.5) in an amount equal to to ⅕ of the amount of the culture medium. The suspension was disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract. To 25 μL of each of the cell-free extracts was added the same amount of an 80% dimethylformamide solution, followed by leaving the mixture at 30° C. for 30 minutes. An amount of 200 μL of 100 mM phosphate buffer (pH 6.5) was added to the mixture and they were mixed. To 15 μL of the solution was added 250 μL of 100 mM phosphate buffer (pH 6.5) containing NADPH at a final concentration of 0.625 mM and 12.5 mM 2,3-butanedione dissolved therein, and they were mixed. After shaking for 5 seconds, NADPH absorbance (at 340 nm) was measured using a Benchmark Plus microplate spectrophotometer (from BIO-RAD) for 15 seconds. From the rate of decrease in the absorbance, the activity for 2,3-butanedione reduction was determined. The enzyme activity with the addition of dimethylformamide compared to the activity without dimethylformamide was calculated by the equation below and used as an indicator of stability to dimethylformamide.
[0000] Relative activity (%)=[enzyme activity (with dimethylformamide)]/[enzyme activity (without dimethylformamide)]×100
[0227] The relative activities of the wild-type enzyme and the altered carbonyl reductases are shown in Table 5.
[0000]
TABLE 5
Residual activity
Mutation site
(%)
Wild-type enzyme
8
H71N-F195L
24
L177F-A220V
47
N45D-N175D-I183T
16
N102I-E226G-S267P
26
K22R
13
Y25F
11
T135A
13
Q155L
13
F195L
29
S212F
11
S212T
10
S212Y
12
E228V
28
T257S
20
K259E
29
N265K
28
S267P
38
K270M
38
R301C
41
S2I-V238I
36
H71R-G300D
12
E109G-K331F
9
I124L-S236N
38
I159F-K259E
15
L177F-A220V
47
K42R-Q155R-K279R
14
N45D-N175D-I183T
16
Q155L-S250P-Q298P
23
E56K-T138N-T190S-D254N
14
[0228] The altered carbonyl reductases shown in Table 5 had better stability to an organic solvent than the wild-type enzyme.
Example 6
Preparation 1 of Altered Carbonyl Reductase with Multiple Mutations
[0229] A double-stranded DNA encoding an N-terminal polypeptide containing a T257S amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm02 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 3: 5′-GTTAATTTCATTAGCGCGATTTTTAATTACATG-3′ (SEQ ID NO:6 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing H71R and K259E amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm02 as a template, primer 4: 5′-CATGTAATTAAAAATCGCGCTAATGAAATTAAC-3′ (SEQ ID NO:7 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing H71R and K259E amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm30. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm30, whereby a recombinant organism E. coli HB101 (pNKPm30) producing an altered carbonyl reductase H71R-K259E was obtained.
Example 7
Preparation 2 of Altered Carbonyl Reductase with Multiple Mutations
[0230] A double-stranded DNA encoding an N-terminal polypeptide containing a T257S amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm02 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 5: 5′-GATCAACCTTTCACCGCTTAACTCATCATTATG-3′ (SEQ ID NO:8 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing T257S and K259E amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm02 as a template, primer 6: 5′-CATAATGATGAGTTAAGCGGTGAAAGGTTGATC-3′ (SEQ ID NO:9 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing T257S and K259E amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm31. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm31, whereby a recombinant organism E. coli HB101 (pNKPm31) producing an altered carbonyl reductase T257S-K259E was obtained.
Example 8
Preparation 3 of Altered Carbonyl Reductase with Multiple Mutations
[0231] A double-stranded DNA encoding an N-terminal polypeptide containing K259E and G300D amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm02 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 7: 5′-CTCGTTATGGACACGATCTCCTTGAGGTAACTC-3′ (SEQ ID NO:10 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing a G300D amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm02 as a template, primer 8: 5′-GAGTTACCTCAAGGAGATCGTGTCCATAACGAG-3′ (SEQ ID NO:11 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K259E and G300D amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm32. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm32, whereby a recombinant organism E. coli HB101 (pNKPm32) producing an altered carbonyl reductase K259E-G300D was obtained.
Example 9
Preparation 4 of Altered Carbonyl Reductase with Multiple Mutations
[0232] A double-stranded DNA encoding an N-terminal polypeptide containing H71R and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 9: 5′-GTTAATTTCATTAGCGCGATTTTTAATTACATG-3′ (SEQ ID NO:12 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing H71R and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm02 as a template, primer 10: 5′-CATGTAATTAAAAATCGCGCTAATGAAATTAAC-3′ (SEQ ID NO:13 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing H71R and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm33. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm33, whereby a recombinant organism E. coli HB101 (pNKPm33) producing an altered carbonyl reductase H71R-K270M was obtained.
Example 10
Preparation 5 of Altered Carbonyl Reductase with Multiple Mutations
[0233] A double-stranded DNA encoding an N-terminal polypeptide containing an N1021 amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 11: 5′-GGATACCTTTAGTACCAATAACAGCTGGGATTAAG-3′ (SEQ ID NO:14 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing N1021 and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 12: 5′-CTTAATCCCAGCTGTTATTGGTACTAAAGGTATCC-3′ (SEQ ID NO:15 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing N1021 and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm34. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm34, whereby a recombinant organism E. coli HB101 (pNKPm34) producing an altered carbonyl reductase N1021-K270M was obtained.
Example 11
Preparation 6 of Altered Carbonyl Reductase with Multiple Mutations
[0234] A double-stranded DNA encoding an N-terminal polypeptide containing an E226G amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 13: 5′-TTTATCAATTTCACTGCCTGTTGGAGCAAACATAGC-3′ (SEQ ID NO:16 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing an NE226G amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 14: 5′-GCTATGTTTGCTCCAACAGGCAGTGAAATTGATAAA-3′ (SEQ ID NO:17 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing E226G and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm35. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm35, whereby a recombinant organism E. coli HB101 (pNKPm35) producing an altered carbonyl reductase E226G-K270M was obtained.
Example 12
Preparation 7 of Altered Carbonyl Reductase with Multiple Mutations
[0235] A double-stranded DNA encoding an N-terminal polypeptide containing a T257S amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 15: 5′-GATCAACCTTTTACCGCTTAACTCATCATTATG-3′ (SEQ ID NO:18 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing T257S and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 16: 5′-CATAATGATGAGTTAAGCGGTAAAAGGTTGATC-3′ (SEQ ID NO:19 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing T257S and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm36. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm36, whereby a recombinant organism E. coli HB101 (pNKPm36) producing an altered carbonyl reductase T257S-K270M was obtained.
Example 13
Preparation 8 of Altered Carbonyl Reductase with Multiple Mutations
[0236] A double-stranded DNA encoding an N-terminal polypeptide containing a K259E amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 17: 5′-GACAAGATCAACCTTTCACCAGTTAACTCATC-3′ (SEQ ID NO:20 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing K259E and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 18: 5′-GATGAGTTAACTGGTGAAAGGTTGATCTTGTC-3′ (SEQ ID NO:21 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K259E and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm37. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm37, whereby a recombinant organism E. coli HB101 (pNKPm37) producing an altered carbonyl reductase K259E-K270M was obtained.
Example 14
Preparation 9 of Altered Carbonyl Reductase with Multiple Mutations
[0237] A double-stranded DNA encoding an N-terminal polypeptide containing an S267P amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 19: 5′-TTTGCATAGTGAACGGAGCATTTGACAAG-3′ (SEQ ID NO:22 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing S267P and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 20: 5′-CTTGTCAAATGCTCCGTTCACTATGCAAA-3′ (SEQ ID NO:23 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing S267P and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm38. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm38, whereby a recombinant organism E. coli HB101 (pNKPm38) producing an altered carbonyl reductase S267P-K270M was obtained.
Example 15
Preparation 10 of Altered Carbonyl Reductase with Multiple Mutations
[0238] A double-stranded DNA encoding an N-terminal polypeptide containing K270M and G300D amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm04 obtained in Example 2 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 21: 5′-CTCGTTATGGACACGATCTCCTTGAGGTAACTC-3′ (SEQ ID NO:24 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing a G300D amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm04 as a template, primer 22: 5′-GAGTTACCTCAAGGAGATCGTGTCCATAACGAG-3′ (SEQ ID NO:25 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K270M and G300D amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm39. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm39, whereby a recombinant organism E. coli HB101 (pNKPm39) producing an altered carbonyl reductase K270M-G300D was obtained.
Example 16
Evaluation 1 of Altered Carbonyl Reductase with Multiple Mutations
[0239] The recombinant bacteria with the respective altered carbonyl reductases with multiple mutations obtained in Examples 6 to 15 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. The stability of each altered carbonyl reductase with multiple mutations to dimethylformamide was evaluated in the same manner as in Example 4. The relative activities of the wild-type enzyme and the altered carbonyl reductases evaluated in the presence of 40% dimethylformamide are shown in Table 6.
[0000]
TABLE 6
Residual activity
Mutation site
(%)
Wilde-type enzyme
8
K259E
25
K270M
31
H71R-K259E
30
T257S-K259E
38
K259E-G300D
36
H71R-K270M
29
N102I-K270M
26
E226G-K270M
31
T257S-K270M
44
K259E-K270M
64
S267P-K270M
33
K270M-G300D
44
[0240] The altered carbonyl reductases shown in Table 6 had better stability to an organic solvent than the wild-type enzyme.
Example 17
Preparation 11 of Altered Carbonyl Reductase with Multiple Mutations
[0241] A double-stranded DNA encoding an N-terminal polypeptide containing an S2I amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 23: 5′-CCAGTAGCACCTGTAACTAAAACAATCAT-3′ (SEQ ID NO:26 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing S2I, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 24: 5′-ATGATTGTTTTAGTTACAGGTGCTACTGG-3′ (SEQ ID NO:27 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing S2I, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm40. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm40, whereby a recombinant organism E. coli HB101 (pNKPm40) producing an altered carbonyl reductase S2I-K259E-K270M was obtained.
Example 18
Preparation 12 of Altered Carbonyl Reductase with Multiple Mutations
[0242] A double-stranded DNA encoding an N-terminal polypeptide containing an I124L amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 25: 5′-GGCAGCAATTGAAGAAGTCAGAACAAATTTCTTCAC-3′ (SEQ ID NO:28 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing I124L, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 26: 5′-GTGAAGAAATTTGTTCTGACTTCTTCAATTGCTGCC-3′ (SEQ ID NO:29 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing I124L, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm41. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm41, whereby a recombinant organism E. coli HB101 (pNKPm41) producing an altered carbonyl reductase 1124L-K259E-K270M was obtained.
Example 19
Preparation 13 of Altered Carbonyl Reductase with Multiple Mutations
[0243] A double-stranded DNA encoding an N-terminal polypeptide containing an L177F amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 27: 5′-CCTTTATTCTCTTCAAAGAAGTTCCAAGCAGC-3′ (SEQ ID NO:30 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing L177F, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 28: 5′-GCTGCTTGGAACTTCTTTGAAGAGAATAAAGG-3′ (SEQ ID NO:31 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing L177F, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm42. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm42, whereby a recombinant organism E. coli HB101 (pNKPm42) producing an altered carbonyl reductase L177F-K259E-K270M was obtained.
Example 20
Preparation 14 of Altered Carbonyl Reductase with Multiple Mutations
[0244] A double-stranded DNA encoding an N-terminal polypeptide containing an F195L amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 29: 5′-GGACCAAAGACCAGAACTGGGTTGATCG-3′ (SEQ ID NO:32 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing F195L, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 30: 5′-CGATCAACCCAGTTCTGGTCTTTGGTCC-3′ (SEQ ID NO:33 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing F195L, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm43. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm43, whereby a recombinant organism E. coli HB101 (pNKPm43) producing an altered carbonyl reductase F195L-K259E-K270M was obtained.
Example 21
Preparation 15 of Altered Carbonyl Reductase with Multiple Mutations
[0245] A double-stranded DNA encoding an N-terminal polypeptide containing an A220V amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 31: 5′-CTGTTGGAGCAAACATCACTTCCTTGATGATTTC-3′ (SEQ ID NO:34 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing A220, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 32: 5′-GAAATCATCAAGGAAGTGATGTTTGCTCCAACAG-3′ (SEQ ID NO:35 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing A220V, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm44. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm44, whereby a recombinant organism E. coli HB101 (pNKPm44) producing an altered carbonyl reductase A220V-K259E-K270M was obtained.
Example 22
Preparation 16 of Altered Carbonyl Reductase with Multiple Mutations
[0246] A double-stranded DNA encoding an N-terminal polypeptide containing an S236N amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 33: 5′-CGTACATCAACATAGTTACCAAAAACAGATTTATC-3′ (SEQ ID NO:36 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing S236N, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 34: 5′-GATAAATCTGTTTTTGGTAACTATGTTGATGTACG-3′ (SEQ ID NO:37 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO: 5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing S236N, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm45. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm45, whereby a recombinant organism E. coli HB101 (pNKPm45) producing an altered carbonyl reductase S236N-K259E-K270M was obtained.
Example 23
Preparation 17 of Altered Carbonyl Reductase with Multiple Mutations
[0247] A double-stranded DNA encoding an N-terminal polypeptide containing a V238I amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 35: 5′-GCTACATCACGTACATCAATATAACTACCAAAAAC-3′ (SEQ ID NO:38 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing V238I, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 36: 5′-GTTTTTGGTAGTTATATTGATGTACGTGATGTAGC-3′ (SEQ ID NO:39 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing V238I, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm46. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm46, whereby a recombinant organism E. coli HB101 (pNKPm46) producing an altered carbonyl reductase V2381-K259E-K270M was obtained.
Example 24
Preparation 18 of Altered Carbonyl Reductase with Multiple Mutations
[0248] A double-stranded DNA encoding an N-terminal polypeptide containing a T257S amino acid substitution relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 37: 5′-GATCAACCTTTTACCGCTTAACTCATCATTATG-3′ (SEQ ID NO:40 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing T257S, K259E, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 38: 5′-CATAATGATGAGTTAAGCGGTAAAAGGTTGATC-3′ (SEQ ID NO:41 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing T257S, K259E, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm47. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm47, whereby a recombinant organism E. coli HB101 (pNKPm47) producing an altered carbonyl reductase T257S-K259E-K270M was obtained.
Example 25
Preparation 19 of Altered Carbonyl Reductase with Multiple Mutations
[0249] A double-stranded DNA encoding an N-terminal polypeptide containing K259E and N265K amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO: 4 in the sequence listing), and primer 39: 5′-GCATAGTGAATGAAGCTTTTGACAAGATCAACCTTTCACC-3′ (SEQ ID NO:42 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing K259E, N265K, and K270M amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 40: 5′-GGTGAAAGGTTGATCTTGTCAAAAGCTTCATTCACTATGC-3′ (SEQ ID NO:43 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K259E, N265K, and K270M amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm48. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm48, whereby a recombinant organism E. coli HB101 (pNKPm48) producing an altered carbonyl reductase K259E-N265K-K270M was obtained.
Example 26
Preparation 20 of Altered Carbonyl Reductase with Multiple Mutations
[0250] A double-stranded DNA encoding an N-terminal polypeptide containing K259E, K270M, and G300D amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 41: 5′-CTCGTTATGGACACGATCTCCTTGAGGTAACTC-3′ (SEQ ID NO:44 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing K259E, K270M, and G300D amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 42: 5′-GAGTTACCTCAAGGAGATCGTGTCCATAACGAG-3′ (SEQ ID NO:45 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K259E, K270M, and G300D amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm49. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm49, whereby a recombinant organism E. coli HB101 (pNKPm49) producing an altered carbonyl reductase K259E-K270M-G300D was obtained.
Example 27
Preparation 21 of Altered Carbonyl Reductase with Multiple Mutations
[0251] A double-stranded DNA encoding an N-terminal polypeptide containing K259E, K270M, and R301C amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (N-terminal DNA) was obtained by PCR using the plasmid pNKPm37 obtained in Example 7 as a template, primer 1: 5′-GGGAATTCCATATGAGTGTTTTAGTTACAGG-3′ (SEQ ID NO:4 in the sequence listing), and primer 43: 5′-CTTCTCGTTATGGACGCAACCTCCTTGAGGTAACTCG-3′ (SEQ ID NO:46 in the sequence listing). Similarly, a double-stranded DNA encoding a C-terminal polypeptide containing K259E, K270M, and R301C amino acid substitutions relative to the amino acid sequence of SEQ ID NO:1 (C-terminal DNA) was obtained by PCR using the plasmid pNKPm37 as a template, primer 44: 5′-CGAGTTACCTCAAGGAGGTTGCGTCCATAACGAGAAG-3′ (SEQ ID NO:47 in the sequence listing), and primer 2: 5′-ATACGCGTCGACTTACTATTGTTCTTGAACCTTCA-3′ (SEQ ID NO:5 in the sequence listing). The N-terminal DNA and the C-terminal DNA were mixed, and with the DNA mixture as a template, PCR was carried out using primer 1 and primer 2 to obtain a double-stranded DNA encoding a polypeptide containing K259E, K270M, and R301C amino acid substitutions in the amino acid sequence of SEQ ID NO:1. The double-stranded DNA was introduced into pUCN18 in the same manner as in Reference Example 2 to prepare pNKPm50. E. coli HB101 competent cells (from Takara Bio, Inc.) were transformed with the pNKPm50, whereby a recombinant organism E. coli HB101 (pNKPm50) producing an altered carbonyl reductase K259E-K270M-R301C was obtained.
Example 28
Evaluation 2 of Altered Carbonyl Reductase with Multiple Mutations
[0252] The recombinant bacteria with the respective altered carbonyl reductases with multiple mutations obtained in Examples 17 to 27 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. The stability of each altered carbonyl reductase with multiple mutations to dimethylformamide was evaluated in the same manner as in Example 4. The relative activities of the wild-type enzyme and the altered carbonyl reductases evaluated in the presence of 50% dimethylformamide are shown in Table 7.
[0000]
TABLE 7
Residual activity
Mutation site
(%)
Wild-type enzyme
0
K270M
1
K259E-K270M
5
S2I-K259E-K270M
2
I124L-K259E-K270M
25
L177F-K259E-K270M
3
F195L-K259E-K270M
21
A220V-K259E-K270M
16
S236N-K259E-K270M
24
V238I-K259E-K270M
15
T257S-K259E-K270M
33
N265K-K259E-K270M
15
G300D-K259E-K270M
20
R301C-K259E-K270M
35
[0253] The altered carbonyl reductases shown in Table 7 had better stability to an organic solvent than the wild-type enzyme.
Example 29
Preparation 2 of Mutant Enzyme Library
[0254] A mutant enzyme library was prepared in the same manner as in Example 1, using as a template the plasmid pNKPm37 containing the mutant RKP gene for K259E-K270M mutant enzyme obtained in Example 15. This library is referred to as mutant enzyme library 2.
Example 30
Selection 3 of Altered Carbonyl Reductase
[0255] Altered carbonyl reductases having better resistance to the reaction inhibition by dimethylformamide, which is an organic solvent, were selected from the mutant enzyme library 2. The recombinant bacteria from the mutant enzyme library 2 prepared in Example 29 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each inoculated on an LB medium plate containing 100 μg/mL ampicillin.
[0256] The thus obtained colonies were transferred to a nylon membrane (Biodyne A, 0.45 μm), and the nylon membrane was immersed in 50 mM 3-(N-morpholino)propanesulfonic acid (MOPS) buffer containing 40% dimethylformamide for 30 to 60 minutes. Then, the nylon membrane was immersed in 50 mM MOPS buffer containing 1 mM NADP + , 200 μM nitroblue tetrazolium, 10 μM 1-methoxy-5-methylphenazinium methylsulfate, and 5% (v/v) 2-propanol at room temperature for 30 minutes. Thereafter, the nylon membrane was washed with distilled water, and then stained colonies were selected as candidates for recombinant bacteria with altered carbonyl reductases having better resistance to the reaction inhibition by an organic solvent. The candidate strains were each inoculated into 5 ml of 2×YT medium (1.6% tryptone, 1.0% yeast extract, and 0.5% sodium chloride, pH 7.0) containing 200 μg/ml ampicillin, and cultured for 20 hours. The cells in the obtained culture media were disrupted and centrifuged, followed by removing the precipitate to obtain a cell-free extract. The cell-free extracts were dispensed in an amount of 200 μL into a 96-well plate (from AGC Techno Glass Co., Ltd.), followed by adding and mixing 50 μL of 0.1M phosphate buffer (pH 6.5) containing 0.625 mM NADPH and 10 mM 2,3-butanedione. NADPH fluorescence was measured with time using a Benchmark Plus microplate spectrophotometer (from BIO-RAD). Samples in which NADPH was consumed due to the reduction of 2,3-butadione and thus fluorescence was quenched were selected as recombinant bacteria with altered carbonyl reductases having even better resistance to the reaction inhibition by an organic solvent. Plasmids were extracted from the culture media of the selected recombinant bacteria, and the base sequence of the mutant RKP genes was determined using BigDye Terminator Cycle Sequencing Kit (from Applied Biosystems Japan, Ltd.) and Applied Biosystems 3130xl Genetic Analyzer (from Applied Biosystems Japan, Ltd.), whereby the mutation sites were identified. The obtained altered carbonyl reductases having better resistance to the reaction inhibition by an organic solvent are shown in Table 8.
[0000]
TABLE 8
Plasmid
Mutation site
pNKPm51
K22R-F87I-K259E-K270M
pNKPm52
D90G-K259E-K270M
pNKPm53
K39R-T51A-K259E-K270M
[0257] The three enzymes shown in Table 8 having better resistance to the reaction inhibition by an organic solvent were obtained.
Example 31
Evaluation 3 of Altered Carbonyl Reductase
[0258] The recombinant bacteria with the altered carbonyl reductases obtained in Example 30 and E. coli HB101 (pNKP) (control) prepared in Reference Example 3 were each cultured in the same manner as in Reference Example 4. The cells in the obtained culture media were collected by centrifugation and suspended in 100 mM phosphate buffer (pH 6.5) in an amount of ⅕ of the amount of the culture medium. The suspension was disrupted with a model UH-50 ultrasonic homogenizer (from SMT), followed by removing the cell debris by centrifugation to obtain a cell-free extract. An amount of 100 μL of each of the cell-free extracts was mixed with 400 μL of 1M phosphate buffer (pH 7.0), 500 μL of water or a 60% DMF solution, 1% 2-hexanone, 5% NADPH, and 3.4% glucose. The mixture was reacted with stirring at 30° C. for 2 hours. After the reaction, the reaction mixture was extracted with ethyl acetate. The thus obtained extracts were analyzed under the conditions described below in “Analysis conditions for gas chromatography” to determine the production of 2-hexanol. Conversion ratio was calculated from the peak areas of 2-hexanol and 2-hexanone.
[Analysis Conditions for Gas Chromatography]
[0259] Column: InertCapI capillary column (30 m, inner diameter: 0.25 mm, product of GL Sciences)
[0260] Detector: hydrogen flame ionization detector
[0261] Injection site temperature: 250° C.
[0262] Column temperature: 50° C.
[0263] Detector temperature: 250° C.
[0264] Carrier gas: helium, flow rate=150 kPa
[0265] From the conversion ratio, the relative activity of the recombinant bacteria in the presence of 60% dimethylformamide compared to the activity in the absence of dimethylformamide was calculated. The relative activity was calculated by the equation below and used as an indicator of reaction inhibition by dimethylformamide. The results are shown in Table 9.
[0000] Relative activity (%)=[conversion ratio in the presence of dimethylformamide]/[conversion ratio in the absence of dimethylformamide]×100
[0266] The altered carbonyl reductases having better resistance to the reaction inhibition by an organic solvent are shown in Table 9.
[0000]
TABLE 9
Residual activity
Mutation site
(%)
Wild-type enzyme
24
K22R-F87I-K259E-K270M
35
D90G-K259E-K270M
31
K39R-T51A-K259E-K270M
31
[0267] The three enzymes shown in Table 9 having better resistance to the reaction inhibition by an organic solvent were obtained. The altered carbonyl reductases shown in the table had better resistance to the reaction inhibition by dimethylformamide, which is an organic solvent, than the wild-type enzyme.
Example 32
Production of 3-[(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one
[0268] To 700 μL of the culture of the recombinant E. coli expressing the carbonyl reductase RKP (wild-type) derived from Vanderwaltozyma polyspora NBRC0996 obtained in Reference Example 4 or a culture obtained by culturing the recombinant E. coli producing the altered carbonyl reductase T257S-K259E-K270M obtained in Example 24 in the same manner as in Reference Example 4 were added glucose dehydrogenase (trade name: GLUCDH “Amano” II, product of Amano Enzyme Inc., 12.5 U), 80 mg of glucose, 0.6 mg of NADP + , 300 μL of dimethylformamide or 0.1M phosphate buffer (pH 7), and 10 mg of (S)-1-(4-fluoro-phenyl)-5-(2-oxo-4-phenyl-oxazolidin-3-yl)-pentane-1,5-dione, and the mixture was stirred at 30° C. for 20 hours. The reaction mixture was diluted with dimethyl sulfoxide and analyzed by high-speed liquid chromatography under the conditions described below to determine the conversion ratio to 3-(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one and the optical purity thereof. The results are shown in Table 10.
[0000]
TABLE 10
DMF
Conversion
concentration
ratio
Optical purity of
Enzyme
(%)
(%)
S-form (% e.e)
Wild-type
0
54.4
89.21
Wild-type
30
16.6
87.89
T257S-K259E-K270M
0
47.5
80.15
T257S-K259E-K270M
30
99.0
73.91
Method for Calculation and Analysis Conditions of Conversion Ratio to 3-(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one
[0269] Column: COSMOSIL 5C8-MS (250 mm, inner diameter: 4.6 μm, product of Nacalai Tesque, Inc.)
[0270] Column temperature: 40° C.
[0271] Detection wavelength: 254 mm
[0272] Mobile phase: water/acetonitrile=1/1
[0273] Retention time: [3-[(5)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4)-phenyl-1,3-oxazolidin-2-one=about 8.5 minutes, 1-(4-fluoro-phenyl)-5-(2-oxo-4-phenyl-oxazolidin-3-yl)-pentane-1,5-dione=about 12.9 minutes
[0000] Conversion ratio=[produced amount of 3-[(5)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4)-phenyl-1,3-oxazolidin-2-one]/[(produced amount of 3-[(5)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4)-phenyl-1,3-oxazolidin-2-one)+(residual amount of 1-(4-fluoro-phenyl)-5-(2-oxo-4-phenyl-oxazolidin-3-yl)-pentane-1,5-dione)]×100
Method for Calculation and Analysis Conditions of Optical Purity of 3-[(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one
[0274] Column: CHIRALCEL OD-H (250 mm, inner diameter: 4.6 μm, Daicel Chemical Industries, Ltd.)
[0275] Column temperature: 30C.°
[0276] Detection wavelength: 254 mm
[0277] Mobile phase: hexane/ethanol=8/2
[0278] Retention time: 3-[(5R)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one=about 18.1 minutes, 3-[(5S)-(4-fluoro-phenyl)-5-hydroxypentanoyl]-(4S)-phenyl-1,3-oxazolidin-2-one=about 21.7 minutes
[0000] Optical purity of R-form (% e.e .)={(peak area of R-form)−(peak area of S-form)}/{(peak area of R-form)+(peak area of S-form)}×100 | An object of the present invention is to modify a wild-type enzyme that is less reactive in the presence of an organic solvent to provide altered carbonyl reductases having better reactivity in the presence of the organic solvent than the wild-type enzyme, and/or to provide transformants producing such reductases. The present inventors have found altered carbonyl reductases having better reactivity in the presence of an organic solvent than the wild-type enzyme, from among a mutant enzyme library prepared by randomly mutating the wild-type enzyme gene, thereby arriving at completion of the present invention. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation to my prior nonprovisional application, application Ser. No. 08/626,571 filed Apr. 2, 1996 with the US PTO, for APPARATUS AND METHOD FOR SAFE COMMUNICATIONS, now abandoned. This is a file wrapper continuation pursuant to 37 C.F.R. 1.62. The application Ser. No. 08/626,571 is to be abandoned upon granting the benefit of filing date of the parent to the present application.
BACKGROUND OF THE INVENTION
This invention relates to safe public communication systems, and more particularly to such systems which include means for secure distribution of the encryption key and the communication parameters.
Heretofore, various devices and methods were devised for secure voice and/or data communication for public use, using analog or digital encryption means. Common to the various encryption methods is the use of an encryption key, which provides a higher level of protection together with flexibility and standardization. Public key encryption, by using separate encryption and decryption keys, offers better protection for encrypted messages. A public key cryptographic system and method was disclosed in Merkle-Hellman U.S. Pat. No. 4,218,582; the RSA (Rivest- Shamir- Adleman) encryption system and method was disclosed in U.S. Pat. No. 4,405,829.
With the proliferation of encryption machines in commerce and for private use, a situation arises wherein a user desires to establish a secure communication link with another user having an encryption machine. The user poses a problem: How to exchange the encryption keys in a secure way, to establish the secure link. If the key is compromised, then the whole communication is compromised, and the encryption is useless. This is a vicious circle, since a secure link is required to transmit the key to begin with; but, since the other party doesn't have yet the key, the secure link can't be used to transmit the key itself.
Furthermore, data communication systems face the dangers of eavesdropping and impersonation, with the associated risks of the key being intercepted or a false key being transmitted by an impersonator. Accordingly, means are required for secure key distribution, this being an essential requirement for the widespread use of encryption machines, that is for establishing a secure link between parties which had no previous secure communications therebetween.
The security of the encryption process depends on the security of the encryption key, which depends on the security of the key distribution means; therefore, special means are required to provide a higher level of protection for the key distribution means itself.
A directory of public keys could be used, but a fixed list cannot cope with the fast changing situation in this area, with new users joining continuously, users changing address and users changing keys for better protection.
Various attempts at solving the key dissemination problem were devised, for example PGP maintains a public server containing a list of public keys. PGP server accepts and maintains a file with a collection of identification packages (KeyID). Each identification package includes the name and details of a key holder, together with his/her public key, which are signed (authenticated) by a third party which encrypts the package with his/her private key.
Another party desiring to communicate with such a key holder searches for an identification package signed by someone known/ accepted by them, thus "ensuring" that is the true key, which truly belongs to the person as claimed; the third party is "known/accepted" in the sense that the caller believes that its encryption key pair are as claimed and are not compromised. Since any single third party may be unknown to the other party, said key holder submits a plurality of identification packages to the PGP server, each signed by a different third party; another party looking for a reliable encryption key has to desiring to communicate with search all the packages belonging to that key holder, until he finds one signed by a third party known to him.
Thus, the PGP server maintains a file with a collection of identification packages for a multitude of users, and with a plurality of packages for each user. Thus it may be difficult to keep this vast quantity of information to disseminate it to users.
Another key dissemination method is employed by VeriSign, which distributes digital "certificates" valid for a long time period, for example 5 years. A certificate includes the name and additional information for a user, together with the public key for that user and the expiry date of the certificate, all encrypted with the private key of the issuing authority. Another certificate is issued to that first issuing authority by a higher second authority, and so on. This is a hierarchical authorization structure, with a user bringing signatures from persons/entities at several levels, until a level high enough is reached which is also part of the hierarchy of the calling party.
A great effort is put into ensuring the identity of a user before issuing a certificate, and in keeping the certificates; however, a certificate once issued may be compromised during its long lifetime, in which case it is difficult to replace. The center has no control over the use of an issued certificate while the certificate is still valid, during the long period as set at issue time; only the "black list" at the center may give a warning to that effect, but that can only prevent communications. A reliable key has yet to be exchanged between the parties, which is difficult in this case.
RSA Data Security Inc. offers another system including a center which issues certificates, that is digital documents containing the name and details for a user, together with his/her public key and an expiration date, all encrypted with the private key of the center. The expiration date is a weak link for this system since, as the key approaches its expiry date, the chance of its being compromised increases, and more verification requests will be placed with the center.
If a key is compromised, it is practically impossible to remove it from the server; PGP and RSA only keep a second list (the black list) of disabled or canceled keys, but this is a cumbersome and inefficient method.
If the private key of the RSA or other similar centers is compromised, this results in a "catastrophe", since anyone can impersonate other users.
Another user of public key encryption is the PC Fax program package offered by Microsoft for the transmission of FAX messages. The FAX may be encrypted using a password or a digital key. Again, they face the same problem of reliable key dissemination. Microsoft advises to exchange diskettes containing the key, clearly a difficult to use method. A public key can be exchanged by communication means, and again there is the problem of identifying the other party- how one is to know that the answering party is truly the person it claims to be. Caller identification is a problem encountered in various situations in the modern period of widespread use of global communications and information exchange.
SUMMARY OF THE INVENTION
According to the present invention, there is provided an apparatus and method for transferring the encryption key in a secure way, to facilitate establishing a secure communication link, comprising a key management device attaching to each user's encryption machine for the purpose of key distribution, and a secure encryption key distribution center providing the service of secure encryption key dissemination to authorized users.
According to one aspect of the present invention, there is provided a key management device attaching to each user's encryption machine, containing a list of secure communication partners and their respective encryption keys and parameters. To initiate a secure link session, the user keys in the identification of the desired addressee; if the details of that addressee are stored in the communication partners data list, then the encryption key and other communication parameters pertaining to that person are transferred automatically to the encryption machine, and the secure link is established.
Likewise, if this machine is accessed by another user's device, then the other device transmits its identification, and again the encryption key and other communication parameters are read from the list and transferred automatically to the encryption machine. A display is used to display to each user the true, reliable identity of other party, as established during the secure link setup.
According to another aspect of the present invention, if the desired addressee data is not found in the secure communication partners data list, then the key management device automatically connects a secure key distribution center, to get the encryption key and parameters for that addressee. This data is then transferred to the encryption machine and is also stored in the local list for future use.
According to a third aspect of the present invention, the communication with the key distribution center is protected by encryption using the public key method. The encryption key request is transmitted to the center after encryption with the center's public key; the center uses its private key to identify the inquirer and the addressee, and then transmits the desired information after encryption with the inquirer's public key.
Thus, only the center knows who asked what information, this preventing center impersonation; only the inquirer can decrypt the answer, thus an eavesdropper can't use the information. Furthermore, by providing only the public key of the desired addressee, a higher level of protection is achieved, since even if the key is compromised, the encrypted message using that key is still protected, since the private key was not disclosed.
According to a fourth aspect of the present invention, a secure encryption key distribution center is disclosed, performing the key distribution process as detailed hereinbefore, when addressed by a user's key distribution device. Also disclosed is a system including a plurality of such centers, connected in a wide area network for fast updating of key information so all the centers provide identical, updated information.
According to a fifth aspect of the present invention, the key distribution center creates a "certificate", that is a digital safe key/identification package for each user. The certificate can be used in an open link transaction between users for the secure link establishment. Each certificate includes the public key for a user, together with identification information for that user and the issue date, all encrypted with the private key of the key distribution center. The algorithm is based on a public key algorithm which is symmetrical with respect to the encryption and decryption keys, using package encryption with the private (decryption) key of the key distribution center. Unlike other key distribution systems, in the present invention there is no need to keep local lists of other users keys; during the link setup transaction, each party sends its certificate to immediately and reliably establish its identity.
According to a sixth aspect of the present invention, the certificate can be frequently changed, to maintain a high level of security. This protects the information if the user's key is compromised, and also provides for easy recovery if the private key of the center itself is compromised; this is a catastrophic situation for other systems.
According to a seventh aspect of the present invention, the certificate can be used to access a multitude of remote databases or other information services on an irregular basis, without the need to subscribe to all of them. The method involves the user to present a certificate issued to him by the center, including an authorization to access databases and an optional list of permitted operations therein.
According to an eighth aspect of the present invention, the certificate may be used for secure payment over insecure links, for example the Internet. The credit card information is protected from unauthorized use by the seller or third parties participating in Internet for example, by the inclusion of the credit card information in the encrypted certificate, with that certificate capable of being decrypted only by the authorized party, the credit card issuer for example.
According to an ninth aspect of the present invention, the certificate may be used for caller identification, with the subsequent communication being either encrypted or not. Caller identification is implemented by the exchange of certificates as detailed. Applications include Caller identification may be beneficial in a wide variety of applications, for example telephone and fax, cellular/wireless phone, computer communications, remote control/base station, access control.
According to an tenth aspect of the present invention, the certificate allows to implement flexible authorization schemes, for example its time period of validity may be limited as desired, according to application and circumstances. Another implementation is to include a list of authorizations or actions permitted for that user to do, or databases to access, or permitted operations in those databases.
Thus, the present invention facilitates secure communications between users having encryption machines which had no previous secure communications therebetween; furthermore, the invention provides protection for database services providers and these services' users, by facilitating user authentication and selective (encrypted) data dissemination. Furthermore, the invention provides for reliable caller identification for encrypted or nonencrypted communications.
Further objects, advantages and other features of the present invention will become obvious to those skilled in the art upon reading the disclosure set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a description of the overall structure of the encryption key distribution system.
FIG. 2 details the key management device connected to a user's encryption machine for analog communications.
FIG. 3 illustrates the key management device connected to a user's encryption machine for digital data communications.
FIG. 4 details the key management device structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described by way of example and with reference to the accompanying drawings.
Referring to FIG. 1, an example of the overall structure of the encryption key distribution system, a user encryption facility 1 comprises an encryption machine 21 and a key management device. Encryption machine 21 includes plaintext channel 211 to communicate with the local user, and ciphertext channel 212 connected to another user through a standard communication channel 213, using wired or wireless communication means.
The key management device includes key management controller 314 and channel interface 41. The operation of the system components will now be detailed, assuming the initiator is facility 1 and the addressee is user encryption facility 3. The user enters the details of the desired addressee through channel 313, which may consist of a local keypad or a link to a computer.
This is the identification of the person or facility to establish a communication link with. If the keys for that addressee are found in the local list in controller 314, as detailed below with reference to FIG. 4, then key setup channel 311 is used to transfer the encryption and decryption keys for that addressee, together with optional additional parameters from key management device 314, to encryption machine 21, said keys being subsequently used by encryption machine 21.
The encryption and decryption keys consist of digital bits or words in serial or parallel form, usable for encryption or decryption using known methods like DES or public key algorithms like the RSA method.
If the keys for the desired addressee are not found in the local list, then key management controller 314 automatically connects the secure encryption key distribution center 11 through key distribution channel 103, and sends an inquiry message asking for the public key for the addressee, facility 3 in this example, the message being encrypted with the public key for center 11. Key distribution channel 103 is a communication channel used for that purpose.
Center 11 decrypts the message, verifying the identity of facility 1 in the process; the answer is sent to facility 1, encrypted with the public key for that facility. The method used for facility 1 identification is detailed below, see step 3b of the key distribution center 11 algorithm.
Facility 1 can now access facility 3, to initiate a mutual identification and key and parameters setting for a secure communication session. The communication path consists of controller 314, through data initiation channel 312, encryption in machine 21, through ciphertext channel 212, channel interface 41, communication channel 213 connected to communication channel 233 at facility 3, to channel interface 43, through ciphertext channel 232, decryption in machine 23, through data initiation channel 332, to controller 334.
Key setup channel 311 is used in facility 1 during an initiating procedure before the abovedetailed communications, to load the encryption and decryption keys in machine 21 from controller 314. Similarly, channel 331 in facility 3 is used to load the encryption and decryption keys in machine 23 from controller 334.
Channel interface means 41 includes means for performing functions as required by communication channel 213, like phone dialing, signal level control, impedance loading.
Interface unit control 812 is used by controller 314 to control the channel interface means 41, according to the operating mode and link establishment stage, as detailed below.
Facility 3 also includes plaintext channel 231, ciphertext channel 232 connected to communication channel 233, addressee details channel 333, interface unit control 832, key distribution channel 107.
A secure encryption key distribution center 11 is connected to a multitude of user encryption facilities, two of these being designated as 1, 2 in FIG. 1. Center 11 uses key distribution channels designated 101, 102, 103, 104. Center 11 includes a (not shown) computer including a list of users with their respective public keys and other data: each user's phone number and address, last update date, whether a dialer/user automatic identification is to be performed. The computer also controls the various activities in the center with the encryption machine, the channel interface and the local operator.
The computer also includes an interface to operator (not shown) for status or warnings display, control and manual keys update. Channel interface means (not shown) in center 11 are similar to channel interface means 41 in facility 1 as detailed above, including means for performing functions as required by communication channels 101, 110 like phone dialing, signal level control, impedance loading. Since center 11 is capable of connecting simultaneously to numerous users, a channel interface having this capability is used, as known in the art.
Encryption machine means (not shown) in center 11 are similar to that in facility 1. Faster, more powerful machines may be used for higher throughput.
Facility 2 comprises encryption machine 22 and key management controller 324, with interface unit control 822, channel interface means 42, communication channel 223, data initiation channel 322, used in facility 2 to communicate with facility 1 or any other user. Facility 2 also includes encryption machine 22, key management controller 324, plaintext channel 221, ciphertext channel 222, addressee details channel 323, key distribution channel 104. Channel 321 is used to load the encryption and decryption keys in machine 22, from controller 324.
Likewise, key distribution center 12 is connected to a multitude of user encryption facilities, like facility 3, using key distribution channels designated 105, 106, 107, 108, 109. All the centers 11, 12, . . . contain the same list of encryption keys.
Inter-center links 110, 111, 112 are used to connect the key distribution centers for key data updates, using a digital, secure (encrypted) format. Thus, after a user updates his/her key with the local center, the lists in all the centers are updated automatically, to provide updated information to all the system's users.
Thus, the abovedetailed apparatus and method for transferring the encryption key allow to establish a secure communication link between two facilities with encryption machines. Moreover, reliable identification of the parties to a new communication session can be performed, that is each party can ascertain the identity of the other party. The reliable identification can be performed between parties which had no previous communications therebetween, the parties being strangers to each other and at separate locations, remotely located; the identification process uses the same data communication link as the data communication to be performed after the identification stage.
Furthermore, each user equipment can include a key generation machine, that is a processor which accepts a random number from the user and generates a key pair (a public key and a private key). Only the public key is transmitted to the center or otherwise displayed; the private key is kept secret, inside the machine, and is only used to decrypt or encrypt messages. This apparatus and method allow to generate new keys whenever the user so desires, and the private key is securely kept.
Additional physical key protection means can be used, for example the key generation machine is mounted in a cellular telephone; the user personally keeps that telephone, thus ensuring that the private key is safe.
For the use of the invention in a cellular telephone, another implementation is not to include the key pair generating machine in the telephone; the user can go to a cellular telephone company center to compute there and load new keys, for example by connecting to terminals in that center.
Another implementation uses an external key generating machine carried by a cellular telephone representative. The machine has the processing ability required for key generation, but has no internal memory to keep the generated keys. Thus, the machine is connected to a cellular telephone, it generates the key pair and transfers the keys to the cellular telephone.
Since the machine cannot keep the keys, only the user of that cellular telephone has the key pair, thus the keys cannot be compromised even by the telephone company personnel.
This method for user authentication and selective data dissemination can be used in financial transactions, for example to pay with credit cards through insecure links, and where the payee himself may be unreliable as well. An unreliable payee cannot make unauthorized use of the information in the card, since that information is encrypted and is not available to him/her.
The method can be used to establish cellular phone links, while preventing an impersonator from stealing phone communication rights from the legitimate telephone owner. The method can be used as well to protect wireless remote control devices (for example car locks or garage openers).
The operation of the key management device was described in the context of the whole secure communication system.
The algorithm for each of the system components will now be detailed, assuming the addressee is user encryption facility 3 comprising an encryption machine 23, key management controller 334 and interface 43. These algorithms are executed concurrently or sequentially.
The algorithm for connection initiating device 314 comprises the following steps:
1a. Device 314 receives the addressee 3 details through channel 313
2a. If the addressee 3 details are found in the local list, then: the encryption and decryption keys are transferred to machine 21 through channel 311; jump to step 7a (No need to contact the key distribution center 11)
3a. The desired addressee 3 details, together with identification details for facility 1 and a group of random bits, are encrypted using the public key for key distribution center 11 to form an inquiry message. Communication channel 103 is established with center 11, and the encrypted inquiry message is send to center 11 (which then performs steps 1b to 5b and 7b, or 1b to 3b and 6b, 7b, as detailed below)
4a. The answer from center 11 (step 5b there) is decrypted using the private decryption key for facility 1. That answer contains the public key for the desired addressee 3 and the group of random bits sent to center 11;
5a. If the received group of random bits are not identical to the transmitted random group, then jump to step 6a (Answer from impersonator); otherwise the answer is accepted as legitimate, then: the public key contained therein is transferred to machine 21 through channel 311, together with the private key for facility 1; update local keys list with the key received from center 11; jump to step 7a
6a. Display message: Failure to get public key for desired addressee; Stop
7a. Prepare an initial message for facility 3, comprising data identifying facility 1 and a group of random bits, encrypted with the public key for facility 3
8a. Use channel interface 41 to access facility 3 through channel 213, which is connected to channel 233 at facility 3. Send initial encrypted message to facility 3 (facility 3 performs then steps 1c to 9c or part of these steps, according to its algorithm detailed below)
9a. Caller/addressee identification: Receive message from facility 3, decrypt with the private key for facility 1, extract the group of random bits sent to facility 3 and compare with the group sent; if not identical, then jump to step 10a; otherwise: encrypt the received random bits generated in facility 3 with the public key for facility 3 and send the encrypted message to facility 3; jump to step 11a
10a. Display message: Addressee identification failed; Stop
11a. Display message indicating successful link establishment; End
The algorithm for key distribution center 11 comprises the following steps:
1b. Distribution center 11 receives encrypted inquiry message from facility 1 through channel 103, together with automatic dialer identification data received
2b. The message from facility 1 is decrypted using the private decryption key for center 11.
3b. The inquirer identification contained in the message is compared with the automatic dialer identification data received. If in disagreement, then jump to step 6b
4b. Compile an answer message comprising the desired addressee public key and the group of random bits received; encrypt using the public key for facility 1, that key being stored in the center 11 database together with the other encryption (public) keys
5b. Send the encrypted message to facility 1; jump to step 7b
6b. Display warning message: Illegitimate access event
7b. Store details of transaction for optional future audit; End
The algorithm for the addressed device 334 comprises the following steps:
1c. Controller 334 receives an initial message through channel 233, interface 43, channel 232, decrypted in machine 23, through data initiation channel 332; this is the initial message from facility 1. The message is decrypted with the private key for controller 334, to extract the message including facility 1 identification and the random bits group;
2c. If the details for facility 1 are found in the local list, then: the encryption and decryption keys are transferred to machine 23 through channel 331; jump to step 7c;
3c. The facility 1 details are encrypted using the public key for key distribution center 12, together with identification details for facility 3 and a group of random bits. Communication channel 107 is established with center 12, and the encrypted message is send to center 12, similar to the abovedetailed facility 1 inquiry of center 11;
4c. The answer from center 12 is decrypted using the private decryption key for facility 3. That answer contains the public key for facility 1 and the group of random bits sent to center 12;
5c. If the received group of random bits are identical to the transmitted random group, then: the answer is accepted as legitimate; the public key contained therein is transferred to machine 23 through channel 331, together with the private key for facility 3; update local keys list with the key received from center 12; jump to step 7c
6c. Display message indicating failure to get public key for facility 1; Stop
7c. Caller/addressee identification: Compile a group of random bits, add to the random bits received from facility 1 and encrypt using the public key for facility 1; send the message to facility 1 through interface 43 and channel 233; receive the answer from facility 1, decrypt with the private key for facility 3, and compare with the initial group sent; if identical, then jump to step 9c
8c. Display message: Caller identification failed; Stop
9c. Display message indicating successful link establishment; End
For performing these algorithms and related functions, each facility of initiator/addressee can perform in one of the following modes of operation:
1. Initiate clear link communications with another facility
2. Initiate encrypted link communications with another facility
3. Accept clear link establishment with another facility
4. Accept encrypted link establishment with another facility
5. Initiate encrypted link with key distribution center to get other's key
6. Initiate encrypted link with key distribution center to update own key recording in the center's list
7. Key update: prepare pair of keys; update both in local lists; send only public key to center.
8. Key input through local! keypad, barcode reader, tape reader, magnetic tape reader, voice, another serial communication channel like RS-232 9. Key input from another facility, when that facility changes its keys and sends the new public key to its known addressees (according to the local keys list of that fcility).
The abovedetailed algorithms, being implemented by the key distribution channel, the communication initiator 314 and the addressee 334, provide the benefit that the communication with the key distribution centers 11, 12 is protected by encryption using the public key method. Thus, the encryption key request is transmitted to the center 11 after encryption with the center's public key, such that only the center 11 can decrypt the message using its private key, to identify the inquirer 314 and the addressee 334.
Safe communications are achieved since only after inquirer authentication, center 11 transmits the desired information after encryption with the inquirer 314 public key.
Thus, only the center 11 knows who asked what information, this preventing center impersonation; only the inquirer 314 can decrypt the answer, thus an eavesdropper can't use the information. Furthermore, by providing only the public key of the desired addressee 334, a higher level of protection is achieved, since even if the key is compromised, the encrypted message using that key is still protected, since the private key for 334 was not disclosed.
Additionally, a secure encryption key distribution center 11 structure and operation was disclosed for performing the abovedetailed key distribution process.
FIG. 1 also details a system including a plurality of such centers, detailed as 11, 12 there, connected through links 110, 111, 112 in a wide area network for fast updating of key information.
FIG. 2 details the structure and operation of a key management device connected to a user's encryption machine 21 for analog communications.
The key management device comprises controller 314, dialer/modem 315 and data switch 51. Controller 314 receives the details of the desired addressee through channel 313, and scans a list of known communication partners in its internal memory (not shown).
If the keys for the desired addressee are not found in the local list, then controller 314 automatically connects the secure encryption key distribution center using dialer/modem 315, through channel 316 and channel 103. The illustrated implementation uses a modem/dialer 315 having two outputs. Controller 314 includes digital encryption means (not shown) for secure communication with the key distribution center through channel 103.
Data switch 51 connects the key management device channel 317 to communication channel 213 during the secure link setup stage. During the subsequent communication stage, switch 51 connects encryption machine 21 to communication channel 213. Controller 314 performs the stages of the secure link establishment and controls the state of switch 51 according to the abovedetailed algorithms. Channels 211, 212, 311 were already detailed, with reference to FIG. 1.
FIG. 3 details the structure and operation of a key management device connected to a user's encryption machine 21 for digital communications. The key management device comprises controller 314, dialer 315A and data switch/matrix 61. Controller 314 receives the details of the desired addressee through channel 313, and scans a list of known communication partners in its internal memory (not shown).
If the keys for the desired addressee are not found in the local list, then controller 314 automatically connects the secure encryption key distribution center (not shown) using dialer 315A, through channels 316, 317 and 103. This implementation uses a dialer 315A having one output. Controller 314 uses digital encryption machine 21 for secure communication with the key distribution center through channel 103, using plaintext channel 311 and ciphertext channel 212.
Data switch/matrix 61 connects channel 212 to channel 103 for communication with the key distribution center; it connects channel 212 to channel 213 during the secure link setup stage and during the subsequent secure communications session.
To establish a link with the key distribution center or with the addressee facility, switch 61 connects dialer 315A to channel 103 or channel 213 respectively, under controller 314 control. Controller 314 performs the stages of the secure link establishment according to the abovedetailed algorithms. The operation of channels 211, 312 was already detailed.
FIG. 4 details another implementation of the key management device, for use with an analog encryption machine without dialing capability nor digital communications capabilities. A telephone dial line 103A is used both for communications with the key distribution center and the desired addressee. The key management device comprises controller 314, dialer 315A, encipherer 318, decipherer 319 and data switch/matrix 61. Controller 314 receives the details of the desired addressee through channel 313.
If the keys for the desired addressee are not found in the local list, then controller 314 automatically connects the secure encryption key distribution center using dialer 315A, through channels 315B, 315C and 103A. Controller 314 uses digital encryption means 318 and decryption 319 for secure communication with the key distribution center through channel 103A.
Data switch/matrix 61 connects channel 382 or 392 to channel 103A for data communication with the key distribution center or the addressee; it connects channel 103A to channel 315C during the dialing period. Data switch/matrix 61 operation is controlled by controller 314 through channel 341.
Controller 314 performs the stages of the secure link establishment according to the abovedetailed algorithms. After the successful link establishment, controller 314 transfers the encryption and decryption keys to the encryption machine to be used for the secure communication session, through channel 311, then sets switch 61 to connect ciphertext channel 212 from the encryption machine to communication channel 103A. Controller 314 uses channels 381 and 391 to connect to encryption means 318 and decryption means 319 respectively.
There are a wide variety of applications for the abovedetailed key distribution system.
For example, in database systems, the encryption protects both the database and the user; by using encryption, user authentication can be performed, thus controlling information distribution only to qualified users. Moreover, the encrypted information can only be used by the legitimate customer. This also protects the legitimate user from unjustified bills resulting from an impersonator using the database.
Various implementations of the abovedetailed system will become apparent to persons skilled in the art. For example, FIG. 1 details a system implementation using separate channels for key distribution (103) and for communications with another user (213); a different implementation may use the same channel for both purposes.
Communication channels 213, 103, . . . may consist of fixed links set up for that purpose, like point to point wired connections or wireless links at predefined frequencies, or of temporary links like phone dial connections set up specifically for the designated functions and disconnected after the communication session completion. The channels 212, 103 . . . may then contain the telephone exchanges, wiring, wireless components and multiplexers and/or related components of the phone system known in the art. Communication channels 212, 103, . . . may consist of wired and wireless links, like satellite or cellular communications, LAN or WAN systems.
Various algorithms implementations will occur to persons skilled in the art, for example in case of link establishment failure and key obtained from local list; then a key inquiry procedure is initiated with center 11, since the addressee details in the local list may be obsolete; the key from center 11 is compared with the key in the local list; if not identical, then: update local list; try again to establish link.
A procedure to update encryption keys may be periodically initiated at each facility, the procedure comprising key pair computation, local list update and sending the public key to center 11 through a secure link and using a secure procedure; optionally, the new key may be transmitted to the known addressees as found in the local list.
In another implementation of the abovedetailed system operation, open communications (not encrypted) and without self identification, are used to inquire the center about the desired addressee's key and to receive the center's response.
The danger of impersonation or disinformation by the center or the addressee are minimal, since the center doesn't know the identity of the inquirer, so no selective attack can be performed, against a specific facility; if a false key is given, this will only result in the authentic addressee being able to respond; therefore the handshake will fail and the communications will not take place, thus preventing the protected data from being transmitted to an undesired destination.
In another implementation of the present invention, key distribution center 11 creates a digital safe key/identification package, as detailed below. The method uses a symmetrical public key algorithm, that is either the encryption or the decryption key can be used for message encryption, with the other key being used for decryption. A user, for example facility 1, inquires the center 11 about its own (facility 1) public key; center 11 responds with a message including facility 1's name and key, all encrypted with the private key of center 11.
Now, anyone can open that message with the public key of center 11, since the encryption algorithm is symmetrical; but it is very difficult to create a false message, since the center 11's private key, which was used to create the message, is unknown to the public.
Facility 1 can transmit that encrypted digital message "as is" to a desired addressee, facility 3 for example, to say in effect "I claim to be facility 1, and this is truly my public key, as attested by the center 11 which is known and accepted by both of us". Facility 3 opens the received digital message with the known center's public key, thus ensuring that the public key for facility 1 is that as claimed. In case the digital message is intercepted by an impersonator and subsequently used for communication with facility 3 for example, the communication handshake will fail since the impersonator will not be able to decrypt the answer from facility 3, since it doesn't possess the facility 1's private key. Because of this added protection, an open link (not encrypted) can be used by any user to ask the center 11 about its own or any other user's public key; the center's response, the encrypted message, can be used in an open link with another user to establish a secure link between any two users.
With each user storing a digital message including the encrypted center's answer regarding its own public key, no further communications with the center 11 are required nor a list of other users has to be kept, in order to establish secure communications therebetween: Each user sends to the other its own identification, the encrypted message from center 11 containing its own public key; each user decrypts the received message with the known center's public key, and each user is sure that that is the true key of the other. That public key is then used for subsequent communications handshake and data transfer.
The encrypted response message sent from center 11 may contain the response date and time, in addition to the key and the key user's identification. That date and time may be used to ensure that an updated key (not obsolete) is used.
Advantages of the abovedetailed method: the center can be accessed on an open line (not encrypted), without self identification. This protects from disinformation by an intruder at the center. For example, a fraudulent center operator or a fraudulently inserted routine may wait for the inquiries of a specific user, and respond falsely only to selected users which they desire to attack, for maximum damage and difficulty of detection. By using open inquiries, without self identification, this danger is minimized.
Various key management device implementations will occur to persons skilled in the art, like using a DIP switch or solid state memory for the encryption key setting, or a link to a personal computer. Solid state memory devices may include EEPROMs, flash memory, CMOS RAM or other device known in the art. Computing means may be used to compute new encryption keys or key pairs for public encryption.
A plug-in device may contain the keys, which device may be programmed at the key distribution center, then inserted by the user in the key management device; this ensures easy key updates as required, together with good physical protection. For example, the plug-in device may be kept in a safe while not in use.
Each user equipment can include a key generation machine, that is a processor which accepts a random number from the user and generates a key pair (a public key and a private key). Only the public key is transmitted to the center or otherwise displayed; the private key is kept secret, inside the machine, and is only used to decrypt or encrypt messages. This apparatus and method allow to generate new keys whenever the user so desires, and the private key is securely kept.
The random number from the user is optional; where desired, an internal random numbers generator can be used, or a time- related number may be used to generate the key pair.
The method for use of the equipment including the key generating machine will now be described by way of example.
The method used for the initial key pair generation:
1d. The user is given the equipment, for example the cellular telephone or remote control unit, at an authorized distribution center; the user is physically identified there, for example by means of an identification card or driver license. Thus, the center is sure that the equipment was delivered to the person which is supposed to receive it;
2d. The equipment is activated to generate an encryption key pair, that is a private key and a public key. The private key is never displayed or transmitted, but is only kept inside the equipment. The public key is displayed and/or transmitted by a digital channel to the center;
3d. The user- related information is registered (written) in memory means in the center, that information including the user identification details and the public key generated as detailed in (2d) above; and
4d. Anyone can now ask the center what is the public key of that specific user, and the inquirer will be given a reliable answer, that is encrypted with the center private key, that that indeed is the public key for the user as asked; the user can ask about his own key, and will be given a reliable, encrypted answer as well.
Another implementation of (2d) above, for use in a cellular telephone, consists in using facilities in a cellular telephone company center to compute and load new keys, for example by connecting to terminals in that center.
Still another implementation of (2d) above uses an external key generating machine carried by a cellular telephone representative. The machine has the processing ability required for key generation, but has no internal memory to keep the generated keys. Thus, the machine is connected to a cellular telephone, it generates the key pair and transfers the keys to the cellular telephone.
The method used for subsequent key pair update:
1e. The user connects the center and identifies himself, that including the following steps: He/she receives a random data block from the center, encrypted with user's public key; the user decrypts that message with his private key and encrypts it back with the center's public key; the encrypted message is sent back to the center; the center decrypts the message with center's private key and verifies that indeed the received message is identical with the transmitted message, this being proof of user's identity;
2e. The equipment is activated to generate an encryption key pair, that is a private key and a public key. The private key is never displayed or transmitted, but is only kept inside the equipment. The public key is encrypted with center's public key and is transmitted by a digital communication channel to the center;
3e. The center decrypts the message with its private key, thus reliably receiving the new, update user's public key; and
4e. The new, updated user- related information is registered (written) in memory means in the center, that information including the user identification details and the public key generated as detailed in (3e) above.
This method allows for a distributed center structure, with small local centers for user keys initial setting and subsequent update. Each local center then transmits the updated public key to the regional or worldwide center.
Another implementation of (2e) above uses an external equipment to compute and load the key pair into the cellular telephone, as detailed in connection with step (2d) above.
Another variation of (2e) above would be to the user to encrypt the new key with that user's old private key, then the center using the old user's public key to decrypt it.
Still another variation of (2e) would be to the user to send the new public key without any encryption at all, since the public key is not secret.
If the equipment containing the private key is lost, the system security is preserved by the following method: The user, as soon as he detects the equipment loss, notifies the center accordingly. The center then records that that user's public key is obsolete, and any other user asking for that user's public key will be notified accordingly.
The user can load a new key pair while he reliably identifies himself, for example as detailed in method (1d) to (4d) above.
An optional watchdog circuit can be attached to the private key memory means. If a predefined time limit is exceeded without the equipment being used or updated from center, then it is assumed that the equipment was lost, and the private and/or public key is destroyed.
The user equipment may include a complete message from center, that message including (user's name; user's public key; expiry date or last update date) all encrypted with center's private key. This allows the user to identify himself for safe communication purposes, as detailed above. The user can update his public key with the center anytime he desires, for example if he suspects the previous key was compromised; an impostor having a copy of the old message from center will not be able to use the old copy subsequent to that public key update.
If unauthorized attempts at reading the private key are detected, then the private key is destroyed as well. Additional physical key protection means can be used, for example the key generation machine is mounted in a cellular telephone; the user personally keeps that telephone, thus protecting the private key.
This method for user authentication and selective data dissemination can be used in financial transactions, for example to pay with credit cards through insecure links, and where the payee himself may be unreliable as well. A method to achieve that goal is as follows, for example while User desires to buy an article from Seller, and to pay using his credit card, for example Visa:
1f. User decides on the article to buy and finds its price;
2f. User encrypts the information (Seller details; article price; User credit card number and expiry date) with the Visa public key;
3f. User sends his/her order to Seller, including the encrypted information as per (2f) together with the nonencrypted information, including (Seller details; desired article details and price; User details, like name and address);
4f. Seller encrypts the whole message as per (3f), including the clear and the encrypted parts, with Visa's public key and sends it all to Visa;
5f. Visa decrypts the message using its private key once or twice as required, verifies the integrity of the whole message and checks User's credit, and prepares a sales authorization message;
6f. Visa encrypts the sales authorization message with the private Visa key or seller's public key and sends the message to Seller; and
7f. Seller decrypts the message with Visa public key or his private key according to the key used at encryption, thus receiving a secure, provable and untamperable with authorization to that sale.
The abovedetailed method offers the following benefits: User's credit card details (card number, expiry date) are protected from eavesdroppers on the communication channel and from Seller, since these details are encrypted with Visa's key, which only Visa can read; thus, no unauthorized use of User's card information can be made. Seller can't tamper with the price, since Seller has no access to the encrypted sales price data. Seller can prove that he received Visa approval for that sale, since only Visa can encrypt that authorization message with Visa's private key.
In another variation, User encrypts the information sent in (3f) above with Seller's public key, to ensure no unauthorized person can read the order details at all. Only Seller can decrypt the information and read it using his private key, thus preserving the information integrity on one hand, and providing proof that Seller received User's order on the other hand.
User can save Seller the effort to connect Visa to verify User's credit, as follows: User connects Visa before buying from Seller, and ask for a credit verification; Visa sends a package to User, including (User's details; credit approval and/or credit limit; time and date stamp) all encrypted with Visa's private key; User sends that package to Seller; Seller opens the package with Visa's public key, thus accepting Visa's approval for the sale.
This method can be used to implement a debit or money card, since each time a sale is authorized, Visa deducts the amount of that sale from that user's credit, until a limit is reached and no sales approvals are issued thereafter.
For regular plastic credit cards, the information recorded on the magnetic stripe may be encrypted as well, to protect the information in the card. Encryption is done using Visa's public key for example. The reason is that the information is passed to Visa anyway for approval and payment to seller, and only Visa actually needs the information stored in that card. It is safer that the information in the card should not be displayed to seller nor be stored in seller's data storage means.
That approval service may also be performed by an independent services provider, for example an insurance firm; that firm can offer insurance and approval services, with fees varying according to the update/verification rate: if more frequent verifications are made, then a lower fee may be asked for, since the risk is lower.
The method can be used to establish cellular phone links, and to protect wireless remote control devices, for example car locks or garage openers. For that purpose, the cellular local center (or the garage) sends an encrypted message to User; user decrypts it with his private key, thus proving his identity; this reliable identification method thus prevents unauthorized use of cellular telephone services by an impersonator; similarly, a garage opening device or a wireless car lock system can be protected from unauthorized use.
Thus, reliable identification of the parties to a new communication session can be performed, that is each party can ascertain the identity of the other party. The reliable identification can be performed between parties which had no previous communications therebetween, the parties being strangers to each other and at separate locations, remotely located; the identification process uses the same data communication link as the data communication to be performed after the identification stage. The abovedetailed secure communication means can also be used for fax communications as well.
The abovedetailed system and method allow a person on the move to establish secure communications with another person, from anywhere to any place on the globe. Various data communication means can be used, for example telephone lines, radio wireless, noncontact means like ultrasound or magnetic or capacitive. Acoustic couplers can be used to connect to a telephone line without disconnecting the telephone or the lines, but through the telephone microphone and speaker, like that used in modems.
Magnetic induction means may be used to connect to the telephone lines, for example using a ferromagnetic loop placed around a telephone wire; a second winding on that ferromagnetic loop generates alternative signals, which are induced in the telephone lines without disconnecting these lines. The alternative signals contain the desired information to be transmitted.
Similarly, electrical signals may be induced into a magnetic card reader in a way similar to that used by the credit cards; again, the alternative signals contain the desired information to be transmitted.
The key management device contains a connector for connecting a plug- in device containing the encryption key storage means; the plug- in device contains a corresponding connector and a nonvolatile memory for storing the key while being disconnected from the key management device. This allows for the key to be transportable, to be carried to the center for programming, or for being kept in a safe place.
According to the structure and capabilities of encryption machine 21, machine 21 may be used to encipher/decipher messages with center 11 and key setup messages with facility 3, or additional encryption means in controller 314 may be used for that purpose. Therefore, the key distribution device can use the encryption and dialing facilities of the existing encryption machine, or these features may be incorporated in the key management device.
The device may include a "CLEAR/SECURE" switch, which is set by the user to start controller dialing and secure communication establishment. The secure communication device can include a display, for communication related data and the details of the partner to the communication session. Thus, after secure key exchange and secure communication link establishment, each party can see the name and details of the other party; each party can thus ensure that he is speaking with the desired person.
Various means for key distribution center 11 can be used, like automatic dialer identification, together with said dialer information being stored in the distribution center for comparison with the actual reading. This feature may be optional, to also support users which don't have this capability or where the calls pass through a switchboard.
A free key distribution service can be provided to qualified users, like the use of a 800 number in the U.S.A., or an 177 number in Israel.
Suitable means are required to protect the center's public key. One possibility is frequent key changes, and public notification, for example by proper publications such as BBS' or other data bases.
Center 11 may comprise a centralized structure with one large computer with communication to remote locations, or a distributed secure network of local centers, with countrywide or global total coverage.
The method of operation of the center in the present invention will now be detailed in comparison with existing key dissemination centers.
PGP key management: PGP maintains a public server containing a list of public keys. PGP server accepts and maintains a file with a collection of identification packages (KeyID). Each identification package K includes the name and details of a key holder A, together with his/her public key, which are signed (authenticated) by a third party B which encrypts the package with his/her private key.
Another party C desiring to communicate with a key holder A searches for an identification package K signed by someone known/accepted by them, thus "ensuring" that that is the true key, which truly belongs to the person as claimed; the third party is "known/accepted" in the sense that B believes that its encryption key pair are as claimed and are not compromised.
Since any single third party B may be unknown to the other party C, key holder A submits a plurality of identification packages Ki, each signed by a different third party Bi; another party C desiring to communicate with B searches all the packages Ki belonging to A, until he finds one signed by a third party Bj known to him. Bj is the "common acquaintance" to A and C. Thus, the PGP server maintains a file with a collection of identification packages for a multitude of users, and with a plurality of packages for each user. Thus it may be difficult to keep this vast quantity of information to disseminate it to users.
Another key dissemination method is employed by VeriSign, which distributes digital "certificates" valid for a long time period (for example 5 years). A certificate includes the name and additional information for a user, together with the public key for that user and the expiry date of the certificate, all encrypted with the private key of the issuing authority. Another certificate is issued to that first issuing authority by a higher second authority, that certificate including the public key and additional information for that first issuing authority, and so on.
This is a hierarchical authorization structure, with user A bringing signatures from persons/entities Bi at several levels, until a level high enough is reached which is also part of the hierarchy of C, thus establishing the key transfer which is authorized by the common accepted third party.
A great effort is put into ensuring the identity of a user before issuing a certificate, and in keeping the certificates; however, a certificate once issued may be compromised during its long lifetime, in which case it is difficult to replace it; the other party may not known that the key is compromised, and may not ask the center about the validity of the certificate (since it is within the validity period).
The center has no control over the use of an issued certificate while the certificate is still valid, during the long period as set at issue time; only the "black list" at the center may give a warning to that effect, but that can only prevent communications. A reliable key has yet to be exchanged between the parties, which is difficult in this case. Users of this system are encouraged to keep a local list of certificates, but this does not solve the abovementioned problems, although it may reduce the workload on the center.
The center in our invention, however, contains a single package for each user for any specific key; the same user may maintain several keys, for different uses or levels of security or under different pseudonyms or to be assigned each to a specific person holding a specific position. This key management method is beneficial in situations where a person changes position in a firm; the new person in the job will not be able to read mail addressed to the previous person, since the new person will be given a new key pair. PGP server and the other centers cannot cope with such a situation in an easy manner.
In the present invention, the center checks the validity of the identification package by identifying the user, for example by his/her holding a valid credit card and/or calling from a specific location or phone number. This is a lower level of security, implemented by less severe user identification than the other methods, with the express purpose of providing an easily accessible and usable method of key dissemination for the common people; this level of security, however, is maintained all the time with the presented method of easy issue of updated certificates at frequent times; thus, the present method is overall more secure than other methods, and it is also more easier to use.
If required, a subset of the certificates may include a higher level of security, based on more stringent user identification for example. This can easily be integrated in the present invention. But for widespread use, even users in that more secure subset are likely to use certificates issued at the lower level, to communicate with the majority of the users. The center issues a certificate which is a digital file/document containing the name/pseudonym and details for a user, together with his/her public key and the issue date, all encrypted with the private key of the center. The center ensures there are no duplicate user names/pseudonyms; new names can be added with relative ease, but to change an existing name the center has to approve the transaction, thus achieving better user key protection.
To ensure key validity in VeriSign, each package includes an expiration date. Each key is intended to be used for the whole period as planned, for example one year or two or five years. This is a weak link for other systems as well, for example RSA. As the key approaches its expiry date, the chance of its being compromised increases, and more verification requests will be placed with the center. In our invention, however, the method is such that the identification package includes the issuing date, such that any other party can estimate the validity and reliability of the key therein. Any key update results in a new updated package, which is available to all.
PGP does not manage the key information, for example by checking the validity of the information or by preventing name duplications.
If a key is compromised, it is practically impossible to remove it from the server; PGP and RSA only keep a second list (the black list) of disabled or canceled keys, and users are advised to check that list to ensure key reliability. A compromised key cannot be reliably removed since, although that key can be physically deleted, the PGP server cannot prevent a package containing the same key from being reloaded by anyone; since an unknown number of users may hold copies of the signed package with that key, any one of them may reload the key into the PGP server.
This has the disadvantage that the second list (the black list) will be under severe overload stress, since any user receiving a package near the expiry date will presumably want to check it for validity; any other user desiring to communicate sensitive information will probably desire to check the key as well.
In our center, however, there is no second, "black" list but only a reliable list of certificates. The owner of a key may update it at any time, so a compromised key will not have severe repercussions- the user just changes it and receives an updated certificate with a new date embedded therein. The user presents that certificate to other parties to establish secure communication therewith. There is no need to keep lists of certificates or keys, since an updated key is presented by the other party with each new communication transaction. All is needed is an updated public key of the center supporting these transactions, to use in checking the presented certificates.
The other party to a communication transaction can always chose to check the key by accessing the center; the center issues updated certificates to anyone, attesting to the validity of the key for any desired user. There is no need to read a black list and therefore there is less load on the center.
The user, while establishing an account with the center, is given a "cancellation code", that is an identification code for key changes or cancellation purposes. Only change request thus authorized will be honored, to prevent the files from unauthorized changes.
If the private key of the RSA or other similar centers is compromised, this results in a "catastrophe" according to their explanation, since anyone can impersonate other users. This is a "total loss" situation. All existing keys and identification packages must be updated, each with its multiple approvals.
In our invention center, however, if the private key of the center is compromised, then a user should not accept an old certificate which may be affected by that key, but should ask for a new certificate or access the center for an updated, reliable certificate. Thus it is easier to recover from an occurrence of a compromised key of the center. Even if someone succeeds in finding the private key of the center, they still cannot impersonate the center, that is they cannot answer phone calls placed with the center. Any user suspecting a certificate presented to him has the option of calling the center to get a reliable, updated version of the certificate which cannot be tampered with. Thus, the physical phone connections of the center provide a still higher level of security protection in our invention.
The key distribution center in our invention functions like a phone information service, that is service 1-411 in the U.S., or 144 in Israel. It provides an updated certificate including the user identification and his public key to anyone, that is to any anonymous caller. Unlike the phone information service, however, the key distribution center in the present invention allows for frequent changes in the certificates issued.
In PGP, people are encouraged to keep local lists with keys for desired correspondents; this is especially important since keys are to be authorized by third parties; in RSA, certificates are issued for a long period of use. No such local keys lists are needed in the center in our invention, since the center holds the most recently updated key for each user, available to all; each user can hold a certificate of/for himself, with a recent authorization, to be presented to another party as required.
Another user of public key encryption is the PC Fax program package offered by Microsoft under Windows. This package facilitates the transmission of FAX messages which may be optionally encrypted. The FAX may be encrypted using a password or a digital key, which are conceptually the same. It uses a public key and a private key, under the "Fax Security/Advance Security" menu.
Again, they face the same problem of reliable key dissemination. Microsoft advises to exchange diskettes containing the key, clearly a difficult to use method.
A public key can be exchanged by communication means, and again there is the problem of identifying the other party- how one is to know that the answering party is truly the person it claims to be. This lack of a practical solution attests to the need which is filled with the present invention, of reliable key management and dissemination using reliable certificates including the public key and information for each user. In the method described in the present invention, the problem faced by Microsoft is easily solved: Each party sends its certificate to the other, and a secure link is immediately established. The certificate exchange method can be easily integrated in the fax communication program provided by Microsoft. This is an indication of the nonobviousness of the present invention, which addresses a hitherto unsolved problem.
Another use of the present method of key dissemination is to access remote databases or other information services on an irregular basis. With the proliferation of remote information services, it is practically impossible for any single user to subscribe to all of them. The subscription is necessary for the service provider to charge the user for the service as provided. It may be difficult or not economic for the information providers as well to handle a multitude of users, each using the database to only a small extent. Usually the information is accessed from a remote site through data communication links like the Internet.
In this application, the key management center acts as a user authorization party, by assigning to interested users a certificate which enables them to access a multitude of databases.
The method includes the following steps:
1g. The key management center signs agreements with a multitude of information providers, for the providers to accept irregular users which are authorized by the center as attested by presenting a digital certificate issued by the center, and to charge the center for the services provided;
2g. the center accepts and authorizes users to use the information services it has business relations with, including the steps of:
A. a user accesses the center from a remote site;
B. (optional) the user downloads from the center a software package to generate an encryption key pair and maybe a communication routine for subsequent communication with the center;
C. the user identifies himself/herself, for example by providing a name or pseudonym, and a credit card number, which may be encrypted using the center's public key or the key pair generated in (B) above;
D. the center checks the validity of the credit card; and
E. if the credit card is valid, then the user is issued a certificate which includes the information supplied by the user and additional optional information like the issue date and center details, all encrypted with the private key of the center; and
3g. the user thus authorized accesses the desired remote services, presents the certificate and is accepted as a user of that service.
Other embodiments of the abovedetailed method are possible, for example in (C) above the user may provide not the explicit credit card number but an encrypted package containing that number, for example encrypted with the public key of the credit card issuer; then in (D) the center sends that package to the card issuer which opens it using its private key and issues a transaction authorization to the center, while the center has no copy of the credit card itself. This method may prevent the card number being misused or getting into the wrong hands.
The software package sent to a user in step 2g(B) above may be itself encrypted with the private key of the center, to protect from tampering with that software which is an important constituent of the abovedetailed method, since the encryption key has to be generated by a secure method.
The service provider may charge directly the user for the service as provided, using the credit card number if included in the certificate, or it may charge the center which issued the certificate, which in turn may charge the end users.
Another application of the method detailed above is caller identification, with the subsequent communication being either encrypted or not. Caller identification is implemented by the exchange of certificates as detailed above.
Caller identification may be beneficial in a wide variety of applications, for example telephone, fax, cellular/wireless phone, computer communications, remote control/base station, access control. Present caller identification methods may identify a phone number belonging to a firm or organization, but there is no identification of a specific user or telephone within that organization. This problem is solved with the present invention.
The user's encryption machine may include display means for displaying the other user identification information which is included in the received certificate. This may include the real user's name or a nickname or a pseudonym, together with a company name and that person's position. This provides for easy and reliable identification of the parties involved in a remote communication transaction.
Since the certificate includes the issue date, its validity may be limited as desired, according to application and circumstances. For example, access control to a parking lot may be permitted with a monthly permit in one season, whereas a weekly permit may be required in another season. These flexible time limits can be easily enforced with present computer technology implementing the method detailed in the present invention.
The certificates issued according to the present invention may optionally include a list of authorizations or actions permitted for that user to do, or databases to access, or permitted operations in those databases. The authorizations may be based on the user track record or experience or credit rating or security/identification level. This offers the benefit that each user is given access to facilities or is allowed to perform operations without the need to recheck their authorization each time they access the system. | Disclosed is a method for safe distribution of encryption keys including a known public and secret private keys in establishing a secure link between computer users resided at separate location whom have no previous secure communications. The secure communication link occasionally and anonymously interrogates the key distribution center for the certificate pertaining to the computer users in ensuring the validity and integrity of the information stored in the center which is not tampered by any unauthorized persons. The interactively interrogating of the key distribution center is conducted via a trusted and verified certificate decision making process which encompasses the acknowledging to user who receives a valid certificate, accepting an encrypted message, key distributed center's answer to the correct up-to-date certificate, decrypting the key distributed answer via the public key, and matching the answer's identification. As the result of the muli-steps process exchanged among users via key distributed center and other secure devices, the secure link can be established between the computer users in allowing data to be transferred from one computer location to another computer location in providing a very high reliability and confidentiality of users' data connectivity. | 7 |
PRIORITY
[0001] The present application claims priority to a U.S. provisional patent application filed on Apr. 30, 2007 and assigned U.S. Provisional Patent Application Ser. No. 60/914,801, the contents of which are incorporated herein by reference.
BACKGROUND
[0002] Despite significant advancements in nanowire growth techniques and device descriptions, establishment of electrical contacts to nanowire assemblies through non-destructive methods has not been successfully realized. The commonly employed method involves physically removing nanowires from the sample, dispersing them in solution, and transferring them onto another surface containing probe pads, and depositing contact electrodes onto individual nanowires through some form of lithography. Such a series of steps are not only destructive, but also expensive and tedious.
[0003] Another method described in the literature involves burying the nanowire array in an insulating matrix such as spin-on glass or polystyrene, followed by plasma etching to expose the nanowire tips. However, this approach prevents access to the surface of the nanowires, which would be necessary for applications like gas sensing.
SUMMARY
[0004] The present disclosure is directed to a vertically aligned nanowire assembly and a gas sensing device having said assembly. The present disclosure is also directed to a method for growing electrodes in situ in contact with the top of the vertically aligned nanowire assembly by selectively attaching gold nanoparticles to the tips of nanowires and forming a continuous film. The electric field enhancements around the sharp tips of nanowires as well as their high aspect ratios are exploited in this procedure, which is generic to a wide range of nanomaterials and nanostructures. The result is a device which is an ensemble of single nanowire devices connected in parallel.
[0005] For sensor applications there may be signal-to-noise advantages in such an arrangement compared to single nanowire devices. Prior art nanowire-based sensors have involved disordered nanowire networks, where electrical contact is determined primarily by the contacts between individual nanowires. In contrast, the properties of the device according to the present disclosure reflect the electrical transport along isolated nanowires. The method according to the present disclosure may also be suitable for applications other than sensors, such as, for example, for electrically driven optical devices based on nanowires.
[0006] It is envisioned that the nanowire assembly in accordance with the present disclosures can be suitable for applications other than sensing, such as gas sensing, applications. Therefore, the gas sensing device in accordance with the present disclosure having the nanowire assembly is one specific application of the nanowire assembly.
[0007] Additionally, the method described herein toward electrically contacting the top of an aligned nanowire array using a conductive nanoparticle film can be employed for nanotube arrays.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1( a ) and 1 ( b ) represent substrate surfaces before and after nanowire growth, respectively. Clean SiO 2 wafers were placed on top of the substrate before nanowire growth to enable electrical contact to the bottom of the nanowires grown on each individual catalyst pad.
[0009] FIG. 2( a ) is an SEM image of ZnO nanowires on Au and SiO 2 (left and right portions) clearly indicate alignment of nanowires on Au and lack of alignment on SiO 2 .
[0010] FIG. 2( b ) is a more magnified SEM image at the well-aligned nanowire array of ZnO on Au. Scale bars for (a) and (b) are 10 μm and 3.75 μm, respectively.
[0011] FIGS. 3( a )-( c ) show SEM images of Au nanoparticles attached to the tips of nanowires at different stages of deposition—(a) 10 min, (b) 1 hour, and (c) 2 hours. Scale bars=1 μm.
[0012] FIG. 4( a ) is a schematic diagram of electrical contacts to the nanowire array.
[0013] FIG. 4( b ) is a graph showing the I-V characteristic of the nanowire array measured in air.
[0014] FIGS. 5( a ) and ( b ) are graphs showing gas sensing responses of the nanowire array to pulsed concentrations of nitrous oxides and methanol (10-50 ppm), respectively, in air at 325° C.
[0015] FIG. 6 is a block diagram of a gas sensing device having the nanowire assembly in accordance with the present disclosure.
DETAILED DESCRIPTION
[0016] In the present disclosure the term nanowire is defined as an electrically conductive nanorod; alternatively, a wire with a diameter of nanometer dimensions. The term nanoparticle is defined as structure having three dimensions of 100 nm or less. The term nanotube is defined as a fullerene molecule having a cylindrical or toroidal shape.
[0017] A nanowire assembly of zinc oxide (ZnO), owning its great potential in the development of new electronic and photonic devices, was grown and studied. ZnO is a wide-bandgap semiconductor (E g =3.37 eV) with a wurtzite crystal structure that has been grown into several morphologies including nanowires, nanocombs, nanobelts, nanorings and nanoribbons, etc. through both gas-phase and solution-phase syntheses. One-dimensional ZnO nanowires have been observed to act as gas sensors, room temperature ultraviolet (UV) lasing cavities, UV/visible photodetectors and field effect transistors. Synthesis of well-aligned nanowire arrays of ZnO is of prime importance for the realization of nanoelectronic devices such as light emitting diodes (LEDs) and laser diodes. Several groups have synthesized ZnO nanowires by simple thermal evaporation of commercial Zn and ZnO powders. Metal-organic chemical vapour deposition (MOCVD) of ZnO nanorods has also been described using precursors like diethyl zinc and zinc acetylacetonate hydrate.
[0018] In accordance with the present disclosure, nanowire arrays of ZnO on gold (Au) catalyst layers deposited on silicon dioxide (SiO 2 ) substrates were grown, through direct thermal evaporation of Zn powder within a tube furnace maintained at about 550° C. The nanowires were found to be well aligned and vertically oriented, with an average diameter of 60-75 nm and had faceted, hexagonal heads, with a growth direction along the c-axis.
Experimental Section
Growth of ZnO Nanowire Arrays
[0019] Silicon dioxide wafers (1 cm 2 ) 100 (see FIG. 1( a )) were ultrasonically cleaned in acetone and four square pads 102 of 15 nm of chromium (Cr) followed by 150 nm of gold (Au) were deposited (Cr was deposited to ensure better adhesion of Au to the substrate). The substrates were then placed in an alumina boat containing commercial Zn powder (Aldrich, 99.5%), and loaded into a quartz tube placed within a horizontal tube furnace, the substrates being held 5 cm downstream of the Zn powder. The tube was then evacuated using a rotary mechanical vacuum pump, and this was followed by the introduction of 150 sccm (standard cubic centimeters per minute) nitrogen (N 2 ) and 10 sccm oxygen (O 2 ) and brought back up to atmospheric pressure.
[0020] The nanowires 104 a , 104 b were grown at about 550° C. for about two hours and the substrates were then cooled down to room temperature. A schematic diagram of the substrate surface before and after nanowire growth is shown in FIGS. 1( a ) and 1 ( b ). The unexposed Au layers 105 are shown in FIG. 1( b ).
Nanoparticle Generation and Deposition
[0021] Au nanoparticles were generated through an aerosol spray-pyrolysis method. A 0.03 M (mol 1 −1 ) aqueous solution of hydrogen tetrachloroaurate (HAuCl 4 ; Sigma Aldrich Inc.) was sprayed into droplets with an atomizer, using a carrier gas flow of 2 slpm (standard litres per minute) N 2 . The flow containing the droplets was passed through silica gel dehumidifiers, and then into a tube furnace maintained at 600° C., to thermally crack the precursor and form Au particles. The particles were then positively charged with a homebuilt unipolar charger and introduced into a electrostatic precipitator containing the substrate with the grown nanowire arrays of ZnO. A high negative electric field of −10 kV cm −1 was applied to drive the particle deposition.
Nanowire Characterization and Gas Sensing Measurements
[0022] The morphology of the substrates was imaged using a Hitachi S-4000 scanning electron microscope (SEM). Wide-angel x-ray diffraction (XRD) patterns were recorded on a Siemens D-500 diffractometer using Cu Kα radiation, while transmission electronic microscopy (TEM) and selected area electron diffraction were performed using a Zeiss CM 10 microscope.
[0023] For gas sensing measurements, the sample was glued onto a large square package containing pin contacts for electrical connections using a high temperature adhesive paste (Ceramabond 503; Aremco Products Inc., NY). Wire bonds were attached to all four gold pads 102 for resistance measurements. Controlled mass flow rates of test gases and zero-grade dry air were delivered through a computer-automated delivery system, to the sample that was placed on a temperature-programmable hotplate. Fixed temperature responses of the nanowire array (at 325° C.) to various concentrations (10-50 ppm-parts per million by volume or μl 1 −1 ) of methanol (CH 3 OH) and nitrous oxide (NO x ) were measured and analysed.
Results and Discussion
Morphology and Crystallography of ZnO Nanowire Arrays
[0024] SEM images of the ZnO nanowires are presented in FIG. 2 . The nanowires 104 a grown on the Au catalyst layer are well aligned along the vertical direction with widths between 60 and 80 nm, and lengths between 5 and 10 μm, while the nanowires 104 b on the adjacent SiO 2 portion are more randomly oriented.
[0025] In a typical XRD pattern obtained from the nanowires, the sharp peak at a 2-theta value of 34.42° corresponds to the (0 0 2) plane of the hexagonal ZnO crystal. TEM and electron diffraction analysis of individual nanowires revealed that the nanowires are single crystalline, with a growth direction along the c-axis of ZnO. The growth mechanism for the nanowires on Au 104 a generally follows a vapour-liquid-solid (VLS) mechanism, wherein Zn vapour is transported and reacted with the Au catalyst, forming alloy droplets which provide nucleation sites for ZnO vapours to condense and grow into well-crystallized nanowires. Growth on SiO 2 generally follows a non-catalytic vapour-solid (VS) mechanism, in which zinc and zinc suboxides condense on the SiO 2 surface to form droplets which act as nuclei for ZnO nanowire growth.
Nanoparticle Film Contact Description and I-V Characteristics of ZnO Nanowire Array
[0026] Even though nanowire arrays of various materials have been routinely synthesized and studied, there has been surprisingly little progress in the development of methods for electrically contacting them as grown, i.e., without removing them from the substrate. In accordance with the present disclosure, a technique has been developed for achieving electrical contacts to both ends of nanowire array 200 ( FIG. 4 ) using the Au catalyst layer 202 as the bottom electrode, and an Au nanoparticle film 204 as the top electrode. The nanoparticles were attracted onto the nanowire arrays using a high electric field, as described in the experimental section above. The bottom electrode 202 is provided on a SiO 2 substrate 205 .
[0027] The key aspect of the high field deposition is that the regions near the tips of the nanowires have the highest field and result in particle collection only at the top of the nanowires. SEM images of Au nanoparticles deposited on the nanowire assembly 300 for different deposition times are shown in FIG. 3 , and confirm that particles only deposit on the ends of the nanowires and subsequently branch out to begin to form a continuous film at larger deposition times. Typically, particle depositions were carried out for two hours in order to create a continuous film of Au.
[0028] A probe station was used to measure resistances between various points on the same contact electrode to verify film continuity, and between the top and bottom contacts 208 , 206 to measure the nanowire array resistance. Before nanowire growth, electrical isolation between the various pads 102 of Cr/Au was confirmed. Following nanowire growth and nanoparticle film deposition, both the underlying and overlying Au layers were verified to be conducting, and there was no visible shorting between the bottom and top electrodes 204 , 202 . Typically, the Au nanoparticle film 204 was deposited such that it made contact with two of the four gold pads 102 , thereby enabling simple electrical continuity verification. A representative diagram of the electrodes 202 , 204 contacting the ends of the nanowire array 200 is shown in FIG. 4( a ). I-V characteristics of the nanowire array 200 in air were measured and averaged for different bias voltages applied between the two contacts 206 , 208 indicating good contact between the nanowires and nanoparticles, as seen in FIG. 4( b ). These results confirmed that the approach or method to create a top contact for nanowire arrays using a nanoparticle aerosol source was successful.
Gas Sensing Properties of the ZnO Nanowire Arrays
[0029] Semiconducting metal oxides such as tin oxide (SnO 2 ), titanium dioxide (TiO 2 ) and zinc oxide (ZnO) have been widely utilized as active materials in solid-state gas sensing devices. In particular, ZnO surfaces with a variety of morphologies including thin films, flakes and nanowires have been tested for the detection of gases including ethanol, carbon monoxide, hydrogen sulphide, oxygen and nitrous oxides. Due to their very high surface to volume ratio, nanowires present an attractive alternative to thin films for improved gas sensing characteristics, including sensitivity and overall speed of response.
[0030] As a first practical test of the nanowire assembly approach/method according to the present disclosure, it was demonstrated in the implementation of a gas sensing device. In the past, as-grown nanowire arrays could not be used for gas sensor testing, possibly due to difficulties in achieving a continuous top contact to the nanowires using standard approaches like thermal evaporation, without interfering with the ability of the analytes to interact with the sensing material (nanowires). The technique according to the present disclosure for attaching electrodes 202 , 204 to nanowire arrays 200 could solve this vexing problem since the nanoparticle film 204 is a porous but electrically continuous electrode, allowing gases to come into contact and absorb onto the nanowires 104 a , 104 b both from the sides as well as the top.
[0031] Typically, the sample was initially annealed in air at 300° C. for over eight hours, and the stability of the electrodes on the device was evaluated at various temperatures. Fixed temperature responses of the nanowire assembly 300 to pulsed concentrations (10-50 ppm) of methanol (CH 3 OH) and nitrous oxides (NO/NO 2 ) were measured at 325° C., and are shown in FIG. 5 . As expected, the resistance of the ZnO nanowires increased upon exposure to the oxidizing analyte, NO x , and reduced or decreased upon exposure to the reducing analyte, CH 3 OH. The sensor response clearly tracks the pulsed input of the analyte. However, the recovery time for the sensor to re-attain its original resistance was somewhat high, possibly due to slow desorption rates.
[0032] The continuity of the contact layers as well as sensor responses were found to be remarkably stable and reproducible for repeated testing cycles and the sensitivities were comparable to an existing ZnO nanowire-based sensor. While the gas sensing device 250 using the nanowire assembly shown by FIG. 4( a ), and other components 400 indicative of gas sensing devices, such as a processor, audible alarm, display, etc. (see FIG. 6) , is still in a primitive state, it does demonstrate the efficacy of the nano-assembly approach/method according to the present disclosure.
CONCLUSIONS
[0033] In summary, an original, generic approach or method toward achieving electrical contacts to vertically aligned ZnO nanowire arrays using electrostatically assisted deposition of Au nanoparticles was devised and tested. The Au nanoparticle electrode is observed to be both mechanically and electrically robust even at high temperatures. This approach of creating a top contact to a vertically aligned nanowire assembly as grown, may be useful for the design and fabrication of electrically driven nanowire lasers and LEDs. The first successful application of this nanowire assembly or architecture shown by FIG. 4( a ) and according to the present disclosure is a gas sensing device, which exhibits high sensitivities to low concentrations (10 ppm to 50 ppm) of both reducing (methanol) and oxidizing (nitrous oxide) gases.
[0034] The described embodiments of the present disclosure are intended to be illustrative rather than restrictive, and are not intended to represent every embodiment of the present disclosure. Various modifications and variations can be made without departing from the spirit or scope of the disclosure as set forth in the following claims both literally and in equivalents recognized in law. | An in situ approach toward connecting and electrically contacting vertically aligned nanowire arrays using conductive nanoparticles is provided. The utility of the approach is demonstrated by development of a gas sensing device employing the nanowire assembly. Well-aligned, single-crystalline zinc oxide nanowires were grown through a direct thermal evaporation process at 550° C. on gold catalyst layers. Electrical contact to the top of the nanowire array was established by creating a contiguous nanoparticle film through electrostatic attachment of conductive gold nanoparticles exclusively onto the tips of nanowires. A gas sensing device was constructed using such an arrangement and the nanowire assembly was found to be sensitive to both reducing (methanol) and oxidizing (nitrous oxides) gases. This assembly approach is amenable to any nanowire array for which a top contact electrode is needed. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a turbocharger system including not only a turbocharger, but also a mounting pedestal configured with internal utilities needed to operate and position the turbocharger.
2. Related Art
Turbocharging has been used for a number of years with internal combustion engines. Although early turbochargers were often cooled primarily by air, as well as by the flow of oil through the turbocharger's bearings, later model turbochargers, especially larger turbochargers and those installed in heavy duty engines, generally utilize coolant circulating from the engine's cooling system through the turbo, and then back to the engine's main cooling system. Of course, turbochargers also require an oil supply and drain utilities to lubricate the bearings associated with the turbocharger. Needless to say, the provision of a source of coolant and a source of oil, with both being under pressure, as well as draining the oil and coolant from the turbocharger and returning these fluids separately to the engine, has necessitated a good deal of external plumbing. Unfortunately, external fluid connections and associated pipes and hoses cause problems because hoses and fittings are known to leak and are subject to damage which may be accelerated by the high temperatures prevailing within engine compartments. Moreover, aside from durability issues, the need for external plumbing for turbochargers increases the space required by the turbocharger in an already crowded underhood environment. U.S. Pat. No. 6,125,799 discloses a turbocharger mounting arrangement using a bulky mix of internal and external utility plumbing to mount twin turbochargers upon the extreme ends of an engine.
Turbochargers mounted on engines typically consume a good deal of space for another reason. Because known mounting arrangements are not susceptible to locating the turbocharger close to the engine block, turbochargers must be spaced away from the engine to permit the insertion and removal of the turbochargers' fasteners. Moreover, known turbocharger mounting systems increase radiated noise because of a lack of rigidity and because of the dimensional problems associated with their usage.
It would be desirable to provide a turbocharger, including a mounting system having a pedestal with internal and integral supply and return passages for coolant and lubricating oil.
BRIEF DESCRIPTION OF THE INVENTION
According to an aspect of the present invention a turbocharger system for an internal combustion engine having a cylinder block includes a turbocharger and a utility pedestal extending between the turbocharger and a hard point associated with the cylinder block. The utility pedestal includes a mounting pad for the pedestal and an oil supply passage for conveying lubricating oil under pressure from the cylinder block to the turbocharger. A return oil passage conveys lubricating oil from the turbocharger to a lubrication system incorporated within the engine. A coolant supply passage conveys coolant under pressure to the turbocharger, and a coolant return passage, configured at least in part within the utility pedestal, conveys coolant from the turbocharger to a cooling system incorporated within the engine. According to another aspect of the present invention, the coolant return passage may include a passage configured, at least in part, within the engine's cylinder block, as well as within the utility pedestal.
According to another aspect of the present invention a coolant return passage from the turbocharger may be configured so as to convey the coolant to a mixing chamber within which the coolant from the turbocharger is mixed with coolant flowing from at least one cylinder head.
According to another aspect of the present invention, a return oil passage from the turbocharger conveys waste oil from the turbocharger to a crankcase sump without allowing the waste oil to contact moving parts within the engine.
According to another aspect of the present invention, a hard point associated with the cylinder block for mounting the turbocharger includes a generally planar mounting pad configured on a portion of the cylinder block, with the mounting pad of the utility pedestal having a lower mating surface matched to the generally planar mounting pad. The cylinder block's mounting pad is configured with lubricating oil and coolant utilities.
According to another aspect of the present invention, a turbocharger's generally planar mounting pad may be configured upon a cylinder block within a valley defined by the cylinder banks of a V-block engine.
According to yet another aspect of the present invention, the turbocharger pedestal mounting pad of the utility pedestal comprises a number of mounting bosses having fastener bores extending therethrough at an acute angle with respect to horizontal plane such that fasteners inserted within the bores pass inboard to threaded bores formed in the hard point associated with the cylinder block.
According to another aspect of the present invention, the return, or waste, oil passage extending from the turbocharger and through the utility pedestal is designed to prevent foamed or frothed oil flowing from the turbocharger from impairing engine lubrication. This is accomplished by preventing the waste oil from contacting moving parts within the engine as the oil flows back to the crankcase sump.
It is an advantage of the present turbocharger system that the turbocharger and pedestal may be assembled at one geographic location and installed upon an engine as a single unit at a second geographic location without the need for making external utility connections for lubricating oil and water feeds and drains.
It is another advantage of a turbocharging system according to the present invention that the turbocharger system, including the turbocharger and the utility pedestal, with its oil and coolant utilities, is compact and ideally suited for mounting in the valley of a V-block internal combustion engine.
It is yet another advantage of a turbocharging system according to the present invention that the noise signature of the turbocharger will be reduced because of the stiffness inherent with the close mounted utility pedestal featured in the present invention.
It is yet another advantage of the present invention that the lubricating oil and coolant supply and drain passages required for a turbocharger are routed internally within the present utility pedestal.
Other advantages, as well as features of the present invention, will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of an engine having a turbocharger system according to the present invention.
FIG. 2 is an end view, partially cut away, of a portion of an engine having a turbocharger system according to the present invention.
FIG. 3 is a plan view of an engine block showing a turbocharger pedestal mounting pad and utility passages for lubricating oil and coolant according to an aspect of the present invention.
FIG. 4 is a side elevation, partially cut away, of an engine having a turbocharger system according to the present invention and showing the routing for several of the utility passages for oil and water according to the present invention.
FIG. 5 is a side perspective view, partially cut away, of an engine having a turbocharger system according to the present invention.
FIG. 6 is a perspective view of a turbocharger mounting hard point configured as a plate suitable for bolting or welding to an engine cylinder block.
FIG. 7 is similar to FIG. 5 , but shows a one-piece utility pedestal and turbocharger combination.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , turbocharger system 10 includes a turbocharger, 14 , and a utility pedestal, 18 . Turbocharger 14 is preferably mounted to utility pedestal 18 before turbocharger 14 is mounted upon an engine. FIG. 1 also shows an engine cylinder block, 30 , having a valley, 20 , into which turbocharger system 10 is placed upon a hard point, which is illustrated as generally planar mounting pad 22 . Utility pedestal 18 provides rigid structural support for turbocharger 14 ; this helps to reduce unwanted engine noise emissions, as well as reducing unwanted vibration associated with the turbocharger. Those skilled in the art will appreciate in view of this disclosure that the term “hard point”, as used herein means either a structurally rigid mounting location such as block pad machined into the parent metal of a cylinder block, or a separate pad, such as that illustrated at 100 in FIG. 6 . Mounting pad 100 is intended to be attached to an engine by bolting, or welding, or by some other suitable process.
Utility pedestal 18 has a mounting pad, 48 , at its lower extremity. Mounting pad 48 includes mounting bosses 50 , which have fastener bores 52 . Fastener bores 52 extend through mounting bosses 50 and make an acute angle, α, with a horizontal plane, H ( FIG. 1 ). Fastener bores 52 allow the passage of a number of threaded fasteners, 56 , which pass through fastener bores 52 and into threaded bores, 28 , formed in generally planar mounting pad 22 of cylinder block 30 . Two of threaded bores 28 are shown in FIG. 1 . FIG. 1 further shows that mounting bosses 50 are angled so that threaded fasteners or bolts 56 extend inboard into bolt holes 28 formed in mounting pad 22 of cylinder block 30 . This geometry is also shown in FIG. 2 . In the event that a separate mounting pad is employed, such as that illustrated at 100 in FIG. 6 , a number of fastener bores, 108 , will be provided in the same manner as bores 52 . Pad 100 also contains fluid passages 26 ′, 42 ′, and 46 ′, which perform the functions ascribed below to passages 26 , 42 , and 46 , respectively. Pad 100 may be fastened to an engine by means of threaded fasteners extending through bores 104 , or, as noted above, by welding, brazing, or other known methods.
As seen in FIG. 2 , the width, A, of utility pedestal mounting pad 48 is less than the overall width, B, of turbocharger 14 . This is an added benefit stemming from the angular orientation of fastener bores 52 , which fortuitously permit turbocharger 14 and utility pedestal 18 to be disassembled as one unit from the engine without removing portions of the turbocharger assembly. The angles of fastener bores 52 also allow turbocharger 14 to be mounted closer to cylinder block 30 , in a vertical direction closer to crankshaft 16 . FIG. 2 shows turbocharger 14 nestled in valley 20 between cylinder heads 38 and cylinder block 30 .
FIG. 3 shows generally planar mounting pad 22 as being located in the mid-portion of the valley of cylinder block 30 between block end walls 88 , 89 . Several of threaded mounting bolt holes 28 are shown. FIG. 3 further illustrates several utilities for turbocharger 14 . The first such utility, oil supply passage 26 , is shown as terminating in a port formed within the planar surface of mounting pad 22 . Coolant supply passage 42 also communicates with this surface, as does coolant return 46 . In other words, portions of oil supply passage 26 , coolant supply passage 42 , and coolant return passage 46 are all co-planar with the uppermost surface of mounting pad 22 . As a result, all of these utilities may be sealed to utility pedestal 18 with a single gasket 24 , which is shown in FIG. 1 . Gasket 24 is illustrated as a unitary carrier incorporating a number of integral o-rings for sealing passages 26 , 42 , and 46 .
Only the uppermost part of return oil isolation passage 34 within cylinder block 30 is shown in FIG. 3 ; for more definition, one must look to FIG. 4 , wherein return oil passage 34 is shown as leading to one end of engine block 30 and down into crankcase sump 98 through a region in which there are no rotating or moving parts. As noted above, the drainback of waste oil from turbocharger 14 to crankcase sump 98 through areas of the engine devoid of moving parts prevents galling or overheating of such moving parts by preventing contact between temporarily aerated oil and parts needing lubrication.
FIGS. 4 and 5 show oil supply internal passage 26 extending up into utility pedestal 18 from within cylinder block 30 . Further, FIG. 5 shows coolant supply internal passage 42 , which extends into utility pedestal 18 from an engine water jacket, 32 . Water leaving turbocharger 14 flows through coolant return internal passage 46 down through utility pedestal 18 and out to the front of engine block 30 , wherein the flow is joined with coolant flow from one or more cylinder heads at a combination point 36 . Coolant return passage 46 may advantageously be configured as a cored passage within cylinder block 30 . Those skilled in the art will appreciate in view of this disclosure that combination point 36 could be configured as a water outlet or coolant surge tank or other device for combining coolant flows from more than one source, such as one or more of the engine's cylinder heads. This combination of flows offers the advantage of mitigating coolant temperature excursions which could otherwise result from the very warm coolant leaving turbocharger 14 .
According to another aspect of the present invention, an inventive method avoids the costly process of connecting external plumbing to a turbocharger within the confines of an engine production line. Rather, turbocharger 14 is pre-assembled to utility pedestal 18 at a location which is separated from the production line. Then, the assembly including the turbocharger and the pedestal may be easily mounted upon the engine without the necessity of connecting any external cooling or lubrication plumbing.
In contrast with FIGS. 4 and 5 , which show turbocharger 14 as being attached to a separate pedestal, 18 , FIG. 7 shows turbocharger 14 as being one piece with pedestal 18 . For certain high production volume applications of a turbocharging system according to the present invention it may be advantageous to integrate pedestal 18 with turbocharger 14 in the manner of FIG. 7 . However, for applications of the present invention for which lower production volumes are the rule, it is probably equally advantageous to provide a separate, more easily modifiable, separate pedestal having the characteristics of FIGS. 4 and 5 .
The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention. Accordingly the scope of legal protection afforded this invention can only be determined by studying the following claims. | A turbocharger system for an internal combustion engine includes a turbocharger with a utility pedestal extending between the turbocharger and a mounting surface associated with the engine. The utility pedestal includes a mounting pad for attaching the combined turbocharger and pedestal assembly to the engine, as well as internal oil and coolant supply passages for supplying the turbocharger with coolant and lubricating oil under pressure. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus which attaches films to the surfaces of sheet materials (hereinafter simply called boards), such as printed circuit boards, electronic circuit boards, and silicone wafers; and, more particularly, the invention relates to a vacuum film laminating apparatus which continuously supplies films and boards into a reduced-pressure chamber and attaches films to each board in the chamber.
A conventional reduced-pressure film laminating apparatus, such as disclosed in Japanese Examined Patent Publication No. 53-31670 (1978), places the whole film laminating apparatus containing a roll of film (hereinafter referred to as a film roll) in a reduced-pressure chamber, and provides a board loading opening and a board unloading opening in the walls of the reduced-pressure chamber. Each opening has a pair of pressure rolls made of, for example, elastic materials which isolate the inside of the reduced-pressure chamber from the outside, making it possible for the boards to be introduced into and removed from the chamber. This reduces fluctuations in the degree of vacuum of the reduced-pressure chamber when boards are transferred into and out from the chamber and assures the efficiency of attaching films to boards at a reduced pressure.
Since this conventional vacuum film-laminating apparatus disposes a film roll in the reduced pressure chamber, the chamber cannot be made smaller. Further, when a new film roll is loaded in the reduced-pressure chamber, it takes a long time to reduce the chamber pressure down to a preset degree of vacuum. Furthermore, keeping a film roll for a long period of time under a vacuum condition may cause its quality to vary.
When boards are loaded into the reduced-pressure chamber, the pressure-rolls may frictionally cause dust to be deposited on the surfaces of the boards. The dust on the board surfaces may make film adhesion incomplete in the film lamination process and may damage board surfaces when they are compressed to be unloaded.
When the pressure rolls are worn out due to friction between the rolls and the boards, the hermetic sealing of the chamber is broken and the chamber cannot maintain a preset reduced pressure. This requires frequent replacement of pressure rolls; and, consequently, this makes it difficult for the conventional vacuum laminating apparatus to respond to the demands imposed on a high vacuum device.
Japanese Examined Patent Publication No. 53-31670 (1978) also discloses an embodiment in which the film roll is disposed outside the reduced-pressure chamber. This embodiment is necessarily equipped with means to feed film sheets into the reduced-pressure chamber, in addition to the provision of said board loading and unloading openings. This film feeding unit has a pair of pressure rolls made of elastic material to feed film sheets there through. However, this embodiment cannot avoid the problems which may be caused by friction between the boards and the pressure rolls.
SUMMARY OF THE INVENTION
The main purpose of the present invention is to provide a reduced-pressure film-laminating apparatus which can form a clean reduced-pressure chamber having a desired degree of vacuum in a short time and continuously attach films to each board in the reduced-pressure chamber.
Another object of the present invention is to provide a reduced-pressure film-laminating apparatus which continuously supplies boards and films into the reduced-pressure chamber and attaches films to the boards in the chamber without damaging them.
To realize the aforesaid objects, the reduced-pressure film-laminating apparatus in accordance with the present invention comprises:
board transfer means for transferring a plurality of boards at preset intervals;
film transfer means for forming film sheets on a base film at the same intervals as the boards are transferred by said board transfer means, wherein these intervals on the base film are treated as processing areas between boards;
a reduced-pressure chamber having a board loading port, a film loading port, laminating means for attaching films to each board on said base film in said chamber, and a board unloading port which ejects the laminated boards;
first shutter means providing a shutter for each of said board loading and unloading ports of the reduced-pressure chamber to open and close the port;
vacuum means for evacuating the reduced-pressure chamber when said respective shutter means close;
second shutter means providing a shutter for said film loading port on said reduced-pressure chamber;
detecting means for detecting the extent of a processing area between boards on the base film to the shutter section of said film loading port; and
control means for operating said second shutter means of said film loading port, said board loading port, and said board unloading port according to the result of detection by said detecting means, thereby to close the shutters, for evacuating the reduced-pressure chamber to a preset degree of vacuum, and for turning on the laminating means.
In accordance with the present invention, the reduced-pressure film-laminating apparatus can supply films into the reduced-pressure chamber without contaminating the film sheets, and it can evacuate the reduced-pressure chamber to a desired degree of vacuum and attach films to clean boards.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a vacuum film-laminating apparatus which represents a first embodiment of the present invention.
FIG. 2 is a magnified sectional view of the reduced-pressure section of said vacuum film laminating apparatus of FIG. 1 .
FIG. 3 is a schematic sectional view of a vacuum film-laminating apparatus which represents a second embodiment of the present invention.
FIG. 4 is a magnified sectional view of the film loading port and its vicinity in the second embodiment illustrated in FIG. 3 .
FIG. 5 is a sectional view taken on the line A—A of FIG. 4 .
FIG. 6 is a fragmentary sectional view of the second embodiment illustrated in FIG. 3 showing an example of how the cover film of the laminate a board is cut out outside the reduced-pressure chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A reduced-pressure film laminating apparatus which represents a first embodiment of the present invention will be explained with reference to FIG. 1 and FIG. 2 .
FIG. 1 is a schematic sectional view of the vacuum film-laminating apparatus of the present invention. The vacuum film-laminating apparatus mainly comprises a film loading section, a reduced-pressure section, a board loading section, and film-laminating and board-ejecting section. FIG. 2 is a magnified view of the reduced-pressure section which is evacuated.
Referring to FIG. 1, the configuration of the film loading port will be explained. Although this embodiment is designed to attach film sheets (of a film roll) to both surfaces of each board 5 a through 5 e (where postfixes “a” to “e” are omitted when boards are generically termed), the attaching of film to the top board surfaces only will be explained below because the top and bottom surfaces of each board are treated in the same manner (vertically symmetrical to the transfer surface of the boards).
As shown in FIG. 1, the dry film roll 1 consists of a continuous sheet formed of a base film 2 , resist films 3 formed on the base film 2 , and a cover film 4 which covers the resist films 3 on the base film 2 . These films are wound with the base film 2 facing outside on the roll 1 . Only the cover film 4 of the dry film roll 1 is taken up by the cover film take-up section 1 a . Since a resist film is attached to the surface of each board with a 3-mm margin around the resist film, the dry film roll 1 must have a preset width in the transverse direction of the board 5 , and, further, the resist 3 must be placed a few millimeters inward from the front end (edge) and the rear end (edge) of each board (in the direction of movement of the board).
For this purpose, the base film 2 is reeled out towards a cradle 6 and into contact with the cradle and is perforated together with the resist film 3 and the cover film 4 by a film perforating means which is disposed above the cradle. In this case, it is possible to perforate only the base film 2 , while cutting out both the resist film 3 and the cover film 4 . The embodiment shown in FIG. 1 and FIG. 2 has two or more film perforating means at preset intervals. For example, the embodiment uses a perforator 7 which gives two lines of perforation at a time. This perforator can be a roulette-of the type used for sewing. The cover-film take-up section 1 a continuously takes up the cover film which is separated from the resist film by the separating roller 8 . The interval between two perforation lines made at one time by the perforator 7 is determined according to the preset intervals between boards as they are transferred. The interval between two perforation lines made on the films at one time by the perforator 7 is designated as a processing area between boards. When the perforated resist 3 on the base film comes in place on the cradle 9 , the base film 2 is vacuum-held by the cradle 9 and the resist equivalent to the processing area between boards is picked up and removed from the base film, for example, by an adhesive means.
The non-resist area on the base film 2 from which the resist has been removed is termed a “processing area 10 ” to distinguish it from the resist area on the base film having resist 3 (film itself) to be attached to a board 5 . The other form of the processing area 10 between boards will be explained later.
The configurations of the board loading section and the reduced-pressure section will be explained next.
As shown in FIG. 1, the chamber 11 in the reduced-pressure section comprises a stationary part 11 a which is fixed relative to the board transfer surface, movable parts 11 b and 11 c which are oppositely disposed and can be moved towards the board transfer surface by means of cylinders 12 a and 12 b , and a movable part 11 d which can move with the moving of the movable part 11 b.
Vacuum seals 13 are provided on surfaces on which the movable parts 11 d and 11 c touch the stationary part 11 a and surfaces on which the movable parts 11 d and 11 b touch each other. In other words, the stationary part 11 a and movable parts 11 b , 11 c , and 11 d are fragmentary sections of the reduced-pressure chamber which are cut in parallel with the board transfer surface, and the vacuum seals are applied to the cut-out surfaces of the sections. When the movable parts move away from the stationary part 11 a , the spaces between the parts respectively form a board loading part (port), a board unloading part (port), a film loading part (port), and a film unloading part (port). When the movable parts close and touch the stationary part, a hermetic chamber 11 is formed. The movable part 11 b is a lid-shaped part. The movable part 11 d and the stationary part 11 a are cylindrical parts, and the movable part 11 c is pan-shaped. Their contact surfaces are provided with vacuum seals 13 .
The board loading section comprises a board feeding conveyor 14 which conveys boards 5 into the reduced-pressure chamber 11 through a clearance between the stationary part 11 a and the movable part 11 d . In the description below, the clearances between the stationary part 11 a and the movable part 11 d are distinguished from each other as a board loading port 15 (in the board loading section) and a board unloading port (in the board unloading section).
Further, a clearance between the movable parts 11 b and 11 d of the reduced-pressure chamber 11 to feed a base film 2 without resists in the processing areas between boards (hereinafter abbreviated as processed base film 2 ) into the reduced-pressure chamber 11 is called a film loading port 17 a . Similarly, a clearance between the stationary part 11 a and the movable part 11 c of the reduced-pressure chamber 11 to feed a processed base film 2 into the reduced-pressure chamber 11 is called a film loading port 17 b.
The processed base films 2 are fed into the reduced-pressure chamber 11 through the respective film loading ports 17 a and 17 b , are conveyed further with the film body in contact with the rollers 18 a and 18 b and tension rollers 19 a and 19 b , which control the tension of each base film 2 in said reduced-pressure chamber 11 , are further conveyed through a pair of lamination rollers 20 a and 20 b with a board sandwiched between two pieces of resist on the base films, and then are ejected out of the chamber 11 through the board unloading port 16 . The lamination roller 20 a , the clamper 21 a , the roller 18 a and the tension roller 19 a are disposed above the conveyor surface. The lamination roller 20 b , the clamper 21 b , the roller 18 b and the tension roller 19 b are disposed below the conveyor surface. The postfixes of the symbols of these parts are omitted when they are used generically.
The roller 18 b , the tension roller 19 b , the lamination roller 20 b , and the damper 21 b are mounted on the stationary part 11 d of the reduced-pressure chamber 11 and will not move up and down relative to the stationary part 11 a . On the other hand, the roller 18 a , the tension roller 19 a , the lamination roller 20 a , and the damper 21 a are mounted on the movable part 11 d of the reduced-pressure chamber 11 and can move up and down together with the movable part 11 d.
When a board 5 is fed by the conveyor 14 into the reduced-pressure chamber 11 through the board loading port 15 , the board 5 is conveyed in the reduced-pressure chamber 11 by a board edge clamping means which is not visible in the figure. For easy comprehension of lamination, boards 5 are identified by postfixes 5 a (for boards which are loaded into the reduced-pressure chamber 11 ), 5 b (for a board which has been loaded into the reduced-pressure chamber 11 and is ready to be laminated), 5 c (for a board which is laminated with resist films 3 in the reduced-pressure chamber 11 ), 5 d (for a laminated board whose base films 2 are still connected with the succeeding board 5 c ), and 5 e (for a laminated board whose base films 2 are cut out).
The control means 100 calculates the quantity of dry film 1 to be fed, using the output of an encoder (which is invisible in the figure) mounted on the shaft of the dry film roll 1 . The control means 100 also determines the length of the base film 2 in the reduced-pressure chamber 11 . For example, the length of the base film 2 in the reduced-pressure chamber 11 is equal to the length of four boards having resist 3 when the processing area 10 of the base film 2 between boards is just at the film loading port 17 . When the processing area 10 of the base film 2 between boards is just at the film loading port 17 , the control means 100 stops the feed of the boards 5 into the reduced-pressure chamber 11 and actuates the cylinder 12 a to move the movable part 11 b down toward the movable part 11 d . When the movable part 11 b touches the processing area 10 of the base film 2 between boards on the vacuum seal 13 of the movable part 11 d , the cylinder 12 a further works to cause the movable part 11 b to push the movable part 11 d together with the lamination roller 20 a , the clamper 21 a , the roller 18 a , and the tension roller 19 a until the movable part 11 d touches the vacuum seal 13 of the stationary part 11 a . In this state, the movable part 11 d at the board unloading section 16 touches the processing area 10 of the base film 2 between boards on the stationary part 11 a.
In other words, the control means 100 actuates the cylinder 12 to hermetically close the reduced-pressure chamber 11 . At the same time, the control means 100 causes the damper 21 to clamp the board 5 c and the damper 22 outside the reduced-pressure chamber 11 to clamp the board 5 d.
Then, the reduced-pressure chamber 11 is evacuated down to a desired degree of vacuum through a vacuum port (invisible in the figure) using a vacuum means which is not visible in the figure. The rollers 18 and the tension rollers 19 are moved perpendicularly to the movement of the boards 5 c so that the distance between the resist 3 and the rear end (edge) of the board 5 b facing the board loading port 15 (hereinafter referred to as the rear end of the board) may be wider than the distance between the resist 3 and the front end of the board 5 b facing the board unloading port 16 (hereinafter referred to as the front end of the board). When the reduced-pressure chamber 11 is closed, the control means 100 working to feed the dry film 1 temporarily stops feeding the dry film 1 as the processing area 10 of the base film 2 between boards is chucked at the film loading port 17 a . Then, the control means 100 moves the rollers 18 and the tension rollers 19 so that a section of base film longer than at least the length of two boards (four boards in this embodiment) may exist in the reduced-pressure chamber 11 when the chamber 11 is closed. In other words, the control means 10 works as a film length control mechanism.
The optimum length of the base film existing in the reduced-pressure chamber 11 when the chamber 11 is closed (equivalent to the length of four boards in this embodiment) is determined in consideration of the fact that a longer film length left in the chamber requires a wider chamber space and more evacuation time although it makes the tension control easier and that a shorter film length left in the chamber after lamination makes the tension control harder.
When the reduced-pressure chamber 11 reaches the preset degree of vacuum, the lamination rollers 20 are positioned as indicated by dotted circles in FIG. 2, and then they move towards roller positions indicated by the solid circles. During this movement from the front board end to the rear board end with the chamber in the vacuum state, the lamination rollers 20 having a heating means attach the resist 3 evenly to the board surfaces with heat and pressure. This lamination causes no air bubbles or wrinkles in the laminated resist films.
After lamination is complete, the lamination rollers 20 go back to the roller positions indicated by dotted circles in FIG. 2 .
Referring to FIG. 1 again, the laminated board unloading section will be explained. This unloading section comprises a board-edge transfer means (invisible in FIG. 1 ), a clamper 22 , a base film removing means (invisible in FIG. 1 ), and a clamper 23 downstream of the board unloading port 16 outside the reduced-pressure chamber 11 .
When the lamination rollers 20 go back to the roller positions indicated by dotted circles (invisible in FIG. 2 ), the control means 100 stops the vacuum means (invisible in FIG. 1 ), releases the clamper 21 in the reduced-pressure chamber 11 and the clamper 22 , outside the reduced-pressure chamber 11 , and actuates the cylinders 12 a and 12 b to open the reduced-pressure chamber 11 as indicated in FIG. 1 . At this time point, lamination of the resist films 3 onto the board 5 b is completed.
Outside the chamber 11 , the front end (edge) of the laminated board 5 d is clamped by the clamper 23 (indicated by dotted lines) and the clamper 23 moves right (in the figure) by the length of one board.
As the damper 23 moves right, the laminated boards 5 b and 5 c having resists attached to them are moved towards the board unloading port 16 by the board edge clamping means (invisible in FIG. 1) in the reduced-pressure chamber 11 . When the rear end of the laminated board 5 c comes into alignment with the dampers 21 , the control means 100 feeds a new part of the dry film 1 into the reduced-pressure chamber 11 through the film loading port 17 , and a new board 5 a is introduced through the board loading port 15 from outside the reduced-pressure chamber 11 .
The board 5 c whose rear end is between the dampers 21 in the reduced-pressure chamber 1 moves to the position of the board 5 d in the board unloading section and the front and rear ends of the board are clamped by the dampers 22 . These dampers work as an unloading mechanism which can hold at least two laminated boards.
The clampers holding the front end of the board are disposed just upstream of a base film removing means (invisible in FIG. 1 ). While the dampers 23 clamp the board 5 e at the damper position indicated by solid lines, the base film removing means, for example, a vacuum-pickup means (invisible in FIG. 1) vacuum-picks the base film in the processing area between boards (at the front end of the board 5 d ). As the base film 2 already has perforations in the processing area 10 between boards made by the roulette type device, the processing area 10 between boards is easily removed by vacuum-picking, and the boards 5 d and 5 e are separated from each other.
Then, the dampers 23 release the board and the board edge clamping means (invisible in FIG. 1) sends the board 5 e to the succeeding processes. After this, the dampers 23 return to the initial position and move to the front end of the board 5 d . The dampers 22 and 23 clamp the board 5 d . Another new board 5 a is fed for continuous lamination.
As explained above, the embodiments shown in FIG. 1 and FIG. 2 are hermetically sealed at the processing areas 10 of the base films 2 between boards, and vacuum seals are provided at the film loading port 17 a , formed by the movable parts 11 b and 11 d , and at another film loading port 17 b , formed by the movable part 11 c and the stationary part 11 a.
Similarly, the board unloading port 16 formed by the movable part 11 d and the stationary part 11 a is hermetically sealed at the processing area 10 of the base film 2 between boards by the vacuum seal 13 . With this hermetical sealing, the reduced-pressure chamber may be easily evacuated to a desired degree of vacuum, which is retained during lamination. Further, since the roll of dry film 1 is provided outside the reduced-pressure chamber 11 , the chamber 11 can be smaller and the desired degree of vacuum can be quickly obtained.
Further, since this embodiment feeds resist films into the reduced-pressure chamber 11 without applying any frictional force to or effecting contamination of the resist 3 to be attached to the boards 5 , this embodiment can keep the boards clean during lamination in the reduced-pressure chamber, and thus greatly reduce the number of faulty laminated boards.
Also, when the laminated boards 5 are ejected from the reduced-pressure chamber 11 , they are protected against damage by frictional forces from the vacuum seal, since the boards do not touch the vacuum seal. Further, this extends the service life of the vacuum seal 13 and does not require frequent replacement of the vacuum seal 13 .
Another embodiment of the present invention will be explained with reference to FIG. 3 .
FIG. 3 is a schematic sectional view of a vacuum film-laminating apparatus which represents a second embodiment of the present invention. In contrast to the previous embodiment, this embodiment moves the boards 5 in the reduced-pressure chamber 32 during lamination. The vacuum film-laminating apparatus of this embodiment mainly comprises a film loading section, a reduced-pressure section, a board loading section, and a laminated board unloading section. The film loading section and the board loading section of this embodiment are functionally almost the same as those of the first embodiment shown in FIG. 1 and FIG. 2 and identical symbols are used in the figures to identify the same or similar parts. Their detailed explanation will be omitted here.
As seen in FIG. 3, the reduced-pressure section comprises a reduced-pressure chamber 32 having film loading ports 30 a and 30 b , a board loading port 31 a , and a board unloading port 31 b . A vacuum means (invisible in FIG. 3) is provided for evacuating the reduced-pressure chamber 32 through an evacuation hole (invisible in FIG. 3) on the reduced-pressure chamber 32 . The film loading ports 30 a and 30 b of the reduced-pressure chamber 32 are respectively equipped with an inlet valve 33 which can be operated by an opening and closing means, as will be explained later. When the inlet valve opens, the resist 3 and the base film 2 can be fed into the reduced-pressure chamber 32 without touching the port.
An example of means and methods for opening and closing the inlet valve 33 in the film loading port 30 a will be explained with reference to FIG. 4 and FIG. 5 .
FIG. 4 and FIG. 5 respectively show a magnified view of the film loading port and its vicinity. FIG. 4 shows the inlet valve in its is open state. FIG. 5 shows a sectional view of a closed inlet valve taken on the line A—A in FIG. 4 . Parts which are functionally identical are given an identical symbol in FIG. 4 and FIG. 5 .
As seen from FIG. 4 and FIG. 5, the inlet valve is a hollow member having a deformable sealing material 33 , for example, which is made of an elastic material at its end. The inlet valve is a little wider than the base film 2 . The other end of the inlet valve 33 has an air inlet hole 33 C through which air is supplied to the hollow part of the valve. This air inlet hole 33 C is connected to an air supplying and evacuating means (invisible in FIG. 3 ). Air is taken into or from the inlet valve 33 through this inlet hole 33 C.
To open the film loading port 30 a , the inlet valve is evacuated through the air inlet hole 33 C. The deformable sealing-material 33 A shrinks to form a dent in the inlet valve 33 above the film conveying surface as shown in FIG. 4 . When the processed base film 2 reaches a preset position in the reduced-pressure chamber 32 , the processing area 10 of the base film 2 between boards comes under the inlet valve 33 .
When air is supplied to the inlet valve 33 through the air inlet port 33 C from the air supplying and evacuating means (invisible in FIG. 3 ), the deformable sealing material expands to touch the base film 2 at the processing area 10 between boards only. In other words, the film loading port 30 a can be closed completely with the base film 2 in contact with the inlet valve 33 without touching the portion of the resist 3 on the base film 2 .
Referring to FIG. 3 again, means for closing the board loading port 31 a and the board unloading port 31 b of the reduced-pressure chamber 32 will be explained.
The board loading port 31 a and the board unloading port 31 b respectively have shutters 34 a and 34 b which can move vertically. These shutters 34 a , 34 b are driven by a moving means (invisible in FIG. 3) to close the board loading port 31 a and the board unloading port 31 b to hermetically seal the reduced-pressure chamber 32 .
The processed base films 2 and resists 3 are fed into the reduced-pressure chamber 32 through the film loading ports 30 a and 30 b , respectively, are conveyed further with the film body in contact with the moving rollers 35 a and 35 b and adjusting rollers 36 a and 36 b in said reduced-pressure chamber 32 , and are further conveyed through a pair of lamination rollers 37 a and 37 b with a board 5 sandwiched between two pieces of resist 3 on the base films 2 . The moving rollers 35 a and 35 b are movable left and right (in FIG. 3) by moving means which are invisible in FIG. 3 . Similarly, the lamination rollers 37 a and 37 b are movable up and down perpendicularly to the board conveying surface by moving means which are invisible in FIG. 3 . The adjusting rollers 36 a and 36 b are fixed at positions located by a preset distance away from the board conveying surface.
The inlet valves 33 , the moving rollers 35 a and 35 b , the adjusting rollers 36 a and 36 b and the control means 100 for controlling their movement work together to adjust the length of the film in the reduced-pressure chamber 32 so that a preset length of film (length of at least two boards or more) exists in the chamber 32 when the chamber 32 is closed.
The lamination rollers 37 a and 37 b which can move vertically toward and away from the board conveying surface have a function to adjust the length of the film which is not in contact with the board in the closed reduced-pressure chamber.
The reduced-pressure chamber can contain a board 5 b to be laminated and laminated boards 5 c and 5 d simultaneously. A cutter 38 is provided between the laminated boards 5 c and 5 d to cut the base films. Clampers (invisible in FIG. 3) are provided before and after the cutter 38 to hold the laminated boards together with the base films 2 .
In this way, the board conveyors 40 and 41 and the dampers work to hold and pickup at least two laminated boards.
As explained above, when the processed base film 2 is fed into the reduced-pressure chamber 32 through the film loading port 30 a and a board 5 a is carried into the chamber 32 by the board conveyor 14 , the board 5 b on the board conveyor 39 is moved to the position of board 5 c and the board 5 c is moved to the position of the board 5 d in the reduced-pressure chamber 32 .
When the front end of the board 5 b on the board conveyor 39 reaches a space between the lamination rollers 37 a and 37 b , the inlet valves 33 close the film loading ports 30 . Further, the shutters 34 a and 34 b are moved up by the moving means (invisible in FIG. 3) to close the board loading port 31 a and the board unloading port 31 b . Thus, the reduced-pressure chamber 32 is closed hermetically. Then, the vacuum means (invisible in FIG. 3) starts to evacuate the chamber 32 . When the vacuum pressure in the reduced-pressure chamber 32 reaches a preset pressure, the lamination rollers 37 start to move toward the board conveyor 39 . In this case, the reduced-pressure chamber 32 contains resist 3 of a length equivalent to the length of two boards or more.
While the lamination rollers 37 maintain a pressure on the resists 3 against the board 5 b , the board conveyors 39 and 40 work in synchronism to convey the board 5 b to the unloading section. At the same time, the moving rollers 35 move right to allow the board 5 b to be conveyed.
In other words, by moving the rollers 35 in synchronism with the movement of the board conveyor 39 while the base film 2 is clamped by the inlet valve 33 in the film loading port 30 a , the lamination rollers 37 can evenly press the base film 2 on the whole surface of the board 5 b (from the front end to the rear end) with force. At the same time, the lamination rollers 37 containing heating means apply heat to the resist 3 through the base film 2 during lamination. Thus, the resists 3 are attached strongly to the surfaces of the board 5 b with heat and force.
In this case, as the board conveyor 40 also works in synchronism with the board conveyor 39 , the laminated board 5 c is carried to the board position 5 d . When the board 5 d is detected by a board detecting means 82 , such as a photo sensor, in the board unloading port 31 b or its vicinity, the upper and lower dampers (invisible in FIG. 3) vertically clamp the front and rear ends of the board 5 c . The cutter 38 cuts the base film 2 in the processing area 10 between boards 5 c and 5 d to separate the boards 5 c and 5 d from each other. At the end of cutting, the shutters 34 a and 34 b and inlet valves 33 a and 33 b are opened.
When the reduced-pressure chamber 32 is opened to the atmosphere, the board conveyors 41 and 42 are driven to send the board 5 d to the board position 5 e outside the reduced-pressure chamber 32 . In this case, the board conveyors 39 and 40 are not driven, and the chamber 32 , which is open to the atmosphere, still contains the laminated board 5 c.
When the board detecting means 82 in the board unloading port 31 b or its vicinity detects no board in the board position 5 d the board conveyor 14 starts to feed a new board 5 a into the reduced-pressure chamber 32 and positions it in the board position 5 b . Then, the reduced-pressure chamber 32 is closed and starts to effect another lamination.
As explained above, in accordance with the present invention, the inlet valve 33 presses the base film 2 at the processing area 10 between boards to hermetically close the reduced-pressure chamber 32 without touching any part of the resist 3 . Therefore, the boards 5 will never be contaminated, by any dust of resist 3 and can be laminated perfectly.
The cutting of the cover film after lamination can be done outside the reduced-pressure chamber 32 to keep the inside of the reduced-pressure chamber 32 clean.
An embodiment similar to FIG. 3, which cuts the cover film outside the reduced-pressure chamber 32 , will be explained with reference to FIG. 6 .
FIG. 6 is an enlarged sectional view of the board unloading section of the reduced-pressure chamber 32 and its vicinity. The parts in FIG. 3 and FIG. 6 are assigned identical symbols when they are functionally identical. This embodiment, unlike the embodiment in FIG. 3, has an inner cylinder 42 in the board exit side (board unloading part) 31 b of the reduced-pressure chamber 32 . A shutter 34 b is provided on the outer side of the inner cylinder 42 , and a cutter 44 is provided at the outer side of the shutter 34 b . Further, a board conveyor 40 a which can move together with the inner cylinder 42 is provided on the downstream side of the board conveyor which holds the board 5 c in the reduced-pressure chamber 32 .
As shown in FIG. 6, the inner cylinder 42 can be moved (by a moving means which is invisible in FIG. 6) outwards in the reduced-pressure chamber 32 during lamination. The hermetical sealing of the reduced-pressure chamber 32 is assured by the sealing material 43 provided between the reduced-pressure chamber 32 and the inner cylinder 42 .
The shutter 34 b provided on the board exit side 31 b of the inner cylinder 42 is driven up and down by a moving means which is invisible in FIG. 6 and can also be moved left and right as the inner cylinder 42 moves. The cutter 44 is placed at the right side (on the atmosphere side) of the shutter 34 b which is on the board exit side of the reduced-pressure chamber 32 . In FIG. 6, the inner cylinder 42 in solid lines indicates the cylinder 42 which is ready to move and the inner cylinder 42 in dotted lines indicates the cylinder 42 which moved furthest. When the inner cylinder 42 moves, the board conveyor 40 a having the board 5 c moves right separate from the board conveyor 40 . The board 5 c is carried to the board position 5 d . In the descriptions below, the inner cylinder 42 before movement is distinguished from the inner cylinder 42 after movement.
Unlike the embodiment shown in FIG. 3, the embodiment in FIG. 6 has a board detecting means (invisible in FIG. 6) which detects the front end of the board 5 c in the vicinity of the board unloading port 31 b of the inner cylinder 42 . When the board detecting means detects the front end of a laminated board 5 c , the inner cylinder 42 and the board conveyor 40 a having the laminated board 5 c move right (in the figure) separate from the board conveyor 40 .
When the inner cylinder 42 reaches the rightmost end (indicated by the dotted lines), the shutter 34 b moves down to open the reduced-pressure chamber 32 . In this case, the film loading port 30 of the reduced-pressure chamber 32 is closed as shown in FIG. 3 and the base film 2 is located in the dotted position (in FIG. 3) by the movement of the moving roller 35 a.
Just when the shutter 34 b is opened, the laminated board 5 d is held in the dotted position 5 d on the board conveyor 40 a , but the board conveyor 40 a starts to convey the board sd rightward and at the same time, the inner cylinder 42 moves back to the home position together with the open shutter 34 b and the cutter 44 . Simultaneously, a board supporting member (invisible in FIG. 6) is inserted under the laminated board 5 d from the right of the figure to support the laminated board. Therefore, when the inner cylinder 42 returns to its home position, the laminated board 5 d is left on the supporting member from the board conveyor 40 a.
When the inner cylinder 42 moves back (left) to the home position (indicated by the solid lines) with the shutter 34 b (or the reduced-pressure chamber 32 ) open, the board conveyor 40 a which moved back together with the inner cylinder 42 stops just before the front end of a board 5 c on the board conveyor 40 . The cutter 44 cuts the base film 2 in the processing area between the laminated boards 5 c and 5 d . Then the inner cylinder 42 returns to the home position (indicated by the solid lines in FIG. 6) without actuating the board conveyor 40 and the shutter 34 b closes.
As explained above, since the embodiment in FIG. 6 cuts the cover film outside the reduced-pressure chamber 32 , the embodiment can prevent any cutting dust from entering into the reduced-pressure chamber 32 . Even when the cutting dust is sucked into the reduced-pressure chamber 32 (as the cover film cutting is done in the atmosphere), it is exhausted from the reduced-pressure chamber 32 during lamination under a vacuum pressure. Therefore, a clear lamination can be assured.
Although the embodiments in FIG. 1 through FIG. 6 attach a cover film 4 having resist 3 on each surface of a board 5 , there will be no problem when the embodiments attach a cover film having resist on one of the board surfaces only. Further, the boards can be carried by edge-clamping transfer means instead of the conveyors which convey boards on them.
Further, the embodiments in FIG. 1 through FIG. 6 respectively used a roulette type device 7 to apply perforations to the base film 2 in the film loading section and remove a resist portion from the processing area 10 of the base film 2 between boards. However, it is possible to leave cover films in the processing areas between boards instead of removing cover films completely before feeding them into the reduced-pressure chamber. In this case, a dry film removing means is required to remove the resist 3 and the cover film 4 left in the processing areas between boards together with the base film 2 .
Further, it is possible to make the processing areas 10 , non-laminated areas, between boards on the base film 2 by cutting out the resist 3 and the cover film 4 , perforating the base film 2 , removing all cut-out cover films, and applying a tape piece as wide as the processing area between boards transversely onto the resist in the processing area between boards. The set of base film, resist, and tape in the processing area between boards is removed after lamination is complete to make the laminated boards separated.
It is also possible to detect the processing area 10 between boards in the film loading port by an optical sensor provided near the film loading port (by detecting a change in the intensity of light reflected in this area) or to detect it visually using an image sensor.
In accordance with the vacuum film laminating apparatus of the present invention, films and boards can be fed into the reduced-pressure chamber without being damaged and contaminated. The reduced-pressure chamber can obtain the desired degree of vacuum in a short time and films and boards can be continuously laminated in a very clear environment. | A film laminating apparatus attaches films to electronic circuit boards, such as printed circuit boards and silicone boards or wafers. The film laminating apparatus conveys a plurality of boards at intervals, forms pieces of lamination film at the intervals of the boards on a base film with a processing area between boards and continuously conveys the base film into a reduced-pressure chamber having a board loading port, a film loading port, a laminating mechanism for attaching the lamination film on the base film to the boards, and a board unloading port for ejecting the laminated boards. Shutters are provided for opening and closing shutter sections provided in the board loading port and the board unloading port of the reduced-pressure chamber, and a vacuum source is provided for evacuating the reduced-pressure chamber when the reduced-pressure chamber is closed by the shutters. A shutter section is equipped with a shutter in the film loading port of the reduced-pressure chamber, and a detector is provided for detecting when a processing area in the film between boards being fed into the reduced-pressure chamber is in the shutter section of the film loading port. A control means then operates the shutter means of the film loading port, the board loading port, and the board unloading port to close the reduced-pressure chamber according to the result of detection by the detecting means, and actuates the vacuum source to evacuate the reduced-pressure chamber to a desired degree of vacuum. Then, the laminating means is actuated. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to apparatus used for the launching of fascines and in particular to apparatus used for the launching of inflatable fascines.
Fascines are structures which are commonly used to enable vehicles and personnel to cross ditches and conventionally comprise bundles of elongate members. Recently fascines comprising bundles of plastic pipes have been employed an example of which is described in EP patent 0149314. A fascine which may be stored more compactly and which comprises a core of inflatable members surrounded by a necklace of rigid plastic pipes is described in UK patent 2242468. Fascines of the non inflatable kind are frequently used in military applications to enable tanks and other vehicles to cross ditches and when such an operation is to be performed under enemy fire there is a requirement for the deployment to be effected without exposing personnel. To this end tanks equipped with apparatus for the automatic launching of the fascines have been proposed. Due to the size of fascines required for military applications tank borne apparatus for the launching of the non inflatable type of fascine described in EP patent 0149314 is only able to carry and deploy a small number of fascines. UK patent 2242468 discloses apparatus which can carry and deploy more fascines because they have inflatable core members. Even so relatively frequent return to a safe area to re-stock with fresh fascines will be necessary which will severely inhibit the ability of a fascine deploying tank to keep up with the front line of an armoured advance.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a fascine launching apparatus which overcomes the above mentioned disadvantages of the prior art fascine launching apparatus. It is a further object of the invention to provide a fascine launching apparatus which will have a relatively low profile when used and which displays reduced variability between successive launching operations.
Thus according to the invention there is provided apparatus for deploying inflatable fascines comprising a movable conveyor defining a plurality of fascine support locations a conveyor support structure, drive means adapted to move the conveyor with respect to the support structure in order to sequentially bring the fascine support locations to a fascine launching region, inflation actuation means for initiating fascine inflation at the fascine launching region and fascine release actuation means for causing release of a fascine from the apparatus.
Fascine launching equipment constructed according to the invention will be capable of sequentially delivering uninflated fascines having a low profile to a fascine launching region, inflating the fascines and then launching them. As each inflated fascine will be launched from a single fascine launching region the variability of sequential fascine launches will be reduced and the directional control of the launching process will be made more predictable. Detrimental raising of the centre of gravity Of a vehicle equipped with the apparatus will be kept to a minimum thus improving stability and cross-country mobility. The delivery of the fascines to the fascine launching region in a low profile unitflared state will reduce the chance of enemy detection. Furthermore providing apparatus which moves fascines to be deployed to a fascine launching region by means of a conveyor enables the apparatus to handle more fascines than have hitherto been handleable by prior art fascine launching apparatus and rapidly launch consecutive fascines where there is a requirement to place more than one fascine in a given ditch.
As the fascines to be launched by the conveyor are inflatable and are likely to need support prior to and possibly during inflation the conveyor conveniently comprises a continuous loop of articulated rigid members which constitute the fascine support locations.
In order to facilitate automatic operation of the apparatus and to reduce the possibility of foreign objects jamming the fascine inflation actuation means the actuation means is preferably electrical and more preferably comprises an electrical contact associated with each fascine support location which is registrable with a source of electrical power when each fascine support location occupies the fascine launching region.
In order to facilitate automatic operation of the apparatus still further the apparatus preferably comprises stop means for automatically halting the conveyor when a fascine support location arrives at the fascine launching region.
As launching of a fascine will normally be succeeded by movement of a further fascine into the fascine launching region preferably fascine release is effected by forward movement of the conveyor. As the conveyor will be moving in close proximity to the support structure such a release actuation may conveniently be performed by the camming action of a surface fixed to the support structure
The invention also provides a fascine launching apparatus in combination with one or more uninflated packaged fascines the or each of which is connected to the conveyor at a fascine support location.
In order to reduce the number of commands required to operate the apparatus remotely the packaging associated with each fascine preferably includes at least one containment member which is releasable by partial inflation of the fascine so as to allow full inflation of the fascine. In this way a separate command relating to partial release of the fascine to allow full inflation to take place is not required. The containment member is preferably frangibly or hingeably connected to the remainder of the packaging.
Suitable materials for making the fascines out of include reinforced polyurethane, polyethylene, polyetherurethane, polyesterurethane or polyvinylchloride material. Such materials are rugged enough for the application and are capable of being joined to form seams using adhesive bonding, thermal bonding or radio frequency welding techniques.
In order to facilitate connection of fascines to the apparatus, release of fascines from the apparatus, topping up pressure in a fascine when in situ and replacing fascine inflation reruns when a fascine is in situ each packaged fascine preferably includes at least one reservoir of pressurised gas for fascine inflation purposes. The gas reservoirs will preferably be rechargeable. The inflation means may alternatively include chemical gas generation means.
As gas leakage from the fascine may occur when a fascine is left in situ for a long period or if the fascine becomes punctured each reservoir of pressurised gas is preferably connected to its associated fascine via pressure control means which act to regulate gas supply to the fascine so as to maintain pressure in the fascine at a substantially constant pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only with reference the accompanying drawings in which;
FIG. 1 Is a plan view from above of a fascine launching apparatus according to the invention with upper and lower conveyor members removed.
FIG. 2 Is a vertical cross section on the line B--B of the apparatus shown in FIG. 1 (all conveyor members and two packaged fascines are shown).
FIG. 3 Is a vertical section on the line C--C of FIG. 1 and shows one end of a conveyor member and the fascine release actuation means.
FIG. 4 Is an end elevation of the conveyor member shown in FIG. 3 (in the direction of the arrow D) and shows a packaged fascine.
FIG. 5 Is a vertical elevation of the conveyor member shown in FIG. 2 (in the direction of arrow E) with the frangible cover and fascine removed to reveal the fascine release mechanism.
FIG. 6 Is a vertical cross section on the line F--F of the conveyor member shown in FIG. 5 supporting an inflated fascine ready for release.
FIG. 7 Is a schematic representation of the fascine inflation means.
FIG. 8 Is a schematic vertical cross section of one type of fascine which could be launched from the apparatus shown in FIGS. 1 to 6.
FIG. 9 Is a schematic vertical cross section of an alternative type of fascine which could be launched from the apparatus shown in FIGS. 1 to 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A fascine launching apparatus according to the invention is shown generally at FIGS. 1 and 2. The apparatus is adapted to be mounted on the top of a vehicle such as a tank by means of stands 1 which are connected to either side of the apparatus. The apparatus includes a horizontal conveyor support structure 4 which is in the form of a rectangular frame. Near the front of the support structure 4 two bearing supports 5 are located which serve to rotatably support a transverse shaft 7a. Similar bearing supports 5 near the rear of the support structure rotatably support a further transverse shaft 7b. The ends of each shaft 7a and 7b extend outwardly beyond the bearing supports 5 and are connected to drive wheels 9. Each drive wheel 9 is provided with eight equally spaced conveyor engaging lobes 11. A cross member 3 which extends across the support structure 4 bears an electric motor 6 which constitutes the drive means for a conveyor 2. A flexible belt 8 connects the electric motor to a pulley 13 on the rearmost shaft 7b.
Passing round the outside of the drive wheels 9 is a continuous conveyor 2 which is constituted by sixteen rigid conveyor member 12 which are interconnected by pivot pins 15 (the upper and lower conveyor members have been removed from the plan view in FIG. 1 for clarity). At each end of the inner surface of each conveyor member a lobe engaging protrusion 17 is provided which has a curved surface designed to engage the lobes 11 on the drive wheels 9.
Each conveyor member 12 constitutes a fascine support location to which a packaged fascine 24 is connectable. Two such packaged fascines are shown in FIG. 2 one of which is located in a fascine launching region 14. An enlarged end view of an isolated conveyor member 12 with a packaged fascine 24 connected to it is shown in FIG. 4. A deflated fascine 23 is housed between a backing plate 25 and a frangible containment member 26. The backing plate 25 and the containment member 26 are held together by bolts 29 which also act to hold the packaged fascine to a conveyor member 12. A pinned connection may be used instead of the bolts 29. Additional securing means which are not shown are also provided for securing the containment member to the backing plate when the packaged fascine is not mounted on the conveyor member. With each packaged fascine a reservoir of pressurised gas 32 is provided (see FIGS. 2 and 7) which is connected to the uninflated fascine 23 for inflation purposes as shown in FIG. 7. A fascine engagement mechanism 42 extends along each backing plate as shown in FIGS. 5 and 6.
The fascine engagement mechanism 42 is used to retain a fascine while it is being inflated and is releasable by means of a fascine release actuation mechanism which is shown generally in FIG. 3 in order to enable the release of a fascine once it has been inflated. The fascine engagement mechanism comprises a tube 46 containing gaps 48 for allowing fascine straps 53 to be engaged by sliding bolts 28 which constitute the fascine engaging members and are slideable in the tube 46. Each sliding bolt 28 is connected through a slot 50 in the tube 46 to an single actuating rod 52 which runs the length of the backing plate 25 and protrudes past one end of the backing plate 25 for connection to the fascine release actuation mechanism 44.
The fascine release actuation mechanism is illustrated in FIG. 3 and includes a camming rod 56 which is slideably mounted in a bore 60 in the lobe engaging protrusion 17 at one end of the conveyor member 12. One end of the camming rod 56 which extends past the end of the backing plate 12 is connected to a plate 54 which is provided with an arcuate slot 64 for engaging the actuating rod 52. The opposite end of the camming rod 56 passes through a camming rod guide 58 connected to the rear of the associated conveyor member and is located so that the end of the camming rod is slideable over a camming surface 22 of a camming block 62 which is rigidly connected to the conveyor support structure 4 (not shown in FIG. 3).
At the opposite end of each conveyor member to that at which the release actuation mechanism 44 is located a magnet 68 and an electrical contact 16 are provided (see FIG. 1). The magnet 68 is positioned such that when the conveyor member arrives at the fascine launching region 14 it trips a proximity switch 20 which is rigidly connected to the support structure 4 and which is electrically connected to an electronic apparatus control device (not shown). The electrical contact 16 is electrically connected to an inflation valve 34 mounted on the compressed gas reservoir 32 via an easily connectable plug 33 which may be plugged in when a packaged fascine 24 is mounted onto a conveyor member 12. The electrical contact 16 is positioned such that when the conveyor member arrives at the fascine launching region 14 it comes into contact with a source of electrical power 18. Both the proximity switch 20 and the source of electrical power 18 are connected to the support structure 4 by means of an extension member 70.
Each packaged fascine is supplied with an inflation system which is shown schematically in FIG. 7. The system includes a reservoir of pressurised gas 32 which is connected via an inflation valve 34, a flexible pipe 82, a one way valve 84 and a pressure control valve 36 to each-inflatable cell 30 of the fascine 23. The inflation valve 34 includes a sliding valve member 72 containing a main passage 78 for allowing gas to pass from the reservoir 32 into the pipe 82 and a side passage 80 which permits gas in the maim passage 78 to communicate with one end of the valve member 72. The valve member 72 is biased to the right as viewed in FIG. 7 by a spring 74 and is biasable in the opposite direction by a solenoid 76.
Each fascine may be constituted by a single bag as shown in FIG. 6 but is preferably constituted by a number of inflatable cells 30 as shown in FIGS. 8 and 9. Suitable materials for the manufacture of the fascines include reinforced polyurethane, reinforced polyetherurethane, reinforced polyesterurethane or reinforced polyvinylchloride. Suitable material for the reinforcement of the polymer material include Kevlar (RTM), Nylon (RTM), Spectra (RTM) and Dyneema (RTM) fabric. The outer surface of each fascine may be provided with rigid members such as the plate like members 38 shown in FIG. 8 or tubular members 40 such as those shown in FIG. 9 where the intended use of the fascine calls for extra protection. The bulky nature of these rigid members however means that the volume into which the uninflated fascine can be packed will be significantly increased and for this reason their inclusion is normally avoided.
The operation of the fascine launching apparatus will now be described with reference to FIGS. 1 to 7.
On receipt of an electrical signal by the electronic apparatus control device (not shown) from an operator indicating that there is a requirement to launch a fascine electrical current is supplied to the electric motor 6. Drive from the motor 6 is conveyed to the shaft 7b (in an anti clockwise direction as viewed in FIGS. 1 and 2) by means of the flexible belt 8 and the pulley 13. Rotation of the shaft 7b causes the drive wheels 9 located at each end of the shaft to rotate. Due to the fact that the conveyor members are engaged with the drive wheels by means of lobe engaging protrusions 17 the conveyor 2 is also circulated in an anti clockwise direction.
When a packaged fascine 24 arrives at the fascine launching region 14 the magnet 68 connected to the rear of the associated conveyor member comes into register with the proximity switch 20 mounted on the extension member 70 of the support structure. The tripping of the proximity switch results in an electrical signal being sent to the control device which causes electrical current supply to the electric motor 6 to be stopped which causes the conveyor 2 to halt. As this is occurring the electrical contact 16 which is also mounted on the rear of the conveyor member 12 comes into contact with the source of electrical power 18. Current from the contact 16 passes via the plug 33 (see FIG. 7) to the inflation valve 34 connected to the reservoir of compressed gas 32. The current energises solenoid 76 and forces the sliding valve member 72 to the left (as viewed in FIG. 7) against the biasing effect of the spring 74. When gas in the reservoir 32 can enter the main passage 78 in the valve member 72 gas also flows along side passage 80 into a sealed chamber containing the solenoid 76 and is thus able to bear on the right hand end of the valve member 72. Due to the fact that the chamber containing the spring 74 is vented to the atmosphere the differential pressure on the valve member 72 forces the valve into the fully open position shown in FIG. 7. Due to the fact that the inflation valve 34 is held open by the pressure of gas in the reservoir once the valve has been opened the inflation valve will remain open even after the plug 33 has been disconnected by the launching of the fascine and no further current is being supplied to the solenoid. Gas then flows along the pipe 82 and passes through one way valves 84 and pressure control valves 36 into individual inflatable cells 30 of the packaged fascine 24. The pressure control valves are designed so that when the pressure in a particular cell reaches a required level the valve closes but when the pressure falls below this threshold the valve is forced open under the action of a spring and allows gas from the reservoir 32 to enter the cell. In this way if a slow leak develops in a fascine which is in situ then the pressure will be topped up to the required level by gas from the reservoir provided that the reservoir 32 has not been exhausted. The one way valves 84 will ensure that in the event of the reservoir becoming exhausted and a leak developing in one of the cells 30 only the cell having the leak will become deflated.
As the packaged fascine 24 starts to inflate the outer surface of the frangible containment member 26 breaks off leaving only the part shown in FIG. 6. A hingeable containment member may alternatively be provided which includes a hinge located at the point of the break in member 26 shown in FIG. 6 which allows the containment member to hingeably open. During inflation the fascine is held to the backing plate 25 by four straps 53 which are connected to the outer surface of the fascine 27 and each of which passes round a sliding bolt 28.
When the operator is satisfied that the fascine to be launched is fully inflated he sends a further electrical signal to the control device (not shown) which causes the electric motor 6 to advance the conveyor a small distance in the anti clockwise direction. As this occurs the camming rod 56 associated with the conveyor member situated in the fascine launching region 14 slides down the camming surface 22 of the camming block 62. The effect of this camming action is that the camming rod 56, plate 54 and actuating rod 52 are moved to the left as viewed in FIG. 3, and to the right as viewed in FIG. 5. The sliding bolts are retracted into the tube 46 thus releasing the straps 53 and allowing the inflated fascine 27 to be launched. As this occurs the plug 33 which is connected to the fascine is disconnected from the conveyor member 12.
As described above when the fascine is inflated and in situ the inflation valve will remain open and the pressure control valves 36 will ensure that the pressure in each cell is maintained at a particular threshold value. If the reservoir of compressed gas 32 becomes exhausted then the reservoir can be recharged from an external source via refill valve 90. When there is a requirement to deflate the fascine the dump valves 88 can be manually opened. If a gas other than air such as carbon dioxide, nitrogen or helium has been used to inflate the fascine then apparatus may be provided for collecting the gas as the fascine is deflated so that it can be reused.
The dump valves 80 may also be used for inflation of the fascine from a compressor or vehicle exhaust system in the event of the inflation system described above failing to operate correctly.
As an alternative to the reservoir of compressed gas being packaged and launched with a fascine each conveyor member may be equipped with a reservoir which is connected to its associated fascine by means of a coupling which is disconnectable by the action of releasing the fascine from the conveyor leaving the reservoir connected to the conveyor. In this way the fascines may be packaged more compactly and need not be stored with a relatively inaccessible reservoir of compressed gas. This may be an advantage if the fascines are likely to be stored for long periods of time. A further alternative to the provision of a reservoir of compressed gas is to provide chemical gas generation means which may be either packaged with the fascine or permanently connected to the conveyor as described above. The advantage of a chemical gas generating means is that the volume and weight of the source of pressurised gas can be significantly reduced. | Apparatus for launching inflatable fascines comprising a conveyor system to which uninflated fascines are attachable for delivery to a launching region and an inflator to effect inflation and launch of the fascines. The conveyor (2) comprises a number of rigid conveyor members (12), each of which constitutes a fascine support location. At each of the support locations a packaged fascine (24), comprising a deflated fascine (23) housed between a backing plate (25) and a frangible or hingeable containment member (26), is attachable. The packaged fascines (24) may also contain a reservoir of pressurized gas (32) for inflation purposes. The conveyor (2) is connected via drive wheels (9) to a motor (6) such that the support locations carrying the packaged fascines (24) are sequentially delivered to a fascine launching region (14). | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 34 251.9 filed Sep. 24, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a fiber tuft feeder for supplying a textile fiber lap to a fiber processing machine such as a carding machine, a roller card unit or the like. The feeder is of the type which has a vertical first chute (upper or reserve chute), at the lower opening of which a feed roller is disposed, cooperating with an opening roller situated therebelow. From the opening roller, approximately tangentially thereto, a second chute (lower or feed chute) extends which is associated with a device which provides a densifying (fiber-compressing) air stream that passes through the fiber material situated in the feed chute. Such a fiber-compressing air stream flows along the opening roller, codirectionally with its direction of rotation.
According to a known apparatus, as disclosed in German Offenlegungsschrift (application published without examination) 39 12 565, an air outlet duct is provided for guiding a transporting air stream out of the upper chute after such transporting air stream deposited fiber tufts into the upper chute through an upper inlet thereof. In the air outlet duct a fan is disposed which branches off a partial air stream of the transporting air stream. Such a partial air stream proceeds along the cylindrical surface of the opening roller and subsequently flows tangentially to the opening roller to the clearance defined between the feed roller and the opening roller. During this occurrence, the air stream emanating from the fan and accelerated along the opening roller impinges upon the clearance and is abruptly braked thereby, causing a significant air turbulence. Such an undesired vortex generation is further amplified by the fact that the air stream generated by the fan is pulsating, that is, such an air stream is not uniform. Furthermore, the transporting air stream supplied to the fan is also fluctuating because of the fluctuating supply of fiber tufts in the upper chute. It is further disadvantage of the known arrangement that the air stream is significantly weakened by the clearance between the feed roller and the opening roller and thus its densifying (compressing) effect is adversely affected.
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, improves the flow of the densifying air stream and makes possible an improved guidance of the fiber material in the lower chute.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber tuft feeder includes a first chute; a feed roller supported at the outlet end of the first chute; an opening roller adjoining the feed roller and being supported below the feed roller and receiving fiber tufts therefrom; a second chute extending downwardly from the opening roller; a densifying air stream generating arrangement for introducing an air stream into the second chute to densify the fiber tufts therein; and a guide arrangement for directing the densifying air stream to flow consecutively along the feed roller and the opening roller.
Thus, according to the invention, the densifying (compressing) air stream first flows along the feed roller. Thereafter, the opening roller entrains the densifying air stream and deflects it into the direction of the lower chute, thus circumventing the clearance between the feed roller and the opening roller. In this manner, the flow behavior of the densifying air stream is improved and a better guidance of the fiber material and the air stream is feasible in the lower chute. Also, in contrast to conventional arrangements, the densifying air stream is not decelerated. By virtue of the fact that the densifying air stream flows around the feed roller, fiber tufts adhering to the feed roller which have not been stripped by the opening roller are advantageously blown off.
The invention has the following additional advantageous features:
The densifying air stream is continuous, particularly as a result of using a fan.
The feed roller and the opening roller rotate in mutually opposite directions.
The densifying air current is directed codirectionally with the direction of rotation of the feed roller.
The densifying current essentially flows along the circumferential surface of the feed roller.
The densifying current flows along the clearance between the feed roller and the opening roller at that side towards which the fiber tufts are thrown by the opening roll.
The densifying air stream and the air stream generated by the rotation of the opening roller form a rectangle or an obtuse angle with one another.
One of the large walls of the lower chute has a preferably planar or curved extension which faces the feed roller.
The extension, the side walls belonging thereto and the feed roller form a channel.
The extension faces the opening roller and bounds the channel.
Upstream of the channel a wide-slotted nozzle is provided for the densifying air stream.
The channel extends from the outlet of the nozzle to the zone of the opening roller at which the fiber tufts are thrown by the opening roller.
The distances of the circumferential surfaces of the feed roller and the opening roller from the extension are approximately identical.
The distances of the circumferential surfaces of the feed roller and the opening roller from the extension have a ratio of approximately 1:2.
The channel is straight in a zone facing the opening roller and is curved in a zone facing the feed roller.
The channel-like chamber is of concave curvature in a zone facing the opening roller.
The channel-like chamber has a constriction in the zone of the opening roller.
The cross section of the constriction in the channel is approximately 50 to 70% that of the cross-sectional area in the zone of the feed roller.
The feed roller and a counterface formed by the adjoining wall portion of the upper chute form a channel-like space.
In the region of the clearance between the feed roller and the opening roller the densifying air stream and the air stream generated by the rotation of the opening roller are oriented at an obtuse angle to one another.
The wide-slotted nozzle and the upper chute have a common wall surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional side elevational view of a preferred embodiment of the invention.
FIG. 2a is an enlarged schematic sectional side elevational view of a detail of FIG. 1.
FIG. 2b is a schematic sectional side elevational view of a part of FIG. 2a showing flow behavior.
FIG. 2c is an enlarged detail of inset IIc in FIG. 2a.
FIG. 3 is a schematic sectional side elevational view of a variant of the preferred embodiment.
FIGS. 4, 5 and 6 are schematic side elevational sectional details of the general construction of FIG. 1 showing three variants.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, a tuft feeder generally designated at TF is arranged at the input side of a carding machine 1. The tuft feeder TF has a vertical reserve chute (upper chute) 2 which is charged through an upper chute inlet with finely opened fiber material. Such charging operation may be performed, for example, by means of a condenser, via a supply-and-distributing duct 3. In the upper zone of the reserve chute 2, air outlet openings 4 are provided through which the transporting air stream G may pass into a suction device 5 in the direction of the arrow H after the fiber tufts have been separated from the transporting air stream. The lower end of the reserve chute 2 is obturated by a feed roller 6 which cooperates with a feed tray 7. The feed roller 6 advances the fiber material I into an underlying adjacent, rapidly rotating opening roller 8 which is provided with pins 8b or a sawtooth clothing and which, along a path of its circumference, faces a feed chute (lower chute) 9. A phantom-line circle 8c in FIG. 3 indicates the periphery of the opening roller 8 as defined by the points of pins 8b. The opening roller 8 which is rotated in the direction of the arrow 8a delivers the fiber material caught thereby into the feed chute 9. The feed chute 9 has at its lower end a delivery roller 10 which advances the fiber material (fiber lap) from the feed chute 9 to the carding machine 1. The feeder with features as outlined above, may be, for example, an EXACTAFEED FBK model, manufactured by Tr utzschler GmbH & Co. KG, M onchengladbach, Germany. A motor M, associated with appropriate gearing M', rotates the feed roller 6 slowly in the direction of the arrow 6a while it rotates the opening roller 8 rapidly in the opposite rotary direction 8a.
The lower wall portion of the feed chute 9 is provided with air outlet openings 11a, 11b. Also referring to FIG. 3, the feed chute 9 communicates at its top with a chamber 12 with the intermediary of a channel 12a. The chamber 12 is connected at one end with the pressure side of a fan 13.
The rotating feed roller 6 and the rotating opening roller 8 continuously supply a certain amount of fiber material into the feed chute 9 and the same amount of fiber material is withdrawn from the feed chute 9 by the delivery roller 10 and advanced to the carding machine 1. In order to ensure that such quantities are uniformly condensed and maintained constant, a densifying air stream is driven by the fan 13 through the chamber 12 and a constriction (wide-slot nozzle) 14 downstream of the chamber 12. In the feed chute 9 the fiber material is exposed to the densifying air stream. The fan 13 draws air from the air outlet channel 15a communicating with the air outlet openings 11a, 11b and drives the air into the fiber mass present in the feed chute 9. Thereafter the air exits through the air outlet openings 11a, 11b at the lower end of the feed chute 9 into the air outlet channel 15a as illustrated by the arrow F. The opening roller 8 and the feed roller 6 are partially circumferentially surrounded by a wall face of respective housings 16 and 17. These wall faces conform to the circular configuration of the rollers 6 and 8. As viewed in the direction of rotation 8a of the opening roller 8, the housing 16 is interrupted by a separating opening 18 for the fiber material. The separating opening 18 is joined by a channel 19 bounded by the housing 16 and the circumferential surface of the opening roller 8. The channel 19 extends to the feed roller 6. The feed tray 7 is arranged at the lower end of the wall region facing the feed roller 6. The edge 7a of the feed tray 7 is oriented in the rotary direction 8a of the opening roller 8.
Referring particularly to FIG. 2a, The plane J which contains the rotary axes of the feed roller 6 and the opening roller 8 is inclined under an angle α of between about 30° to 90° (for example, 35° ) with respect to the vertical plane K containing the rotary axis of the opening roller 8, in the direction of rotation of the opening roller 8. Stated differently, the plane J divides the opening roller 8 into a first and a second side. By virtue of the direction of rotation of the opening roller 8, the fiber tufts are thrown thereby into the first side. The plane J is inclined relative to the plane K towards the first side. The channels 18 and 19 and the feed chute 9 are in communication with one another. The wall face 9a of the feed chute 9 may be adjusted in the width direction as illustrated in FIG. 2a.
Particularly referring to FIGS. 2a and 3, the densifying air stream exits from the pressure side of the fan 13, passes through the conduit 15b and the chamber 12 as indicated by arrow A 1 , and enters the wide-slotted nozzle 14, as indicated by the arrow A 2 . Thereafter, the densifying air stream proceeds, as indicated by the arrow A 3 through the chamber 19 at that side of the feed roller 6 and the opening roller 8 at which the feed chute 9 begins. First the air stream flows along a significant circumferential part of the feed roller 6 and thereafter along the opening roller 8. During this occurrence, the densifying air current flows against the rotary direction 6a of the feed roller 6 and thus blows back fiber tufts still adhering to the feed roller 6.
The rapidly rotating opening roller 18, as also illustrated in FIG. 2c, entrains an air stream B. The densifying air stream, as shown at A 4 , flows in the direction of the opening roller 8 and merges with the air stream B under an angle β which is at least 90° (β is shown to be obtuse in FIG. 2c). Thereafter, the air streams A 4 and B are combined into an air stream C which flows in the rotary direction 8a of the opening roller 8 in the chamber 18 and passes through a constriction a provided in the chamber 18. During this occurrence, as shown in FIG. 2b, the combined air stream C is aligned and oriented in the direction of the upper opening of the feed chute 9 and flows from the opening roller 8 slightly deflected into the feed chute 9 as an air stream D 1 . At the same time, the air stream D 1 entrains fiber tufts thrown by the opening roller 8. By virtue of the fact that the channel 18 widens in the direction of the feed chute 9 by a curving of the wall faces 18a from distance a to distance b, the fiber tuft-laden air stream D 1 may expand downstream of the opening roller 8 and is thus not entrained by the opening roller 8 into a circumferential path but it enters the chamber 19 only as a branched, lesser residual air stream E.
The opening roller 8 supplies fiber tufts into the air streams C and D 1 . The channel 18 extends essentially along a lateral zone of the opening roller 8 so that the air streams A 4 , C and D 1 in the feed chute 9, serving for densifying the fiber material are effective along the opening roller 8. The separation of the fiber tufts from the needles 8b of the opening roller 8 effected by centrifugal forces may be, for example, pneumatically supported.
As shown in FIG. 4, the outlet of the wide-slotted nozzle 14 faces the circumferential face of the feed roller 6 above the horizontal diameter of the feed roller 6. According to FIG. 5, the nozzle 14 opens underneath the horizontal diameter of the feed roller 6 such that the circumferential surface of the feed roller 6 is essentially screened. As shown in FIG. 6, the wide-slotted nozzle 14 and the upper chute 2 have a common wall 2a, that is, the sheet metal chute wall has a dual use.
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. | A fiber tuft feeder includes a first chute; a feed roller supported at the outlet end of the first chute; an opening roller adjoining the feed roller and being supported below the feed roller and receiving fiber tufts therefrom; a second chute extending downwardly from the opening roller; a densifying air stream generating arrangement for introducing an air stream into the second chute to densify the fiber tufts therein; and a guide arrangement for directing the densifying air stream to flow consecutively along the feed roller and the opening roller. | 3 |
FIELD OF THE INVENTION
The invention relates to a method and an apparatus for manufacturing drawn biodegradable filament and especially concerns with biodegradable micro-filament as polylactic acid and polyglycolic acid drawn at high draw ratio of 100 times or more which can be obtained by those simple and convenient drawing means.
BACKGROUND OF THE INVENTION
In a field of fibers, various kinds of efforts have been made with regard to reduce a fiber diameter and make it to 10 μm or less. That has unique feeling and expensive-looking in apparel usage, and heat-retaining property, heat insulating property and printability are increased with enhanced covering power by increasing fiber density. Further, it is because fiber performances are greatly improved from various points in also industrial and agriculture usage such as to improve greatly flexibility of rope etc., heat-retaining property and also filter features.
Meanwhile, also in fiber industry, biodegradable fibers have been strongly required in also household use, and industrial materials; such as agriculture materials, diaper, packaging materials, etc. for transition to resource recycling type society from a viewpoint of global environment. But, although there is a point of view from raw material cost, it is difficult to make fibers of small fiber diameters as a spinning property and drawing property is bad in also a viewpoint of its manufacturing method and fiber performance (for example, Japanese Patent Laid-Open Hei. 7-305227). In addition, polylactic acid fibers which are typical biodegradable fibers were depended on plasticizer etc. (for example, Japanese Patent Laid-Open 2000-154425) as these are hard and brittle filament and have also a problem from performance side but additives of plasticizer etc. damage strength and heat resistance property and fiber properties are spoiled.
One of essential problematic point that biodegradable fibers have is a request for different biodegradable speed depending on intended end-usage; degradation completion term of rope and sheet for mulching are different in even agriculture usage, and also different from that of a diaper and wiping cloth. It is desired to prepare product groups having various degradation speeds without changing a kind of polymers to fulfill these requests.
Additionally, biodegradable fibers have many usages especially in a non-woven fabric fields and various manufacturing methods are proposed (for example, Japanese Patent Laid-Open 2000-273750 and Japanese Patent Laid-Open 2001-123371). Those are required non-woven fabrics of small filament diameters from a viewpoint of covering power and heat-retaining property of nonwoven fabrics and feeling etc. in a diaper. But, it was difficult to manufacture non-woven fabrics of small filament diameters simply and conveniently and cheaply as performance of spinning and drawing is bad.
In addition, as the broad sense of biodegradable fibers, there are bioerodible absorbable fibers (for example, Japanese Patent Laid-Open Hei. 8-182751) and thin and flexible filament with strength is required for surgical suture threads etc. Additionally, non-woven fabrics consisting of bioerodible absorbable fibers have been used also in various fields such as suture prosthesis, anti-adhesion material, artificial skin and cell culture substratum (for example, Japanese Patent Laid-Open 2000-157622 and Japanese Patent Laid-Open 2004-321484) from medical care side, also in these field, non-woven fabrics consisting of thin filament with strength are required.
On the other hand, the invention relates to drawing technology of filament by infrared rays heating but the technology concerning with these has been performed in many ways conventionally (for example, Japanese Patent Laid Open 2003-166115, pamphlet of International Laid Open No. 00/73556, Akihiro Suzuki, et al. Journal of Applied Polymer Science, Vol. 83, pp. 1711-1716, 2002, Akihiro Suzuki, et al., Preliminary Abstracts of Polymer Science Society, Japan, May 7, 2001, Vol. 50, No. 4, pp. 787, Akihiro Suzuki, et al., Journal of Applied Polymer Science, Vol. 88, pp. 3279-3283, 2003, Akihiro Suzuki, et al., Journal of Applied Polymer Science, Vol. 90, pp. 1955-1958, 2003). The invention, further improving these technologies, is made effectively applicable to biodegradable filament. In addition, a zone drawing method and a zone heat treatment method shown in the literature (Journal of Applied Polymer Science, Vol. 90, pp. 1955-1958, 2003) are beneficial means to conduct also re-drawing or heat treatment of the drawn biodegradable filament of the invention.
Accordingly, the invention solves problematic points of biodegradable filament by further developing the conventional technology of above-mentioned inventor, and the object in the invention resides in to obtain highly drawn and oriented biodegradable micro-filament easily by spinning thick biodegradable filament at stable spinning condition and drawing them to high ratio with simple and convenient means. And the other object resides in to obtain filament used for surgical suture threads etc. which are flexible and have strength by making filament consisting of bioerodible absorbable polymer to be super-micro. Additionally, the other object resides in to be product groups with different biodegradable speed by various product (threads, rope, fabrics, non-woven fabrics and so on) groups different in filament diameters by this simple and convenient drawing means. In addition, the other object resides in to be able to manufacture long fiber non-woven fabrics consisting of biodegradable micro-filament having high degree of molecular orientation. Further, the other object resides in to offer non-woven fabrics consisting of bioerodible absorbable filament, which are used for suture prosthesis, anti-adhesive material, artificial skin, cell culture substratum, etc.
DISCLOSURE OF THE INVENTION
The invention relates to drawn biodegradable filament. Biodegradable filament is filament consisting of a biodegradable polymer, and a biodegradable polymer (JISK3611) is degraded relatively easily by a microscopic organism and a biologic enzyme existing in soil and seawater of natural world and its degradation product is harmless polymer material. The biodegradable filament in the invention is composed of above-mentioned biodegradable polymer; the polymer is a thermoplastic polymer, for example, it is said to filament that following polymers are a main component (30% or more). It consists of aliphatic polyester typified by polylactic acid, polycaprolactone, polybutylene-succinate and modified polymers etc. of those; these are a main component (30% or more) and may be one that also include the other component.
Aforementioned biodegradable filament is filament that strength becomes preferably ½ or less; further preferably 30% or less and the most preferably 10% or less according to elapsing 12 months in the ground. It is a prerequisite to have biodegradability in the ground to contribute to recycling type society with microorganism degradability.
Biodegradability of the invention means the biodegradability in the broad sense of the term, a case having bioerodible absorbability is also included. The bioerodible absorbability is said to a property that it has been absorbed within a biological body not to be a harmful substance, although it is used directly contacting cell, blood, connective tissue, etc. in a body tissue and degrades within a biological body. The bioerodible absorbable filament in the invention consists of above-mentioned bioerodible absorbable polymers, for example, it is said to filament consisting of the following polymers. It consists of aliphatic polyester typified by polyglcolic acid, polylactide, polyglutamic acid, poly-p-dioxic acid, poly-α-malic acid and poly-β-hydroxybutyric acid and modified polymer of those, these are a main component (30% or more) and may be one also includes the other components.
The invention relates to drawn biodegradable filament. The filament is the fibers that have substantially continuous length and it is distinguished from staple fibers that consist of short length (from several millimeters to several centimeters). A cross-section of biodegradable filament may also be various shaped one called modified cross-sections and hollow filament. Additionally, it may also be a sheath-core type composite fiber and a composite fiber of side-by-side etc. Still, the filament in the invention has a case that it is a single filament consisting of one filament and a case that it is multifilament consisting of plural filaments. Drawing tension applied to one filament is expressed sometimes “per single filament” but it means “per one filament” and in multifilament, “per individual one filament” that formed of those.
The invention provides means for drawing the original biodegradable filament. The original biodegradable filament in the invention may be already manufactured as the biodegradable filament and wound-up on bobbins and the like, or biodegradable filament to be the material for the drawing means in the invention which are formed into the biodegradable filament from molten or dissolved biodegradable filament by cooling or coagulation in the spinning process, and used successively in the spinning process. The biodegradable resins, especially polylactic acid and polyglycolic acid can not be spun at unreasonable high temperature as pyrolysis property is large, but it can be spun even if polylactic acid etc. of relatively large molecular weight at comparatively low temperature as an original filament of the invention may be thick.
The original biodegradable filament of the invention are characterized in that drawing property is not spoiled so much even if it is molecular oriented already. In the invention, there is a case that drawing is conducted with a swelled portion larger than the diameter of the original biodegradable filament at a drawing starting portion where it is drawn by infrared beam. Such a peculiar phenomenon has not yet been observed in usual drawing for synthetic fibers. It is considered that the phenomenon is derived from that the drawing temperature is increased to the melting point or thereabout of the original biodegradable filament and drawing in the narrow zone is enabled. As described above, by drawing with the swelled portion, it is enabled to draw at a draw ratio of 100 times or more, or 500 times or more and in suitable condition 1,000 times or more.
The original biodegradable filament of the invention is heated to an appropriate temperature for drawing by infrared beams irradiated from infrared heating means (including a laser). The infrared rays heat the original biodegradable filament but a range to be heated to an appropriate temperature for drawing is heated preferably within 4 mm in up-and-down (length direction 8 mm) from axial directions of the filament at the center of the filament, further preferably 3 mm or less and the most preferably 2 mm or less. The invention enables the drawing with high molecular orientation by the rapid drawing in the narrow region and that it was possible to decrease breakage of drawing even in super high draw ratio. Yet, the heating range in this case is within up-and-down 4 mm to a filament axis and there is no limitation in a right angle direction against a filament axis. Still, if the filament irradiated the infrared beams are multifilament, above-mentioned the center of the filament means the center of a bundle of the multifilament.
The irradiation of infrared beams of the invention is preferably irradiated from plural directions. In the biodegradable filament, it is considered that heating from one side only of filament makes it further difficult to draw filament that has large crystallization speed and is difficult to draw by asymmetry heating. Such irradiation from plural directions can be achieved by the irradiation of plural times along a passage of the original filament by reflecting the infrared beam with mirrors. The mirrors of rotating type, not only fixed types, such as a polygon mirror can also be used.
Additionally, as the other means of irradiation from plural directions, there are means to irradiate light sources from plural light sources to the original filament from plural directions. It is possible to be the high powered light sources by using plural laser emitters which are relatively small laser light sources and are stable and not expensive, that the method of using plural light sources is useful as the biodegradable filament of the invention need high watt density.
The wave length of infrared rays is said to be from 0.78 μm to 1 mm but a near infrared region about from 0.78 μm to 20 μm centering on the absorption at 3.5 μm for C—C bonds of polymeric compound is particularly preferred. For the infrared rays, heating heaters referred to a spot heater or a line heater narrowing the focal point into a line or spot shape by a mirror or a lens thereby narrowing the heating area for biodegradable filament with in 4 mm up and down direction or less in the center of filament can be used. Particularly, the line heater is suitable in a case of heating biodegradable filaments of plural number at the same time.
For the infrared heating in the invention, laser heating is particularly preferred. Among all, a carbon dioxide gas laser with a wave length of 10.6 μm and a YAG (Yttrium-Aluminum-Garnet series) laser with a wavelength of 1.06 μm are particularly preferred. Also, an argon gas laser can also be used. Since a laser can restrict irradiation range smaller and the energy is concentrated to a specified wavelength, wasteful energy is decreased. The carbon dioxide gas laser of the invention has the power density of 10 W/cm 2 or more, preferably 20 W/cm 2 or more and the most preferably 30 W/cm 2 or more. This is because the super high ratio drawing of the invention is enabled by concentrating the high power density energy to a narrow drawing region.
Generally, the drawing is carried out by heating the biodegradable filament and the like to an appropriate drawing temperature and applying tension thereon. The applied tension in drawing of the invention, characterized in that drawing is conducted by the tension provided by the own weight of filament. This is different in the principle, from usual drawing where drawing is conducted by the tension provided by the difference of speeds between rollers and by the tension caused by wind-up. In the invention, an optimal applied tension can be selected by changing the own weight of biodegradable filament applied to the heated portion (determined depending on the free falling distance from the heated portion) by the change of the free falling distance. In the usual drawing between rollers, it is difficult to control the draw ratio as large as 100 times or more. It is the feature of the invention that the ratio can be controlled easily by a simple and convenient means of distance. This drawing by the own weight can be used start-up method of super drawing of the invention. The original biodegradable filament is drawn by the tension applied by the own weight, keeping in status that high ratio drawing is conducted to an extent, subsequently guiding the filament drawn to the high ratio to a take-up device, it is possible to be drawn with predefined take-up speed.
Further, the tension in the invention is extremely reduced level, and drawing is conducted by setting applied tension to preferably 10 MPa or less, further preferably 5 MPa or less and the most preferably 3 MPa or less. If the applied tension exceeds 10 MPa, the breakage at drawing is liable to occur and the range of the applied tension as described above is preferred for drawing at a high draw ratio. With such small drawing tension, the extremely high draw ratio such as 100 times or more, depending on the condition 500 times or more or 1000 times or more can be realized. Because, drawing is conducted within extremely narrow drawing region while keeping an extremely high drawing temperature of the melting point or thereabout, so that biodegradable filament can be deformed with no breakage. In the usual drawing for biodegradable filaments between rollers, the filaments are drawn at applied tension of several ten MPa to several hundred MPa. The feature of the invention resides in drawing within a range greatly different therefrom.
In the invention, it is characterized in that the filament is drawn at a super high ratio of the obtained drawn biodegradable filament as 100 times or more, preferably 200 times or more, further preferably 500 times or more and the most preferably 1000 times or more are conducted. Considering that the draw ratio of polylactic acid which represents usual biodegradable filaments is 3 to 7 times, and even in super drawing of PET filament, it is about ten and several times. The invention has a feature in that drawing within an extremely narrow zone is enabled and, accordingly, the drawing temperature can be increased to the melting point or thereabout of the original biodegradable filament which decreases the drawing tension, and that means capable of controlling the small drawing tension and the super high draw ratio has been found. Since the drawing at the super high draw ratio is possible, this enables manufacture of the biodegradable super micro-filament with a diameter of 10 μm or less and further 5 μm or less such as 2 μm and 3 μm. And, the large draw ratio means to increase production speed for manufacture of the biodegradable filament to several hundred times, which is significant also in view of the productivity.
Drawing is conducted to the original biodegradable filament delivered from filament supplying means of the invention. As for supplying means, various types can be used if these can supply the biodegradable filament at constant supplying speed with nip rollers, driven roller groups and the like.
The original biodegradable filament delivered from supplying means of the invention is preferable to provide a guiding tool which controls the position of the original filament just before the infrared beam hit original filament. The just before position is preferably 100 mm or less, further preferably 50 mm or less and the most preferably 20 mm or less. The heating by infrared beam of the original filament characterizes in that the heating is conducted extremely narrow range and the position of biodegradable filament is required to be restricted for enabling the heating of the narrow range. Depending on the exit shape of a blowing duct to be hereinafter described, it is possible to have such function, but the blowing duct focus on air flowing of gas delivering biodegradable filament and easiness of passing biodegradable filament, and after that to control the position of biodegradable filament is preferable by the simple and convenient guiding tool. Although the guiding tool is not required in conventional ordinary drawing as the drawing tensions is large, but in the invention as the drawing tension is small and the draw ratio is large, and very little fluctuation and variation of the drawing point greatly affect the stability of the drawing. Accordingly in the invention, it is possible to contribute largely to the stability of drawing to provide the guiding tool just before the drawing point. As for the guiding tool in the invention, narrow duct or groove, a comb, a combination of fine bar, etc. may be used.
In above guiding tool, it is desirable to have a position control mechanism to be able to adjust finely the position of the guiding tool. For precisely fitting a running position of filament to a narrow region of laser beam, the guiding tool is necessary to control the position in XY directions.
The original biodegradable filament delivered by the supplying means of filament is desirable to be delivered further through the blowing duct by a gas flowing direction of the original biodegradable filament in the blowing duct. As for the gas flowing in the blowing duct, the gas of room temperature is used usually but when pre-heating of the original biodegradable filament is desired, heated air is used. And if the original biodegradable filament is prevented to be oxidized an inert gas such as nitrogen or the like is used and if scattering of water is protected a gas containing water vapor or water is used. Still, the blowing ducts are not necessary to a tubular shape but being groove shape, if the original biodegradable filament can flow together with the gas through in these. The cross section of the duct is preferably circular but may be rectangular or other shape. The gas flow through the duct may be supplied from one of a branched ducts, or may be supplied from an outer duct to an inner duct through apertures and the like using a double walled duct. An air jet interlacing nozzle for filaments used for interlace spinning or Taslan fabrication of synthetic fibers is also used for the blowing duct in the invention. And in a case of drawing by free falling as non-woven fabrics manufacturing in the invention, filament may be provided the drawing tension by air momentum according to the blowing duct of the invention.
In drawing of the biodegradable filament in the invention, it is characterized in that plural numbers of the original biodegradable filaments are gathered together and can be drawn in the same infrared beam. Usually, if the plural numbers of original filaments are drawn together, agglutination among the drawn filaments occurs but in polylactic acid, it is possible to draw without the agglutination as its crystallization speed is fast. The plural numbers of filaments mean that the drawing can be conducted for 2 or more and in some case 5 or more filaments.
The drawn biodegradable filament of the invention is wound-up around a bobbin or a cheese in a following process into products of bobbin-wound or cheese-wound form. In these wind-up processes, the drawn biodegradable filament is preferably wound-up while being traversed. This is because uniformly wound-up form can be ensured by traversing. In the biodegradable micro-filament, occurrences of breakage of filament or fluff result in a most significant problem. In the invention, since filament is highly molecular oriented and drawing tension is small, the filament can be wound-up with a small winding tension, it is characteristics of the invention to decrease also occurrence of breakage of filament or fluff. Yet, when the plural filaments are drawn and wound-up simultaneously, it is possible to wind-up twisting by a twister but it is preferable to wind-up entwining among filaments by an interlace method as running speed of the filaments of the invention is fast.
Subsequent to the drawing step of the invention, a heating apparatus having a heating zone may be disposed to apply a heat treatment to the drawn biodegradable filament. Heating can be conducted by means passing them through a heated gas, radiation heating such as infrared ray heating, passing them over a heating roller, or means such as a combination of them. The heat treatment can provide various effects such as reduction of thermal shrinkage of the drawn biodegradable filament, increase in the degree of crystallinity to decrease aging change of the biodegradable filament or improve Young's modulus. In the case of non-woven fabrics of the invention, the heat treatment may also be applied on a conveyor.
The drawn biodegradable filament of the invention can be wound-up after additional drawing. For the drawing in the subsequent step, drawing means by infrared ray used in the previous step can also be used. In a case where the filament has already been drawn at a sufficiently high draw ratio in the previous step and the biodegradable micro-fibers have already been obtained, inter-roller drawing such as usual godet rollers and pin drawing may also be used. And a zone drawing method and a zone heat treatment method developed by the inventor (Journal of Applied Polymer Science, Vol. 90, pp. 1955-1958, 2003) are especially useful means in also conducting further drawing. By this zone drawing method, the drawn biodegradable super micro-filament that filaments diameters are 3 μm or less and reaches 2 μm can be obtained.
In the invention, it is characterized in that stable drawing is controlled by constant drawing tension, draw ratio, etc. with controlling watt density of infrared beam. Additionally, controlling wind-up speed or supply speed, or both wind-up speed and supply speed according to measuring a filament diameter and feeding back them; it can be controlled to obtain a product of a constant filament diameter. In the invention, a drawn filament diameter is easily fluctuated as draw ratio is large but stable production can be conducted by always controlling a filament diameter.
Non-woven fabrics consisting of the drawn biodegradable filament can be manufactured by accumulating the drawn biodegradable filament of the invention on a running conveyor. In recent years, non-woven fabrics have been demanded vigorously in various fields taking notice on the peculiar characteristics of the non-woven fabrics not merely as substitutes for woven fabrics. Among them, non-woven fabrics of micro-fibers include melt blown non-woven fabrics which are prepared by blowing off molten filament by hot blow to form filament of 3 μm or thereabout and then accumulating them on a conveyor to form non-woven fabrics. They are used mainly for air filters. However, filament constituting the melt blown non-woven fabrics has lower strength than usual non-drawn fibers as 0.1 cN/dtex or thereabout, in which a number of small lumps of resins called as shots or wads are present. The non-woven fabrics consisting of the drawn biodegradable filament of the invention have strength equal with or superior to that of usual drawn synthetic fibers while having a diameter of about 3 μm or thereabout like melt blown non-woven fabrics because the biodegradable filament is highly molecular oriented. And it is possible to prepare non-woven fabrics without containing shots and wads at all. The non-woven fabrics of the invention, adding to effects of being fine texture and luster, light weight, heat insulation, heat retention, water repellent, improved printability and the like by being micro-filament, these can also have characteristics that biodegradable speed of biodegradable filament is quickened. And the non-woven fabrics consisting of biodegradable filament of the invention have characteristic that any filament has the same degradable speed as filament diameters are uniform. Especially, filament of polylactic acid and polyglycolic acid is hard and fragile filament but become one that is soft and good feeling by to be micro-filament according to the invention, and a feature occur that these can be used even in sanitary goods of a diaper etc. Still, as described in a section of back ground art, it is variously discussed conventionally for spunbonded non-woven fabrics consisting of biodegradable filament but filament of the invention have strength and a smaller diameter than those spunbonded non-woven fabrics.
Non-woven fabrics have been made to sheet shape conducting usually any entwining or interlacing among fibers. In the invention, a number of biodegradable filaments per unit weight are extremely increased as filaments diameters are extremely small. Accordingly, not providing an interlacing process especially, the biodegradable filaments are interlaced by vacuum suction below the conveyor and there are many cases that simple pressing up on accumulation of the biodegradable filament on a conveyor is sufficient, with no particular interlacing or entwining process like melt blown non-wove fabrics. Naturally, means such as thermal embossing or needle punching, water-jet, adhesive bonding conducted in usual non-woven fabrics may also be used, which maybe selected depending on application use. In the filter usage as a major application use of micro-fiber non-woven fabrics, collecting efficiency can be increased outstandingly by applying electrostatic treatment to the non-woven fabrics and non-woven fabrics of the invention can also be applied by electrostatic treatment to the field of the filters. When the biodegradable filament is accumulated on the conveyor in the manufacture of the non-woven fabrics of the invention, negative pressure is applied at the back of the conveyor and the flow of air under air suction by negative pressure or the flow of air by the positive use of an air sucker sometimes act as tension for drawing in the biodegradable filament drawing, which is also included in the drawing tension of the invention.
The invention is characterized in that various different filaments diameters can be produced according to using simple and convenient drawing means. The biodegradable filament has different biodegradable speed by filaments diameters. Large diameter filament is slow in biodegradable speed and small diameter filament is fast in degradable speed. Accordingly, as products of biodegradable filament for example regarding rope, preparing product groups differing in filament diameter such as several ten μm to several μm, it is possible to make a product group of different biodegradable speed depend on usage, climate of the district, etc. And, when manufacturing a mulching sheet for agriculture with non-woven fabrics of biodegradable filament of the invention, it is possible to be the product group of controlled biodegradability according to changing a filament diameter by usage.
Molecular orientation of filament in the invention can be shown by birefringence. Birefringence of drawn polylactic acid filament of the invention show extremely high value and it is understandable that those are highly molecular orientated. Birefringence value of a crystal of polylactic acid is said to be 0.033 or thereabout. Birefringence value of drawn polylactic acid filament by the invention is 0.015 or more by being well drawn, further there are many more than 0.020, and there exist also more than 0.030 with extremely drawn one. Additionally, by re-drawing, birefringence that reaches 0.04 is also obtained. In that sense, drawn polylactic acid of the invention is understood to be extremely highly oriented. A measuring method of birefringence in the invention depended on a retardation method.
Yet, orientation degree f of filament in the invention is shown by X-ray half-value breadth method of a following equation.
f (%)=[(90− H /2)/90]×100
Where, H shows half-value of strength distribution along Debye ring of a crystal face having main peak of crystal of biodegradable filaments. The f value drawn polylactic acid filament by the invention is 60% or more, further there many filament above 70% by drawing well, and there exist one above 75% in very well drawn one. In addition, it occurred also one that the degree of orientation reaches 89.9% according to conducting zone drawing and zone heat treatment to drawn filament by the invention. Above-mentioned the degree of orientation is higher. But, for measuring X-ray orientation degree, it is necessary to measure as a bundle of filaments. But to arrange all filaments of the enormous numbers of filaments bundles to a constant direction is technically difficult because drawn filaments diameters of the invention are small and it is considered that X-ray orientation degree is appeared to be rather low due to that.
The draw ratio λ in the invention is represented by a following equation based on the diameter do for the original filament and the diameter d for the filament after drawing. In this case, calculation is performed assuming the density of filament as constant. The diameter measurement of the filament is conducted by a scanning electron microscope (SEM) based on photographs taken at 350× or 1000×, with respect to average values for 10 points.
λ=( do/d ) 2
Advantageous Effects of the Invention
In the invention, concerning biodegradable filament, it was possible to obtain micro-filament easily by simple and convenient means without requiring the special, high-accuracy and high-level devices. Micro-filament obtained by those are 12 μm or less, further 5 μm or less but to obtain micro-filament such as 2 μm and 3 μm, it was also possible to obtain super micro-filament such as 3 μm or less and 2 μm by re-drawing of a zone drawing method, a zone annealing method and the like of drawn filament. This biodegradable micro-filament is realized by super high ratio drawing such as 100 times or more, further 500 times or more and 1000 times or more. To be able to offer realizing means such high ratio drawing, not only the biodegradable micro-filament can be obtained simply and conveniently but also mean that the biodegradable micro-filament can be manufactured at high speed, that the significance from productivity side is large.
Further, long fiber non-woven fabrics consisting of micro-filament could be manufactured by the invention. There are melt blown non-woven fabrics as non-woven fabrics consisting of micro-filament which are on the market but filament has not sufficient strength and small lumps of resins calted shots or wads are also mingled as filaments diameters are irregular such as from 1 μm to 10 μm. Non-woven fabrics of the invention have no such defects, as the filaments diameters have extremely the same level such as ±1 μm or less and have biodegradability, these non-woven fabrics can be used for various applications that are required biodegradability such as agricultural application and diapers. Additionally, spunbonded non-woven fabrics consisting of the biodegradable filament is studied on the market but non-woven fabrics consisting of filament of the invention have also strength and effects that filament diameters are small and the like.
In the invention, fiber products consist of filament differing in biodegradable speed by differing in a diameter, for example, manufacturing product groups of yarn, rope, fabrics, knit fabrics, non-woven fabrics; it was possible to be formed of product groups in conformity with the biodegradable speed of each aimed product. Additionally, highly molecular oriented filament that are super-micro such as 2 to 3 μm can be manufactured and it was possible to be filament with increased biodegradable speed as these are super-micro.
Additionally in the invention, it is possible to obtain micro-filament consisting of bioerodible absorbable polymer such as polyglycolic acid and to be able to make a fine and flexible surgical suture thread; as filament diameters are small, degradability in a biological body is also good.
Moreover, the invention offers non-woven fabrics consisting of micron-filament of bioerodible absorbable polymer. As filament diameter is small, the filament number per unit area is increased extremely (proportional to inverse number of the square of a fiber diameter) to improve covering power. In addition, non-woven fabrics consisting of micro-filament of the invention have characteristics of not having wads, having the equal filament diameter, having high strength of filament and the like, and those also conform to features as bioedrodible absorbable non-woven fabrics. Accordingly, the non-woven fabrics consisting of the bioerodible absorbable filament of the invention conform to wide range of application usages such as suture prosthesis, anti-adhesion material, artificial skin and a cell culture substratum.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process schematic view of a continuous method for manufacturing the drawn biodegradable filament of the invention.
FIG. 2 shows an example of mirror arrangement to irradiate infrared beams from plural directions to original filament of the invention, and Fig. A in FIG. 2 is a plain view and Fig. B in FIG. 2 is a side view.
FIG. 3 shows a plain view of the other example to irradiate infrared beams from plural directions to original filament of the invention in case of having plural light sources.
FIG. 4 is a schematic view of a process in case of re-drawing plural numbers of drawn biodegradable filaments of the invention.
FIG. 5 is a schematic view of blowing ducts used in the invention.
FIG. 6 is a schematic view of the process for manufacturing non-woven fabrics consisting of the drawn biodegradable filaments of the invention.
FIG. 7 is a graph of experimental results showing a filament diameter, birefringence and the like according to drawing polylactic acid filament in the invention.
FIG. 8 is a graph of the other experimental results showing a filament diameter, birefringence and the like according to drawing polylactic acid filament in the invention.
FIG. 9 is a graph of experimental results showing a filament diameter, birefringence and the like according to re-drawing drawn polylactic acid filament in the invention.
FIG. 10 is a graph of experimental results showing a filament diameter, birefringence and the like according to drawing polyglycolic acid filament in the invention.
FIG. 11 is a graph of the other experimental results showing a filament diameter, birefringence and the like according to drawing polyglycolic acid filament in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, the examples of modes to carry out the invention are described based on the drawings. FIG. 1 showed an example of a process for the continuous method of the invention. The original biodegradable filament 1 is reeled off from a state of wound around a reel 11 , passed by way of comb 12 and delivered at constant speed from reel off nip rollers 13 a and 13 b . The delivered original filament 1 falls down at a constant speed while being regulated for the position by guiding tool 15 . The guiding tool 15 is used for accurately determining the laser irradiation position and running position of the filament. While a hypodermic needle with an inner diameter 0.5 mm was used in the drawing, a narrow pipe, a comb, or snail-wire, etc. shown in FIG. 6 can also be used. A laser beam 6 is irradiated to a zone heater M of predetermined width by a laser emitter 5 to the running original filament 1 just below the guiding tool 15 . This laser beam 6 is preferably irradiation from plural directions shown in FIG. 2 and FIG. 3 . The filament is heated by the laser beam 6 and drawn by the own weight of the original filament or the drawing tension given by take-up nip roller 19 , and falls down as drawn biodegradable filament 16 and is preferable to pass through a heat treatment zone 17 formed in the falling path. The drawn biodegradable filament 16 passes along a pulley 18 and then wind-up by way of take-up nip rollers 19 a and 19 b around wind-up reel 20 . In this case, the channel of the drawn biodegradable filament 16 to pulley 18 includes a case where it is drawn as a trace “p” of a free falling of the filament, a case where it is drawn as a linear trace “q” to pulley 18 and a case where it is drawn as an intermediate trace thereof. In the trace “q” and at the intermediate position of the trace “p” and the trace “q”, wind-up tension exerts on the drawing tension in which the drawing tension is preferably 10 MPa or less. The drawing tension may be measured by a tension measuring mechanism dispose to the pulley 18 but as another method, it can be estimated based on the relation of the same supplying speed, the laser irradiation condition and the draw ratio by the load cell measurement of a batch method. Before wind-up around the take-up and wind-up reel 20 , the filament can be further drawn between the heated drawing rolls 21 a , 21 b and the drawing rolls 22 a and 22 b by a speed ratio of the drawing rolls 21 and 22 . The heat treatment zone 17 for the drawn biodegradable filament in this case is preferably disposed subsequent to the drawing roller 22 . Also, when the plural original filaments are drawn simultaneously, it is preferable to have been air interlaced among filaments by a interlace method and the like just before the take-up reel. Additionally, providing a measuring device for a filament diameter to a position such as just before entering the pulley 18 and take-up roller 19 , it is possible to obtain a product of always a constant filament diameter controlling take-up speed or supply speed and the like by feeding back the measured filament diameter.
FIG. 2 shows an example of means to irradiate the infrared beam adopted in the invention to the original biodegradable filament from plural directions. Fig. A in FIG. 2 is a plain view and FIG. B in FIG. 2 is a side view. The infrared beam 31 a irradiated from the infrared emitter reaches the mirror 32 through the region P (inside dotted line in the drawing) where the original filament 1 passes through and is the infrared beam 31 b reflected by mirror 32 , and is infrared beam 31 c reflected by the mirror 33 . The infrared beam 31 c irradiates the original filament through the region P from 120 degree behind of the first irradiation position of the original filament. The infrared beam 31 c passed through the region P is the infrared beam 31 d reflected by mirror 34 , which is the infrared beam 31 e reflected by the mirror 35 . The infrared beam 31 e irradiates the original filament 1 through region P from opposite 120 degree behind direction of foregoing infrared beam 31 c against the fist irradiation position of the original filament. Thus, the original filament 1 can be equally heated from the symmetrical position 120 degrees apart by the three infrared beams 31 a , 31 c and 31 e.
In FIG. 3 , the other example of means adopted in the invention to irradiate the infrared beams to the original filament from the plural directions that is an example of using plural light sources is shown in a plain view. The infrared beam 41 a radiated from the infrared emitter is radiated to the original biodegradable filament 1 . And infrared beam 41 b radiated from the other infrared emitter is also radiated to the original biodegradable filament 1 . Further, the infrared beam 41 c radiated from the other infrared emitter is also radiated to the original biodegradable filament 1 . Thus, the radiation from the plural light sources can be the high power light sources using the plural laser emitters which are relatively small light sources and are stable and not expensive. Still, a case using 3 light sources are shown in the drawing but 2 are possible and 4 or more can also be used. Especially, when drawing the plural filaments, drawing by using the plural light sources like these is particularly useful.
In FIG. 4 , there is shown an example of the biodegradable filaments already drawn by this invention is reeled off the plural number at the same time and drawing simultaneously. The drawn biodegradable filament 52 a , 52 b , 52 c , 52 d and 52 e wound-up around the bobbins 51 a , 51 b , 51 c , 51 d and 51 e are each delivered through the blowing duct 53 and the pipe 54 and are gathered in an air manifold 55 , and are filaments assembly 56 . Still, the biodegradable filaments 52 in the blowing duct 53 and the pipe 54 is not shown in the drawing as is complicated. It is preferable that the bobbins 51 are lowered the reel off tension by rotating at the constant speed because the un-drawn original filament has a low tensile strength and Young's modulus, and fineness of the drawn filaments are small that they can not resist the tension. The delivered filaments assembly 56 are adjusted a running position to be the center of laser beam 58 by a variable pitch mechanism 57 . The variable pitch mechanism 57 is provided with the guiding tool 59 and the running position of the filaments are finely adjusted the position by a rack 60 and a gear 61 . As for the variable pitch mechanism 57 , an example to adjust in one direction only is shown in the drawing but can be adjusted in XY axis directions by providing a set of gears in a right angle. The filaments assembly 56 adjusted the position by the variable pitch mechanism 57 is heated by the laser beam 58 and drawn, and adjusted to the constant take-up speed by take-up mechanism 62 and wound-up to the wind-up bobbin 63 driven by a motor M. In this drawing, the laser beam 58 is shown by one line but is preferably the plural light beams shown in FIG. 2 and 3 . Additionally, an example wound-up directly around bobbins is shown in the drawing but it is preferable to wind-up adding twisting and intertwining among the filament by the interlacing and the like. Also, an example of re-drawing by the infrared beam is shown in FIG. 4 , but the re-drawing can use also the other drawing means of ordinary roller drawing, zone drawing and so on. Still, the air introduced to the blowing duct 53 and the pipe 54 is guided to a channel of the original filament 1 and the filament is delivered by the flow of air, and the tension given by the wind velocity delivering air is added to the drawing tension of the invention. Yet, FIG. 4 is described as an example of re-drawing of the drawn filament but used also as the means for the plural numbers drawing of the un-drawn original filaments with the similar mechanism.
FIG. 5 shows examples of various blowing ducts adopted in the invention. In FIG. A of FIG. 5 , air introduced from an arrow “a” through a branched duct 72 joins to a main duct 71 where the filament 1 passes through. FIG. B in FIG. 5 shows a double walled duct 73 in which the inside is hollow and air introduced along an arrow “b” is guided through a number of apertures 74 perforated in the inner wall of the double walled duct to the channel of the filament. FIG. C in FIG. 5 shows an example of a nozzle used as an air interlace nozzle 75 used for interlace spinning in which the air is blown from both sides c 1 and c 2 . Thus, the reason why the air is actively delivered to the running direction of the filament is not to disturb the running of the filament by the resistance of guiding tool etc. as the drawing tension is small in the invention and it is also possible to add the drawing tension by the momentum of the air when adding the tension actively with the wind-up tension is not possible such as in a case of manufacturing non-woven fabrics. Also, the nozzle in FIG. C of FIG. 5 can be used at the time of interlace winding after drawing of the invention. Yet, the blowing ducts in FIG. 5 show the examples of the tubular shape but a grooved shape which is partially open is also used.
FIG. 6 shows an example of manufacturing non-woven fabrics of the invention. Multiplicity of the original biodegradable filaments 1 are attached to a rack 82 in a state wound around bobbin 81 (for avoiding complexity, only three filaments are shown). These original biodegradable filaments 1 a , 1 b , and 1 c are delivered through snail wires 83 a , 83 b and 83 c as the guiding tool by the rotation of supply nip rolls 84 a and 84 b . The supplied original biodegradable filaments 1 are heated in the course of falling down by the own weight, by line infrared beams emitted from an infrared emitter 85 . The range for the heating portion “N” by the infrared beams in the running process of the original biodegradable filaments 1 are shown by hatched lines. Beams passing through original biodegradable filaments 1 with no absorption are reflected at a concave mirror 86 shown by dotted line and then returned to be condensed to the heating portion “N”. A concave mirror is disposed also on the side of the infrared emitter 85 (in this case, the beam traveling portion from infrared emitter has an open window), which is not illustrated in the drawing. The original biodegradable filaments 1 are heated by radiation heat of infrared rays at the heating portion “N”, drawn by the own weight of filament per se by portion there below and formed into drawn biodegradable filaments 87 a , 87 b and 87 c , which are accumulated on a running conveyor 88 to form a web 89 . Air is sucked in the direction of an arrow “d” by vacuum suction from rear face of the conveyor 88 to contribute to the stability of running of the web 89 . The web is pulled by the tension of the negative pressure “d” exerting on the drawn biodegradable filaments 87 to contribute to the improvement of attenuation and orientation degree of the biodegradable filament and such tension is also regarded as a portion of the tension caused by the own weight in the invention. Although not illustrated in the drawing, a number of bobbins 81 for the original biodegradable filaments 1 are provided in a multi-stage along the running direction of the conveyor 88 , and nip rolls 84 and infrared emitters are provided in a multi-stage to improve the productivity of the web 89 . In case of providing the supply nip rolls 84 etc. in the multi-stage along the running direction, the infrared emitter 85 and the concave mirror 86 can also be utilized for several stages. Yet, in a case that drawing and orientation are small since the drawing tension by the own weight of the filament and the negative pressure from rear face of the conveyor is not sufficient, guiding the filament by blowing duct when the original filaments 1 are guided to the infrared beam portion, the tension given by the air delivering wind velocity of the blowing duct is also added and used.
Example 1
The un-drawn filament consisting of polylactic acid polymer (filament diameter: 75 μm, glass transition temperature: 57° C., crystallization temperature: 103° C., tensile strength: 55 MPa, birefringence: 0.063) were used as the original biodegradable filament. Using the original filament, drawing was conducted using the drawing apparatus of FIG. 1 and the mirror of FIG. 2 for an infrared emitter. The laser emitter in this time, a carbon dioxide gas laser emitter manufactured by Onizuka Glass Co., Ltd. with a maximum power of 10 W was used. A diameter of a laser beam at the time was 4 mm. Delivering this original filament at supply speed of 0.5 m/min and a laser power density being 24 W/cm 2 , and the experiments were conducted by changing wind-up speed. FIG. 7 shows filaments diameters of drawn filament obtained by the experiment, draw ratio calculated from filaments diameters, birefringence and X-ray orientation degree of drawn filament and values of the drawing tension obtained from a batch method that lead to the filament diameter and the orientation degree. From FIG. 7 , at appropriate condition, a filament diameter is 5 μm or less, even reached from 3 μm to 1.2 μm. The draw ratio is 100 times or more and has reached 1,000 times or more, even 3,900 times. The birefringence is 0.015 (round off 0.01478) or more and has reached 0.020 or more, even 0.033. The X-ray orientation degree is 60% or more and has reached even 75% exceeding 70%. In such a case, the drawing tension is within a range from 0.3 MPa to 2.5 MPa.
Example 2
An example when laser power density was made to 12 W/cm 2 with the condition of Example 1 is illustrated in FIG. 8 . From FIG. 8 , a filament diameter is 5 μm or less, and the draw ratio is 100 times or more and has reached 500 times or more. In such a case, the draw ratio is within a range from 0.3 MPa to 2.7 MPa.
Example 3
The filaments obtained by the method of Example 1 of the invention were conducted re-drawing and heat treatment according to a zone drawing method and a zone annealing method. The results are shown in FIG. 9 . From FIG. 9 , it is understandable that filaments are highly molecular orientated as the draw ratio has reached from 3900 times even to 15000 times and the birefringence has reached 0.030 or more, even 0.040 or more. And, also the filaments diameters are 3 μm or less and super micro-filaments of 2 μm are obtained.
Example 4
The un-drawn filament (filament diameter: 82.34 μm, melting point temperature: 219° C., tensile strength: 89 MPa, birefringence: 0.0043) consisting of polyglycolic acid (low viscosity products, viscosity at 240° C.: 1.24×1000 Pa·S) was used as original biodegradable filament. Using this original filament, drawing was conducted by a drawing apparatus and an infrared emitter similar to Experiment 1. Delivering the original filament with supply speed of 0.5 m/min, the experiment was conducted changing wind-up speed. The filaments diameters of the drawn filament obtained by the experiment, draw ratio calculated from the filament diameters and birefringence of the drawn filaments are shown in FIG. 10 . From FIG. 10 , the filaments diameters are 5 μm or less at appropriate condition and are fine to an extent from 3 μm to 2.2 μm. Draw ratio is 100 times or more and has reached 1,000 time or more, even 1,300 times. Birefringence is 0.015 or more, and has reached 0.020 or more, even 0.027.
Example 5
At the condition of Experiment 4, the un-drawn filament (filament diameter: 207 μm, temperature at a melting point: 218° C., tensile strength: 0.11 GPa, birefringence: 0.0013) consisting of a medium density viscosity product (viscosity at 240° C.: 3.41×1000 Pa·S) for original polyglycolic acid was used. Using this original filament, drawing was conducted according to a drawing apparatus and an infrared emitter similar to Experiment 4. Delivering this original filament at supply speed of 0.5 m/min, experiments were conducted by changing wind-up speed. FIG. 11 shows the filament diameters of the drawn filament obtained by the experiment, draw ratio calculated from filament diameters and birefringence of the drawn filament. From FIG. 11 , the filaments diameters are 10 μm or less at appropriate condition and have become thinner to 5 μm. Draw ratio is 100 times or more and has reached 500 times or more, even 1,500 times. Birefringence is 0.015 or more, further 0.020 or more, and even has reached 0.026.
Experiment 6
A filament of filament diameter 1.82 μm and birefringence of 0.056 was obtained by further drawing a drawn filament of 2.5 μm obtained from a method of Experiment 4 of the invention at 170° C. A filament for a suture thread made of polyglycolic acid on the market was a filament diameter of 14 μm and birefringence of 0.060, it is understandable that a filament obtained by the invention is super-micro and also the orientation degree is near to products on the market.
Industrial Applicability
The invention relates to drawing of a biodegradable filament, the drawn biodegradable filament of the invention is used for rope for agriculture, non-woven fabrics for mulching, non-woven fabrics for diapers and the like that are required biodegradability, and bioerodible absorbable filament is used for surgical suture thread, and in forms of non-woven fabrics, suture prosthesis, anti-adhesion material and the like. | The invention resides in enabling biodegradable filament of polylactic acid, polyglycolic acid and the like to manufacture biodegradable micro-filament by simple and convenient means without needing special, high-accuracy and high-level apparatus; it is characterized in that highly molecular oriented micro-filament those of 12 μm or less and generally from 2 μm to 3 μm can be obtained by heating biodegradable filament by infrared beam and the heated original filament is drawn to 100 times or more by tension of 10 MPa or less. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to decorations in general, and more particularly to an adorning article exhibiting a pom-pon appearance in its final state and intended to be attached to a gift package or the like for decorative purposes.
2. Description of the Related Art
There are already known various constructions of adorning articles of the type here under consideration, among them such that are being sold in its final, puffed-up state. Obviously, such articles occupy a considerable amount of space that is often at a premium, be it in storage, in transportation or on display. This problem has been recognized before, and a remedy was found in a ribbon having a drawstring loosely connected to it at spaced points along its length and secured to the ribbon at one end so that the user of the ribbon can draw the ribbon into a number of arcuate loops by pulling on the drawstring. An obvious advantage of this arrangement is that the ribbon can be packed flat, thus greatly facilitating and reducing the cost of storage and transport of the items as compared to those encountered with preformed bows that are relatively bulky and need to be packed in crush-proof containers.
Such prior art devices have, however, suffered from the disadvantage that, on pulling on the drawstring, the ribbon had tended to fold itself into loops aligned along a single vertical plane, thus forming a fan shape. This represents a pronounced inconvenience to the ultimate user who normally requires the bow to be arranged in a more decorative rosette or pom-pon form, and makes it necessary for the user to pull on the individual loops to displace them laterally in an effort to rearrange them so that they are spaced angularly around the axis of the bow. Apart from being time-consuming, this manipulation presents the risk of the bow becoming torn, damaged or soiled in the process.
This problem was addressed in U.S. Pat. No. 4,515,837 to Cheng, in that the ribbon arrangement provided therein includes two ribbons each including a plurality of consecutive segments connected to one another by respective narrow neck portions, the ribbons being connected to one another at the respective neck portions by respective retainer members which, due to the configurations of the neck portions, are caused to assume slightly inclined positions relative to the transverse width of the ribbons. With this ribbon arrangement, as the bow is being formed by pulling on the drawstring, each of the relatively stiff retainer members tends to seat itself on the bow loop that is being formed immediately adjacent thereto in an angularly skewed orientation relative to the latter, and thus imparts a bias tending to skew each loop of the bow relative to the previously formed loop, so that the loops are arranged in an angularly spaced rosette or pom-pon-like form.
As advantageous as this arrangement may be, experience with it has shown that it still leaves something to be desired as far as the appearance of the article in its final or finished form is concerned. More particularly, it was established that the top of the resulting article is somewhat relatively flat, that is, while there is obtained automatic distribution of the loops about the axis of the drawstring, no bias to speak of is applied to the loops to force the topmost ones of them to spread, against the force of gravity, into the empty space above them. This, of course, means that articles of this type are somewhat at a disadvantage as far as their appearance is concerned relative to the preformed pom-pon-like bows that are usually made much fuller on top.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of the present invention to avoid the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an adorning article in the form of a pom-pon that does not possess the drawbacks of the known articles of this type.
Still another object of the present invention is to devise an adorning article of the type here under consideration which has the look virtually indistinguishable from that of a professionally preformed article of this kind even though formed on site just prior to its use.
It is yet another object of the present invention to design the above adorning article in such a manner as to give it a much fuller, fluffier appearance than before in its finished form.
A concomitant object of the present invention is so to construct the adorning article of the above type as to be relatively simple in construction, inexpensive to manufacture, easy to use, and yet reliable in operation.
SUMMARY OF THE INVENTION
In keeping with the above objects and others which will become apparent hereafter, one feature of the present invention resides in an adorning article that includes as its components a pair of elongated ribbons. Each of these ribbons includes a stem portion and a branch portion merging with one another at a merger region. Each such ribbon is subdivided into a predetermined number of successive segments located both on the stem and branch portions thereof and interconnected with one another by respective intervening neck portions formed, in each instance, by a pair of incisions extending from respective edges of the respective one of the ribbons within the stem and branch portions and at the merger region toward each other but terminating short of meeting each other to define the respective one of the neck portions. At least one of the segments of each of the branch portions is folded back into juxtaposition with an adjacent segment of the same branch portion.
The article further includes means for connecting the ribbons to one another at each of the neck portions located on the stem portion between the successive segments and at the merger region, and the at least one folded-back segment of each of the branch portions to that of the neck portions that connects the adjacent segment with the next one, and a pair of drawstrings sandwiched between the stem portions of the ribbons, passing jointly through the neck portions of the stem portion and of the merger region and individually through the neck portions of the branch portions and between the folded-over and adjacent segments, with freedom of longitudinal movement, and each separately secured to a fold region present between the folded-over and adjacent segments. A particular advantage of this arrangement is that the ribbon material of the branch portions tends to fluff up, due to the interaction between the branch portions during the bow formation process, to a much greater extent than what could be attributed merely to the presence of additional ribbon material at the affected location.
Advantageously, each of the branch portions includes at least one segment situated next to the merger region that has no other of the segments of the same branch associated with it, so that it constitutes a weakened region at which deformation of the segments into loops preferentially commences in response to pulling on the drawstrings. It is also advantageous when the connecting means includes a multitude of individual retainer members, at least those of which that are disposed on the stem portions of the ribbons being inclined at predetermined angles with respect to the transverse width of the ribbons.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an adorning article according to the present invention in its initial, bow precursor, state;
FIG. 2 is a cross-sectional view, on a somewhat enlarged scale, taken on line 2--2 through the article of FIG. 1;
FIG. 3 is a view akin to that of FIG. 1 but taken during an initial stage of conversion of the precursor into a bow; and
FIG. 4 is another view similar to that of FIG. 1 but this time taken after the completion of the conversion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing in detail, and first to FIG. 1 thereof, it may be seen that the reference numeral 10 has been used therein to identify an article embodying the present invention, in its entirety. Inasmuch as the ultimate utility of the article 10 is to adorn a gift-containing package or for other decorative purposes, it will be referred to herein generally as an adorning article even when not yet deserving that designation because of not having attained its final decorative shape yet.
In accordance with the present invention, the article 10 includes as one of its main components a ribbon arrangement 11. The ribbon arrangement 11 includes a pair of generally ribbon-shaped main sections or members 11a and 11b disposed in face-to-face relationship. The members or ribbons 11a and 11b are advantageously formed by taking a length of ordinary but decorative (colored and/or patterned) ribbon material, e.g. any suitable commercially available synthetic plastic material having a satin-like fibrous texture, cutting it in half, and then juxtaposing the thus obtained discrete ribbons 11 and 12 in aligned relationship with one another, as may be discerned particularly from a comparison of FIG. 1 with FIG. 2 of the drawing.
As shown particularly in FIG. 1, the ribbon arrangement 11 is bifurcated, that is it includes a pair of auxiliary portions or branches denoted by the reference numerals 12a and 12b, respectively, that merge with each other to form a main portion or stem 12c. It will be appreciated that the article 10 can be stored indefinitely in its substantially flat original state (not shown) in which the branches 12a and 12b lie substantially flat against one another, forming respective continuations of the stem 12c that extend along a common plane with the stem 12c, albeit possibly with the article 10 being folded one or more times upon itself. However, as will become clearer later, the article 10 can be easily and quickly converted, when the need for it arises, from this original state through its initial and partially deformed precursor states illustrated in FIGS. 1 and 3, respectively, to its final bow state visible in FIG. 4.
The article 10 further includes an operating drawstring arrangement 13. As shown, and as currently preferred, the drawstring arrangement 10 includes a pair or individual drawstrings 13a and 13b; however, it is also possible and contemplated by the present invention for the two drawstrings 13a and 13b to be of one piece with one another, being folded at their lower ends, or connected to each other in some other fashion, such as by a knot, at a region situated below the ribbon arrangement 11, both as considered in FIG. 1. Such a connection would help in insuring identical or commensurate movement of the drawstrings 13a and 13b when pulled on; on the other hand, it would render manipulation with the strings 13a and 13b following such movement difficult and in many instances require severance of or a similar breakage or discontinuance of such connection or bond prior to such manipulation. In the final analysis, the decision on whether or not to have the strings 13a and 13b joined will be made based on a plurality of factors including those mentioned above. The drawstring arrangement 13, or each of its constituent parts 13a and 13b, may be made of the same material as the ribbon arrangement 11 but of a much narrower width at least in its final form.
The drawstrings 13a and 13b are connected to the ribbons 11a and 11b, respectively, in a manner and at locations yet to be described; however, before addressing that issue, the ribbons 11a and 11b, their configuration and function, and the way they are connected, will be discussed in some detail. As best seen in FIG. 1, each ribbon 11a and 11b includes a series of respective segments 15a.1 to 15a.n or 15b.1 to 15b.n, wherein n is any chosen integer (in the illustrated embodiment, seven) within reason. The segments 15a.1 to 15b.n are obtained in the ribbons 11a and 11b, which were substantially equally wide throughout to begin with, by forming respective substantially V-shaped indentations or incisions 16 and 17 that are cut or otherwise made on the opposite sides of the ribbon members 11a and 11b.
It may be seen that the segment 15a.1 is folded back along a folding line or crease 14a to become juxtaposed with the segment 15a.2; the same is true with respect to the segment 15b.1 vis-a-vis the segment 15b.2. Moreover, even though that is not shown in the drawing, there could be provided two or more other segments (which could be referred to as segments 15a.0 and 15b.0 for the sake of consistency, even though they are not shown in the drawing) that would then be juxtaposed with the segments 15a.2 and 15b.2, respectively, etc. The "folded-back" segment or segments can be of one-piece with the main ribbon sections 11a and 11b, or they can be discrete auxiliary ribbon sections.
Advantageously, all of the segments 15a.1 to 15b.n have substantially equal lengths, but that is not critical. As a matter of fact, in some cases it may be even preferred to make them of unequal lengths; even in that case, though, the associated ones of the segments 15a.1 to 15b.n, that is those that are directly juxtaposed with one another (such as, for example, 15a.4 and 15b.4 or, for that matter, 15a.1 and 15a.2) do have substantially equal lengths.
For the sake of completeness, it is to be mentioned that, the indentations 16 and 17 are offset, like in the above-cited patent, longitudinally from one another on the opposite edges of the ribbons 11a and 11b so that a narrow neck portion 18 is formed between each pair of indentations 16 and 17 that has its narrowest portion inclined at a small angle of, say, 30° to 40° with respect to the transverse width of the ribbons 11a and 11b. The successive pairs of indentations 16 and 17 are formed such that each neck portion 18 is inclined at an angle different from that of the respective preceding neck portion 18. In a currently preferred implementation, the absolute values of such angles are substantially the same, but each respective neck portion 18 is inclined in a direction from the transverse width of the ribbon members 11a and 11b which is opposite to that of the respective preceding or succeeding neck portion 18 as considered in the longitudinal direction of the ribbon arrangement 11.
A clip or retainer member 19 is applied around each neck portion 18. Each retainer member 19 is advantageously constituted by a small piece of sheet material that is relatively stiff compared to that of the ribbons 11a and 11b. The retainer member 19 may comprise, for example, a piece of relatively thin and stiff synthetic plastic material, e.g. a cellulose plastic material. The retainer member 19 is provided with a central aperture dimensioned to receive a sandwich including the narrow neck portions 18 of the ribbons 11a and 13a and 13b received between them, and has a slit extending from the central aperture all the way to its outer periphery to allow the introduction of the sandwich into the aperture. The retainer member 19 is applied by flexing it slightly to open the slit and by passing the sandwich through the thus widened slit. Once the sandwich is in the aperture, the flexing forces are discontinued and the slit closes again, keeping the sandwich securely in the aperture. Thereafter, the neck portions 18 are received in the aperture with a degree of snugness sufficient for the retainer member 19 to be restrained from moving longitudinally of the ribbons 11a and 11b and to adopt and maintain the orientation or inclination of the neck portions 18. Each retainer member 19 is thus inclined substantially at the same angle as the narrow neck portions 18 relative to the transverse width of the ribbons 11a and 11b. Yet, on the other hand, even the neck portions 18 of the ribbons 11a and 11b confine the drawstrings 13a and 13b loosely enough so that the drawstrings 13a and 13b can be pulled relatively freely between the neck portions 18.
When the retainer members 19 are constructed, and mounted on the ribbon arrangement 11, in the manner described above, then each of them is inclined, in the position of the adorning article 10 that is depicted in FIG. 1, at the same angle as the aligned neck portions 18, and is in the form of a small plate presenting planar upper and lower faces extending generally perpendicularly to a plane that is flanked by the ribbons 11a and 11b, these faces being inclined with respect to the transverse width of the ribbons 11a and 11b. In the example presented here, each of such retainer members is inclined in a direction or sense opposite to that of the respective preceding or succeeding retainer member 19.
While the construction of the retainer members 19 that has been described above is particularly advantageous, if for no other reason than because it does not require the use of any tools for the assembly of the retainer members 19 with the sandwich including the ribbon arrangement 11 and the drawstring arrangement 13, it is also contemplated by the present invention to use other constructions of the retainer members 19 instead, for instance, that including a length of a deformable metal wire encircling and clamped around the aligned neck portions 18. Even then, however, the principle of causing the retainer members 19 to assume respective inclined positions is adhered to. Moreover, as will be appreciated, in order to locate the retainer members 19 on and orientate them at the desired angles with respect to the ribbons 11a and 11b, it is not absolutely necessary (albeit it is advantageous) to give the indentations 16 and 17 the illustrated V-shape. Rather, to give an example, a simple cut may be formed inwardly from each edge of each of the ribbons 11a and 11b, such cuts being substantially aligned with one another as between the ribbons 11a and 11b but offset from one another as far as the respective ribbon 11a or 11b is concerned to provide respective narrow lands or intervening portions around which the retainer member 19 may be clipped.
In those respects that have been described above, the adorning article 10 has so much in common with that described in the above patent that reference may be had to the latter for any details that may need clarification. However, the article 10 of the present invention also differs from that described in the patent in details that are both substantial and substantive.
More particularly, as already mentioned before, the article 10 of the present invention includes the two branches 12a and 12b that effectively double or at least substantially increase the amount of the ribbon material that is available beyond the stem 12c for the formation of a bow. It should be noted in this respect that the drawstrings 13a and 13b, while passing side-by-side with one another through the stem 12c, are separated at the upper end of the stem 12c as considered in FIG. 1 to each individually enter a different one of the branches 12a and 12b and pass next to and/or between the segments 15a.3 (and 15a.0) and 15a.2 and 15a.1, on the one hand, and the segments 15b.3 (and 15b.0) and 15b.2 and 15b.1, respectively. They are connected, such as by respective knots, to the respective crease regions 14a and 14b situated between the segments 15a.1 and 15a.2 and 15b.l and 15b.2 and/or to the respective retainer members 19 if present thereat (they would not have to be if those segments 15a.1 to 15b.2 were about one-half in length of the others, and in that case the indentations, incisions or notches 16 and 17 could be dispensed with as well at those locations). Of course, respective retaining members 19 are used to connect the free ends of the folded-over segments 15a.1 and 15b.1 to the neck portions 18 disposed between the segments 15a.2 and 15a.3 or 15b.2 and 15b.3.
Having so described the construction of the adorning article 10, its conversion from its substantially fiat or developed precursor state of FIG. 1 to its final or bow state depicted in FIG. 4 of the drawing will now be explained in some detail. In use, the article 10, which is distributed and stored prior to use in its flat form, is converted into a decorative pom-pon or rosette-like bow by first grasping the free (lower) ends of the drawstrings 13a and 13b in one hand while simultaneously holding a portion of the segments 15a.n and 15b.n adjacent the retainer member 19 that is situated next to such free drawstring ends lightly between a finger and the thumb of the other hand. The drawstrings 13a and 13b are then pulled outwardly at about the same pace, with the affected finger and thumb of the aforementioned other hand being in engagement with the aforementioned retainer member 19, so that the segments 15a.1 to 15b.n are gathered up into respective loops.
As revealed in FIG. 3 of the drawing, barring unforeseen complications, this gathering process commences at the two branches 12a and 12b, that is, with the segments 15a.1 to 15b.3 contained in them. This preference for the location at which the gathering process commences is attributable, at least in part, to the fact that the segments 15a.3 and 15b.3 are not doubled up, that is they do not have any counterparts juxtaposed with them, so that they constitute "weak links" in the chain of deformation. This overcomes any otherwise possibly existing tendency for the loops to start forming, due to frictional engagement of the drawstrings 13a and 13b with the neck portions 18 of the ribbons 11a and 11b, at the end portion at which the ribbons 11a and 11b are being held, or even elsewhere. It will be appreciated that such an improper commencement of the gathering process would result in irregularities in the loops which would have to be straightened out eventually, in a very laborious manner. Of course, once the gathering process has started properly, it will continue in the same fashion, that is from above to below as seen in FIG. 3 of the drawing, in that the already at least partially accomplished segment deformation will "feed forward" through the deformation chain.
Because of their angled orientations, the retainer members 19 tend to seat themselves on the bow loops at angularly skewed or offset orientations. As a result, the successive loops become skewed or angularly displaced relative to one another at different angles about the axis of the drawstring arrangement 13. In other words, instead of superimposing themselves onto one another, the loops become arranged at varying angles around the axis of the drawstring arrangement 1, to provide a desired rosette-like form at least at the region originating from the stem 12c.
The bifurcation of the adorning articles 10, however, brings about another and possibly even more important advantage. More particularly, in contradistinction to the situation encountered before when the loops had a tendency to form a rosette-like pattern throughout, that is lay themselves on top of one another, albeit at an angular offset, and extend substantially radially along parallel planes normal to the longitudinal axis of the drawstring arrangement 13, the finished article 10 of the present invention will exhibit, because of the presence of the branches 12a and 12b, an even more desirable rather intricate, pom-pon like, substantially semi-spherical shape. This is so because the ribbon material of the branches 12a and 12b is forced, so to speak, to vie or compete for the same space and becomes deflected upwardly as considered in FIG. 4 of the drawing in the process, thus filling the space that used to be void in the past.
Once the conversion of the article 10 into its final state is completed, the drawstrings 13a and 13b may be knotted adjacent the free ends of the segments 15a.n and 15b.n located at the underside of the finished article as considered in its preferred position of use corresponding to that shown in FIG. 4, and the remaining free ends of the drawstrings 13a and 13b may be cut off. Alternatively, such remaining free ends may be used for securing the finished adorning article 10 in the desired position relative to a parcel or package to be decorated by the article, or may even be used for tying such a package.
The article 10 may be furnished to the users in its essentially flat precursor form with an adhesive-backed card having an opening through which the free ends of the drawstrings 13a and 13b either extend already, or are to extend. The adhesive-coated surface of such a card may initially be covered by a release paper that is removed by the user after completion of the formation of the finished article 10 in order to assist in or accomplish securing of the finished article 10 to the package or another item to be decorated.
As already alluded to or even explained before, the bow-forming article precursor 10 may be packed flat for storage and transport. So, for instance, the article precursor may be folded about the narrow neck portions 18, with the segments 15a.1 to 15b.n of the stem 12c and branches 12a and 12b being folded one on the other, to provide a compact folded structure.
In another embodiment, the stem portions can be eliminated altogether, it being sufficient to connect the main ribbon sections together at the merger region.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above.
While the present invention has been described and illustrated herein as embodied in a specific construction of an adorning or decorative article, it is not limited to the details of this particular construction, since various modifications and structural changes may be made without departing from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | An adorning article includes a pair of elongated ribbons subdivided into consecutive segments connected in succession by respective neck portions, a pair of drawstrings, and a multitude of retainer members that are applied to the neck portions to connect them to one another. Each of the ribbons includes a stem portion and a branch portion merging with one another at a merger region. At least one of the segments of each of the branch portions is folded back into juxtaposition with an adjacent segment of the same branch portion and is connected by a respective retainer member to that of the neck portions that connects the adjacent segment with the next one. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The invention, in general, relates to devices for detecting the presence of fluids, such as leaking pollutants, and more particularly, a detector which provides an output that can produce complete status records using relatively inexpensive recording devices.
2. Description of the Prior Art.
Contamination of the environment, such as ground water, by various liquid pollutants, such as gasoline, has become a significant problem in recent years and a number of practical devices for detecting pollutants have been developed. See for example, U.S. Pat. No. 4,116,045 on an invention of Bronson M. Potter and U.S. Pat. No. 4,221,125 on an invention of John N. Oliver and Louis M. Sandler. Recording of the output of such detectors has been found to be useful for controlling pollution and, in some cases, has been made necessary by law. Since in some industries and businesses the sources of pollutants can be multitudious, it would be highly desirable that fluids detectors for the sensing of pollutants provide a output that can be utilized by relatively inexpensive recording devices.
U.S. Pat. No. 4,116,045, referred to above, provides as an output an alarm or a gauge that responds to varying current levels. The output disclosed in U.S. Pat. No. 4,221,125, is a voltage which can vary over a range and which activates a visual or audible indicator. In another prior art device which is based on a microprocessor, the output is provided in the form of discrete voltage levels, i.e. an output of one volt indicates the presence of a polar fluid such as water, an output of two volts indicates the presence of a non-polar fluid such as oil, and an output of three volts indicates the presence of a dry well. Such an output lends itself more readily to the creation of a record of the output, however, the microprocessor based device is relatively expensive. Further, for a complete record of the status of all probes, multiple parallel channels must be recorded simultaneously.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a fluid detector which is in itself relatively inexpensive and which provides an output in a form which may be utilized by a relatively inexpensive recording device.
It is another object of the invention to provide a fluid detector which upon the detection of a condition of pollution or other significant status, continuously provides an output indicating the detection of the significant status.
It is still another object of the invention to provide a fluid detector which has a variety of output modes.
The invention provides an apparatus for detecting the presence of fluids comprising, a sensing means for sensing the presence of a polar liquid, a non-polar liquid, and a dry condition and for producing a polar liquid signal, a non-polar liquid signal, and a dry condition signal, each of which signals are capable of assuming at least two levels, i.e. a first level indicative of the absence of the fluid or condition and a second level indicative of the presence of the fluid or condition. The invention further includes a reference means for setting the second level of the polar liquid signal to a first predetermined value, for setting the second level of said non-polar liquid signal to a second predetermined value, and for setting the second level of the dry condition signal to a third predetermined value. There is also a clock means for producing a timing signal, and an output means responsive to the timing signal for sequencing the polar liquid signal, the non-polar liquid signal, and the dry condition signal on a single output line. Preferably the invention further includes a locking means for locking the signal on the output line at the second predetermined value when the non-polar liquid is detected. The invention also preferably includes a means for changing the frequency of the timing signal. Preferably, the reference means includes a variable resistor having a wiper, and a comparator wired in a voltage follower mode, the wiper of the variable resistor connected to the input of the comparator.
The fluid detector, according to the invention, provides an output which may be utilized by a relatively inexpensive single channel recorder, or other simple and inexpensive recording devices, without degredation of the data.
Numerous other features, objects and advantages of the invention will become apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a diagramatic view of the invention in its operating environment; and
FIG. 2 is an electronic circuit diagram of the central monitor portion of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Directing attention to FIG. 1, a partially sectioned view of the invention as it may be installed at a service station, a typical operating environment. In the foreground 10 is a partial sectional view of the underground environment showing probe assemblies 14 and 16 on either side of a gasoline storage tank 15. Probe 18 at the lower end of the probe assembly 14 senses the presence of a dry condition, a non-polar liquid, or a polar liquid and produces a signal which is processed by electronics 20 packaged in the end of the probe to produce signals indicating the presence or absence of a dry condition, a non-polar liquid, and a polar liquid, which signals are passed along cable 21 to a central monitor station 25. As will be discussed in detail below, electronics within central monitor station 25 processes the three signals and produces a recordable output. This output may be recorded on a nearby recording device (not shown) or communicated to a recording device at a distance, as for example, over a telephone line. The probe assemblies, such as 14, may be commercially available units such as any of parts No. FD221G, FD241G, or FD221T available from Pollulert Systems, Mallory Components Group, P. O. Box 706, Indianapolis, Ind. 46206, and the cable 21 may be the commercially available cable such as part No. POL304 or part No. POL314 available from the same source.
Turning now to the detailed description of the electronic circuitry of the central processing station 25 according to the invention, we refer to FIG. 2. The terminals 30A through 30E are the connections to the cable 21 of FIG. 1. Terminal 30A is the probe power supply output and terminals 30B through 30D are the probe condition status inputs. In the preferred embodiment, the status conditions that these inputs report are air, water, and oil for terminals 30B, 30C and 30D, respectively. Terminal 30E connects to the cable shield and the terminal is grounded to provide a common ground for the entire system.
Electronic parts in the preferred embodiment of the invention include an AMP CPC connector plug 31 having output pins 32, 33A, 33B, and 34A through 34C, 180K ohm resistors 36A through 36E, 1OK ohm variable resistors 41 through 44, comparators 46 through 49, which in this embodiment are part of a single integrated chip type LM2902N, integrated circuit chip 52 which in this embodiment is a type LM555 timer, 4.7 M ohm resistor 53, 47K ohm resistor 54, 100 microfarad capacitor 55, integrated circuit chip 60, which in this embodiment is a type CD4052 multiplexer, and integrated circuit chip 61, which is preferrably a type MM74C93N counter. The preferred circuit also includes fuse 70, transformer 71, full-wave bridge rectifier 72 which includes four type 1N4001 diodes, such as 72A, 500 microfarad capacitor 73A, two type 1N5352A diodes 74A and 74B, a type LM140K-12 voltage regulator 76, four type PN2907 transistors 77, 82, 83, and 95, 1OK ohm resistors 78A, 78B and 78C, 2.2K ohm resistors 79A, 79B, and 79C, type TIL116 optoisolators 80A, 80B and 80C, and 3K ohm resistors 81A, 81B and 81C. Continuing at the lower-left-hand corner of FIG. 2, the parts of the preferred embodiment of the invention further include LEDs 87A through 87D, 820 ohm resistor 88, double pole single throw manual switch 89, alarm 90 which may be a commercially available alarm such as the SONALERT alarm manufactured by Emhart Industries, Inc., 820 ohm resistors 91A, 91B and 91C, type 1N914 diodes 92A, 92B and 92C, four circuit dip switch 93, 1OK ohm resistor 94, 0.1 microfarad capacitor 96, manual trip switch 97, electronic latch switch 98, type 1N4002 diodes 99A and 99B, relay 100, integrated circuit 110 which is preferably another type LM555 timer, 5 M ohm variable resistor 111, 1.0 microfarad capacitor 112, and 1OK ohm resistor 113. Terminals 101 are the outputs for the relay 100, which includes coil 1OOA and contacts 1OOB.
Turning now to the interconnections of the various parts of the circuitry, transformer 71, full-wave bridge rectifier 72, voltage regulator 76 and the associated circuitry provide the power supply for the system. Terminals 105 connect to a conventional 120 volt AC, 60 Hertz power source. Fuse 70 is connected between one line of the power source and one side of the transformer 71. The transformer 71 is connected across the input terminals of full-wave bridge rectifier 72. One output terminal of rectifier 72 is connected to ground and the other side is connected to the input of voltage regulator 76 and is also connected to ground through filter capacitor 73A and regulation diodes 74A and 74B. 30 ohm current limiting resistor 73B is connected between the output of bridge 72 and the cathode of diode 74A, while 15 ohm resistor 73C is connected between the cathodes of the two diodes. The cathode of diode 74B is also connected to the probe power output 30A. The output of voltage regulator 76 provides a positive 12 volt power supply for the rest of the electronic circuitry. The power supply line is connected to ground through filter capacitor 96.
The probe status signals input on terminals 30B through 30D are amplified by transistors 77, 82, and 83, and the associated circuitry. Terminal 30D is connected through 3K ohm resistor 91A to the number 1 pin of optoisolator 80A. The number 2 and number 4 pins of optoisolator 80A are grounded. The number 5 pin is connected to the base 77A of transistor 77 through current limiting resistor 79A. The base 77A is also connected to the positive voltage supply through pull-up resistor 78A. The emitter 77B of transistor 77 is connected to the positive voltage supply. The collector 77C of transistor 77 provides the non-polar liquid (oil) status signal and is connected to the positive side of variable resistor 41. Inputs 30B and 30C are similarly connected to their respective optoisolators and transistors. The output of collector 84 of transistor 82 provides the polar liquid (water) status signal which is input to the positive side of variable resistor 43, while the collector 85 of transistor 83 provides the dry condition status signal which is input to the positive side of variable resistor 44.
Variable resistors 41 through 44 and comparators 46 through 49 provide a reference means for setting the level of the signals indicating the presence of a polar liquid, the dry condition, the circuit power status, and the presence of a non-polar liquid, respectively. The side of variable resistor 41 not connected to the status signal is grounded while the wiper is connected to the positive or high input of comparator 49. The negative or low input of comparator 49 is connected to its output in a voltage follower mode. The other variable resistors and comparators are connected similarly. Note that variable resistor 42 and comparator 48 set the level which is used to indicate that the circuit power is on.
Timer 52 and its associated circuitry provide a clock means for producing a timing signal. The number 1 pin of timer 52 is grounded, and the number 8 and 4 pins are connected to the power supply. The numbers 2, 7 and 6 pins of timer 52 are connected to one side of the switch 93D through resistor 54, the other side of switch 93D through resistor 53, and to ground through capacitor 55. The number 3 pin provides the output timing signal which is applied to the number 14 pin of counter 61.
Counter 61, multiplexer 60, socket 31 and their associated circuitry provide an output means responsive to the timing signal for sequencing the dry condition signal, the non-polar liquid signal, the polar liquid signal, and the circuit power signal on a single output line. The number 4 pin of counter 61 is tied to the positive voltage supply while the number 11 pin is grounded. The number 13 and number 8 pins of counter 61 are connected together and are also connected to the number 10 input of multiplexer 60. The number 9 output pin of counter 61 is connected to the number 9 input pin of multiplexer 60. The number 1 and 2 pins of counter 61, which are the reset pins, are connected to the collector 77C of transistor 77. The number 16 pin of multiplexer 60 is connected to the positive power supply while the number 6, 7 and 8 pins are connected to ground. The number 1, 2, 4, and 5 pins of multiplexer 60 are connected to the outputs of comparators 49, 47, 46 and 48, respectively. The number 3 pin of multiplexer 60 is the output pin and it is connected to the serial output pin 32 of connector 31 through protective resistor 36E. Pin 33A of connector 31 is connected to ground while pin 33B is connected to the positive power supply through protective resistor 36A. Pins 34A, 34B, and 34C of connector 31 are connected to collectors 77C, 84, and 85 of transistors 77, 82 and 83, respectively through protective resistors 36D, 36B and 36C, respectively.
An audible output is provided by alarm 90, while a visible output is provided by LEDs 87A through 87D. One side of alarm 90 is connected to the positive voltage supply while the other side is connected to the pole of switch 89. The throw of switch 89 is connected to the base of transistor 95 through resistor 94. The cathodes of LEDS 87A through 87D are grounded. The anode of LED 87D is connected to the positive power supply through resistor 88 while the anodes of LED 87A through 87C are connected to the collectors 85, 84, and 77C of transistors 83, 82 and 87 respectively through current limiting resistors 91A through 91C, respectively.
Switches 93A, 93B and 93C, relay 100, timer 110, and the associated circuitry provide a programmable relay with a time delay feature. The throws of switches 93A through 93C are connected to the number 4 input pin of timer 110. Pin 4 is also connected to one side of manual trip switch 97, while the other side of manual trip switch is connected to the positive voltage supply. Further, the number 4 pin is tied to one side of latch switch 98 while the other side of latch switch 98 is connected to the collector of transistor 95. The emitter of transistor 95 is connected to the positive voltage supply. In addition, the number 4 pin of timer 110 is connected to one side of variable resistor 111, to the wiper of the variable resistor, to ground through resistor 113, and to the cathode of diode 99A. The number 2 and number 6 pins of timer 110 are connected together and connected to the other side of variable resistor 111, to the anode of diode 99A, and to one side of capacitor 112. The other side of capacitor 112 and the number 1 pin of timer 110 are grounded. The number 8 pin of timer 110 is connected to the cathode of diode 99B and to one side of the coil lOOA of relay 100. The number 3 pin of timer 110 is connected to the anode of diode 99B and to the other side of coil lOOA. The contacts of relay 100 are indicated at lOOB and the relay outputs are indicated at 101.
Turning now to the operation of the invention, the outputs of the probe assemblies, such as 14 and 16, (FIG. 1) are connected in parallel to cable 21 which is connected to inputs 30B through 30D. These inputs are normally at the nominal ground voltage. However, when a dry condition, a polar liquid, or a non-polar liquid, are detected, a positive voltage is placed on the corresponding status inputs 30B, 30C or 30D, respectively. The positive voltage will turn on the corresponding one of the transistors 83, 82, or 77, respectively. The voltage output on the collectors 85, 84 and 77C, respectively, when the transistors are turned on will vary depending on the number of probes in the system and other factors. When the system is manufactured, the variable resistors 41 through 44 are adjusted so that the outputs of the comparators 46 through 49 are at predetermined levels. In the preferred embodiment, variable resistor 41 is set so the output of comparator 49 (the non-polar liquid output) is at two volts when a non-polar liquid signal is received, variable resistor 42 is adjusted so that the output of comparator 48 (which is the power on output) is at a value of 5 volts, variable resistor 43 is adjusted so that the output of comparator 46 (which is the polar liquid output) is at a value of 1 volt, and variable resistor 44 is adjusted so that the output of comparator 47 (which is the dry condition output) is at a value of 3 volts. The multiplexer 60 multiplexes the output signals from comparators 46 through 49 and places them in sequence on the output pin 32 of connector 31. When switch 93D is in the open position, timer 52 will have a period of about 15 minutes, so that each of the different status signals will be output for a 15 minute period on pin 32 for a total cycle time for all the signals of one hour. If switch 93D is closed, then timer 52 will have an approximately 11/2 second period so that each of the status signals will be output on pin 32 for a time of 11/2 seconds for a total cycle time for all status signals of approximately six seconds. If a non-polar liquid is detected, the output of collector 77C applied to the reset pins 1 and 2 of counter 61 will hold the counter reset so that the non-polar liquid status will be continually output on pin 32. The non-polar liquid is generally the pollutant of principal interest.
Switches 93A, 93B and 93C and their associated circuitry provide a programmable output for the detector. The status signals for dry condition, polar liquid, and non-polar liquid, are input on switches 93A, 93B and 93C, respectively. Closing any one or more of the switches will cause the corresponding status signal to turn on timer 110. Once the timer delay, set by adjusting variable resistor 111, is complete, relay 100 is turned on. In addition, via its connection to relay 100, alarm 90 will be turned on. The alarm may be disengaged by the use of switch 89. The relay 100 and the alarm 90 may also be manually turned on by switch 97. Engagement of the relay also causes a signal to be applied to the base of transistor 95, which is turned on and, if switch 98 is closed, applies a signal to pin 4 of timer 110 to latch the relay in the on condition. Alarm 90 also will be latched on if switch 89 is engaged. Diodes 92A through 93C prevent the closing of switches 90A through 90C from lighting the front panel LEDs 87A through 87C.
The invention thus described, provides a parallel output, which has generally been provided in the prior art, on the pins 34A through 34C and 33B of the output connector 31. In addition, it provides a unique serial output on pin 32. This output signal is of a form that can be utilized easily by inexpensive recording means, such as a single channel chart recorder, to record the data necessary for tracking pollutants. Glancing at the output of such a chart recorder will immediately indicate if the unit is functioning and the status of the probes. If a non-polar pollutant has been detected at any time since the chart recorder was last checked, it will be immediately evident and the time of initiation of the polluting condition can be ascertained by checking back on the record.
A novel apparatus for detecting pollutants that provides an output that can be inexpensively utilized, and which has numerous other features has been described. It is evident that those skilled in the art may now make numerous uses and modifications of and departures from the specific embodiments described herein without departing from the inventive concepts. For example, the various electronic components can be replaced by equivalent electronic parts. While the invention has been described in terms of an embodiment which detects the presence of water, oil, or a dry condition the inventive concepts could be used in detecting other conditions, and in particular, the presence or absence of other non-polar liquids or polar liquids. Many other variations may be described. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features present and/or possessed by the fluid detection apparatus described. | A system for detecting fluid pollutants includes probes for sensing the presence of a polar liquid, a non-polar liquid, and a dry condition, and for producing a polar liquid signal, a non-polar liquid signal, and a dry condition signal. A reference circuit which includes a tunable element, such as a variable resistor, is used to set the probe output signals to a predetermined voltage value: e.g. a 1-volt value indicates a polar liquid, a 2-volt value indicates a non-polar liquid, a 3-volt value indicates a dry state, and a 5-volt value indicates that the circuit is on and operating. The output signals are multiplexed and output on a single output line. The definitive signal levels and the serial output mode permit an inexpensive single channel recorder to be used to provide a permanent and complete record of the probe status. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for monitoring the partial pressure of gases, particularly in sterile liquids. One particular application of the invention, though not the only one, is for monitoring the partial pressure or tension of gases in the blood, for example the blood circulating from a heart-lung machine to a patient during open-heart surgery. In the case of blood, the tensions with which one is concerned are the oxygen tension (PO 2 ) and the carbon dioxide tension (PCO 2 ). In the case of other liquids, however, the tensions with which one may be concerned may be different.
Any system for monitoring blood gas tensions must do so without compromising the sterility of the circulating blood. This greatly influences design of electrodes for extracorporeal blood gas monitoring. Up to the present time, all electrodes designed for this purpose have been placed in direct contact with the blood, but this has a number of serious disadvantages. Firstly, the electrode must be sterile, and this imposes constraints on the electrode design. Secondly, because of the need for sterility and the need to calibrate the electrodes, it is essential that the electrodes give the same output before and after sterilization. This is difficult to achieve. Thirdly, the electrodes have to be made to be disposable after a single use, even though this is costly, because of the inconvenience and even greater cost of re-sterilization. Fourthly, once the electrode has been placed in contact with the blood it is not permissible to allow access to the electrode even if a malfunction is detected, in order to preserve the sterility of the electrode. In the event of a malfunction, therefore, useful information about the state of the blood may be lost.
SUMMARY OF THE INVENTION
According to the present invention there is provided an apparatus for monitoring the partial pressure of a gas in the liquid flowing in a line, the apparatus comprising a connector adapted for insertion in the said line, the connector having a wall which includes a membrane permeable to the said gas but impermeable to the said liquid, the membrane having a first face in contact with the said liquid in the connector and a second face oppositely disposed to the said first face, and a sensor located adjacent the said second face and responsive to gas passing through the membrane from the liquid.
The reference herein to a sensor located adjacent the said second face is intended to include the case where the actual sensing is carried out by a device, for example a mass spectrometer or gas chromatograph, located remote from the said face, and gas is fed thereto by a conduit one end of which is located adjacent the said second face.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a longitudinal sectional view showing by way of example an embodiment of an apparatus according to the invention for the measurement of PO 2 ; and
FIG. 2 is a cross-sectional view of part of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus shown in FIG. 1 comprises a connector 1 which is of generally T-shape. The cross-piece of the T forms two arms each of which is provided on its exterior with shoulders to enable the arms to be inserted in adjacent parts of a line in which a liquid containing the gas to be monitored is to flow. The connector is provided with an aperture which is closed by a silicone rubber membrane 2 supported by a perforated stainless steel or nickel cup 3.
The apparatus further comprises an electrochemical sensor 4. The sensor 4 may be of one of a variety of types, and the form of sensor illustrated is purely by way of example. This sensor has a polypropylene membrane 5 covering a silver anode 6 and a platinum cathode 7 which is in the form of a 25 micron diameter wire. The membrane 5 is mounted on the end of a tube 8 by means of an epoxy resin. The sensor further comprises a thermistor 9. The sensor is connected to an external measuring instrument (not shown) by means of a 4-core screened cable 10.
The connector 1 is initially supplied to a user as a sterile, disposable unit, or alternatively it may be designed to be capable of sterilization. The sensor 4 does not need to be sterile, since no part of it is in contact with liquid flowing in the connector. Before the sensor is inserted into the connector it is calibrated against the PO 2 in air which is generally a reliable standard (20.9% oxygen). A few drops of electrolyte are preferably placed between the membrane 2 and the membrane 5 so as to minimize the effect of oxygen leaks from the air to the electrodes of the sensor. A spacer 11 in the connector serves to maintain a predetermined spacing between the two membranes. In use, the top of the arm of the connector in which the sensor is received is sealed by a spring-loaded plug 12, which may, optionally, be made as an integral part of the sensor.
In order for the apparatus to function satisfactorily the maximum amount of oxygen per unit time which can permeate through the membrane 2 must be high compared to that of the membrane 5. Provided this condition is satisfied then, as far as the sensor 4 is concerned, the sensor will measure a PO 2 substantially as if it were in direct contact with the blood. Under this condition the sensor measures the PO 2 in the static liquid film between the two membranes, and the oxygen tension in this film is in equilibrium with the oxygen tension in the blood.
It is also necessary that the consumption of oxygen from this liquid film by the sensor should be negligible, an effect which can readily be achieved using a cathode of the dimensions mentioned above and a membrane 5 which is 12.5 to 25 microns in thickness.
Although the apparatus described above is one for use in measuring the PO 2 in the blood, a very similar apparatus according to the invention can be used to measure the PCO 2 in the blood. PCO 2 is most commonly measured by a potentiometric technique according to Severinghaus. In essence this is a modification of a method for determining the pH. A pH-responsive glass electrode and a reference electrode are placed in an electrolyte and covered by a carbon dioxide-permeable membrane. Carbon dioxide diffusing across the membrane in response to a PCO 2 difference equilibrates the internal electrolyte with the PCO 2 of the medium. Hydration of carbon dioxide in the electrolyte produces a carbonic acid and causes a change in hydrogen ion activity expressed by
CO.sub.2 +H.sub.2 O=H.sub.2 CO.sub.3 =H.sup.+ +HCO.sup.-.sub.3.
The pH electrode detects the alteration in PCO 2 as a change in pH of the electrolyte and a voltage exponentially related to PCO 2 results. Thus, a 10-fold increase in PCO 2 is approximately equivalent to a decrease of one pH unit. Since this is a potentiometric technique no carbon dioxide is consumed and the depletion effects associated with PO 2 electrodes do not arise. In using the Severinghaus technique in an apparatus according to the invention the same connector can be used as that described above with reference to PO 2 measurement. The membrane 2 then forms the diffusion membrane of the CO 2 sensor. A few drops of unbuffered electrolyte are placed on the membrane 2 and the CO 2 sensor is then completed by placing a pH electrode, which can be of known construction, in the electrolyte. In the case of PCO 2 monitoring, therefore, only one membrane is employed, as opposed to the two membranes used in PO 2 monitoring.
The embodiment of the invention, part of which is shown in FIG. 2, is, like the embodiment of FIG. 1, for the measurement of PO 2 . In many ways the embodiment of FIG. 2 resembles that of FIG. 1, and parts in FIG. 2 which correspond to parts in FIG. 1 are denoted in FIG. 2 by the same reference numeral as in FIG. 1 with the addition of 100. Thus, the embodiment of FIG. 2 comprises a connector 101 having a passage 120 within it which is in communication with a line in which a liquid containing the gas to be monitored is to flow. The connector is provided with an aperture which is closed by a silicone rubber membrane 102 supported on a perforated nickel disc 103. The silicone rubber is solvent cast onto the nickel disk. Various types of silicone rubber may be used, for example those sold by Dow Corning Corporation as Q7-2213 (a dimethylsiloxane elastomer dispersed in 1,1,1 trichloroethane) and Q7-2245 (a 3-part system comprising a dimethylsiloxane polymer and a reinforcing silica, a polysiloxane curing agent, and an additive for inhibiting ambient temperature curing of the first two parts).
The apparatus further comprises an electro-chemical sensor 104. The sensor includes a hollow sensor body 121, the lower end of which is provided with a screw thread 122, for reasons which will become apparent from the ensuing description. Within the sensor body 121 is mounted a hollow stem 123 formed, for example, from epoxy resin. The lower end of this stem carries a sensor element 124. The element 124 includes a silver anode 106 and a platinum cathode (not shown) which extends through a cathode-receiving bore 107. The anode is also provided with a bore 125 for receiving a thermistor which detects the temperature at which the sensor element 124 is operating.
The lower end of the sensor element is closed by a sensor membrane 105. The peripheral edge of the membrane 105 is held between the parts 126 and 127 of a 2-part membrane holder body. The upper end of the part 127 has a screw thread which interlocks with the screw thread 122 provided on the sensor body 121. The two parts of the membrane holder body are held together by sealant which is present in annular recesses 128 formed in the two parts. For completeness it should be added that the component formed by the membrane 102 and disc 103 is held in place by a ring 129 which has an external thread cooperating with an internal thread on the adjacent part of the connector 101. The ring 129 is held in place in the connector 101 by sealant which is introduced into apertures 130.
It should be noted that the connector 1 or 101 is relatively cheap and can therefore be disposable, whereas the sensor 4 or 104 is relatively expensive but can be reused since it is removable from the connector.
The embodiments of the invention described above use an electro-chemical sensor. However, in a modification of the apparatus according to the invention, the electro-chemical sensor can be replaced by a purely chemical sensor, for example, a layer of crystals whose color changes in a manner which is a function of the partial pressure of some particular gas. Suitable chemical compounds for this purpose are to be found, by way of example, in a PCT patent application published under International Publication Number WO 79/00696, to which attention is directed.
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail the presently preferred embodiments, with the understanding the present disclosure is to be considered as an exemplification of the principles of the present invention, and is not intended to limit the invention to the embodiments illustrated. The scope of the invention is pointed out in the appended claims. | An apparatus is disclosed for monitoring the partial pressure of a gas in the liquid flowing in a line, for example the PO 2 or PCO 2 tension in blood. The apparatus comprises a connector adapted for insertion in the line, the connector having a wall which includes a membrane permeable to the gas but impermeable to the liquid. The membrane has a first face in contact with the liquid in the connector and a second face oppositely disposed to the first face. A sensor, for example, an electrochemical sensor, is located adjacent the second face and is responsive to gas passing through the membrane from the liquid. | 0 |
This invention relates to a computer implemented automated remote support in a computing system utilizing machine learning to provide a support capability that enhances automatically with use.
BACKGROUND
Product support is a key activity in any business and certainly, the prime focus in a business related to providing services to customers. Traditionally this support is provided in a structured manner depending on the level of support necessary. For instance, many organisations provide a three level support:
1. Level-1: Telephonic support.
2. Level-2: Country/Region expert. May include visits by an engineer
3. Level-3: Highest level of support. Provided by the maintenance/development team.
With the proliferation of products that need to be supported, as well as the rapidly increasing competitiveness as more service providers enter the market and vye for market share, it is becoming increasingly necessary to provide a constantly improving level of support. This situation is further complicated by the scarcity of trained manpower as well as the constant need for upgradation of their skills through training programs. There is now a clear realisation of an urgent need for improving the effectiveness of available manpower.
One approach to solving this problem is to provide some degree of automation in the support activity. Some attempts have been made in this direction. U.S. Pat. Nos. 5,928,369 and 5,488,732 are examples of techniques evolved for this purpose. However, none of the available methods addresses the problem adequately and in a generic manner. U.S. Pat. No. 5,928,369, for example, limits itself to a problem relating only to computer software in which the problem data is submitted in the form of a stack trace. Similarly, U.S. Pat. No. 5,488,732 deals only with a system for generating an automatic support tool and not with the support system itself.
The object of this invention is to provide a system that offers a continuously self-improving capability for automated response with respect to providing customer support.
THE INVENTION
To achieve the said objective this invention provides in a computing system including a means for electronically receiving requests, a computer implemented automated remote support comprising the combination of said computing system with:
a means for prioritising electronically received support request,
a means for parsing each said support request to extract actual and expected behaviour information and test case data, if any, and compiling actual and expected behaviour data in a prescribed format,
the said formatted output is connected to a searching means for previous occurrences of similar behaviour in a data base,
a means for generating the final solution or suggestions, using the results of the search,
a means for updating the database to refine the organization of the data in order to improve the effectiveness of subsequent search operations, the updations being performed even if no input requests are received,
a means for forwarding of the request to a system expert in case a solution is not found.
The support request is received through a mailing system or via a network.
The means for parsing the support request is a standard or custom-designed parsing system.
The searching means is a search engine.
The said database contains information relating to the functionality, specifications and behaviour, including reported problems and their solutions, for individual products as well as combinations of products.
The said database is structured as a single entity or as a combination of multiple entities in order to improve the effectiveness of searching.
The said database consists of a knowledge cache containing the most recent information relating to individual products, a multi-product view cache containing the most recent views on various product combinations, and a set of knowledge bases that contain all available information on individual products as well as product combinations,
The means for generating the final solution or suggestions is an expert system
The means for updating the database is the said expert system or different expert system with self-learning abilities.
The output of the said parsing means is further connected to an automatic test execution means for using test data extracted from the input request in order to confirm the reported behaviour as well as to obtain any additional inputs if possible, the output of said automatic test execution means being connected to the parsing means which generates the final definition of the expected and actual behaviour in a prescribed format.
The said computing system is a single computing system or a plurality of interconnected computing systems.
The test execution system is a computing system or a plurality of interconnected computing systems incorporating data storage devices, for the automatic login and execution of test cases in the right environment.
The expert system is a computing system or a plurality of interconnected computing systems incorporating data storage devices with self-learning capability utilizing machine-learning techniques such as artificial intelligence.
The knowledge cache means, is a computing system or a plurality of interconnected computing systems incorporating data storage devices, containing the most recent data on individual products.
The multiproduct view cache means is a computing system or a plurality of interconnected computing systems incorporating data storage devices, containing the most recent views of various combinations of products.
The knowledge base means is a computing system or a plurality of interconnected computing systems incorporating data storage devices, containing all available data on supported products, not necessarily the most recent data.
The data in the knowledge bases, knowledge cache and the multiproduct view cache is updated whenever the expert system identifies the occurrence of new behaviour, or when a new product or a revision to an existing product are released into the system or when a solution is provided by the system expert to a problem that was forwarded by the automatic remote support system.
The said prescribed format includes but is not limited to Environment, Description, Action, Next, Testcase to facilitate effective interfacing.
The single computing system or a plurality of interconnected computing systems is a part of a network.
In a specific embodiment an automatic remote Support comprises:
a means for prioritising electronically received support request,
a means for parsing each said support request to extract information relating to actual behaviour, expected behaviour, as well as test case data, if any, and compiling final, actual and expected behaviour data in a prescribed format,
the said formatted output is connected to a search engine to search the extracted behaviour data,
one interface of the search engine is connected to a knowledge cache means for searching for a match with previously stored data relating to individual products,
a second interface of the search engine is connected to a multiproduct view cache for searching for a match with previously stored data relating to views on combinations of products,
a third interface of the search engine is connected to knowledge bases for searching for a match with previously stored data relating to supported products, the arrangement being such that the search engine will search first through the knowledge cache and if no complete or partial match is found will then search through the multiproduct view cache followed by the knowledge bases for providing the final output,
the final interface of the search engine is connected to an expert system for providing the final solution or suggestions and follow-up questions in case a complete or partial match is found, and the request is forwarded to a system expert in case no match is found,
one interface of the said expert system provides the solution in response to the input request, while the remaining outputs update the knowledge cache, multiproduct view cache and the knowledge bases using the self-learning abilities of the expert system to refine the organization of the data in order to improve the effectiveness of subsequent search operations, the updations being performed even if no input requests are received, in a controlled manner.
The other features of the specific embodiment are the same as described above.
This invention further provides in a computing system including a means for electronically receiving requests, a method for automatically processing support requests comprising the steps of:
electronically receiving and prioritising the support requests describing expected and observed behaviour and optionally test case data,
parsing the said electronically received request to extract actual and expected behaviour information and test case data, if any,
compiling of final actual and expected behaviour data in a prescribed format,
searching for previous occurrences of similar behaviour in a database,
generating the final solution or suggestions, using the results of the search,
updating of the database in case of new behaviour data as well as by using the self-learning abilities of the expert system to refine the organization of the data in order to improve the effectiveness of subsequent search operations, the updations being performed even if no input requests are received,
forwarding of the request to a system expert in case a solution is not found.
The automatic execution of the test case data derived from the result of the said parsing, is used to confirm the reported actual behaviour.
In cases where multiple requests are received, each request is processed based on a prescribed priority handling mechanism.
In order to minimise delays, at each stage of the system a request is operated upon as soon as the previous request has been cleared without waiting for the completion of the processing of one request, providing the processing of the previous request is not compromised in any manner.
In a specific embodiment, in a computing system including a means for electronically receiving requests, a method for automatically processing support requests comprises the steps of:
electronically receiving and prioritising the support requests describing expected and observed behaviour and optionally test case data,
parsing the said electronically received request to extract actual and expected behaviour information and test case data, if any,
compiling of final actual and expected behaviour data in prescribed format,
searching for previous occurrence of similar behaviour in a knowledge cache, a multiproduct view cache followed by knowledge bases,
generating the final solution or suggestions, using the results of the search,
updating of the knowledge cache, multiproduct view cache and knowledge bases in case of new behaviour data as well as by using the self-learning abilities of the expert system to refine the organisation of the data in order to improve the effectiveness of subsequent search operations, the updations being performed even if no input requests are received,
forwarding of the request to a system expert in case a solution is not found.
The other features of this specific embodiment of the method are the same as described above.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described with reference to the accompanying drawings and examples:
FIG 1 shows the automatic remote support according to this invention.
FIG. 2 shows the specific embodiment of the invention of the automatic support system.
FIG. 3 shows the sequence of activities performed in the processing of the input request.
Referring to FIG. 1, Support Requests ( 1 ) are prioritised by an Input Request Processing System ( 2 ), which comprises of one or more interconnected computing systems and includes a Parser ( 3 ). The interface from the Input Request Processing System ( 2 ) containing the expected and actual behaviour is connected to the input of a Searching Means ( 5 ), which is implemented on a computing system. One interface from the Searching Means ( 5 ) is connected to the input of a Database (DB) containing information relating to the functionality, specifications and expected and actual of individual products as well as combinations of various products, along with identified solutions, which is implemented on one or more interconnected computing systems. The result of the entire search is presented as a final output by the Searching Means ( 5 ) to the interface of an Expert System ( 9 ) which generates the final solution or suggested solutions in case a complete or partial match is found, or forwards the request to a system expert if no match is found. The Expert System ( 9 ) is a self-learning system, which constantly refines and modifies the data in the Database (DB) in order to improve the effectiveness of the search operations even if no requests are received, in a controlled manner
Referring to FIG. 2, Support Requests ( 1 ) are prioritised by an Input Request Processing System ( 2 ), which comprises of one or more interconnected computing systems and includes a Parser ( 3 ). The interface of the Parser ( 3 ) containing the test data extracted from the input request is connected to the input of a Test Execution System ( 4 ) comprising of one or more interconnected computing systems, for verifying the symptoms of the input request. The interface from the Test Execution System ( 4 ) containing the results of the testing is fed back to another input of the Input Request Processing System ( 2 ). The interface from the Input Request Processing System ( 2 ) containing the expected and actual behaviour is connected to the input of a Searching Means ( 5 ), which is implemented on a computing system. One interface from the Searching Means ( 5 ) is connected to the input of a Knowledge Cache ( 6 ), which may also be referred to as a Data Cache, Information Cache Solution Cache, or Problem Cache, containing the most recent report of information pertaining to the expected and actual behaviour of individual products along with identified solutions, which is implemented on one or more interconnected computing systems. A second interface from the Searching Means ( 5 ) is connected to an interface of a Multiproduct View Cache ( 7 ) also termed as Data Cache, Information Cache, Solution Cache, or Problem Cache containing views on the most recent report of information pertaining to the expected and actual behaviour of various combinations of products, which is implemented on one or more interconnected computing systems. A third interface from the Searching Means ( 5 ) is connected to a set of Knowledge Bases ( 8 ) containing all available information pertaining to the expected and actual behaviour of individual products as well as multiproduct combinations along with identified solutions, implemented on one or more interconnected computing systems. Interfaces exist from the Knowledge Cache ( 6 ), Multiproduct View Cache ( 7 ) and Knowledge Bases ( 8 ) to the Searching Means ( 5 ). The result of the entire search is presented as a final output by the Searching Means ( 5 ) to the interface of an Expert System ( 9 ) which generates the final solution or suggested solutions in case a complete or partial match is found, or forwards the request to a system expert if no match is found. The Expert System ( 9 ) is a self-learning system which constantly refines and modifies the data in the Knowledge Cache ( 6 ), Multiproduct View Cache ( 7 ) and Knowledge Bases ( 8 ) in order to improve the effectiveness of the search operations even if no requests are received, in a controlled manner
Referring to FIG. 3, the input Support Requests are first prioritised and then parsed to extract information relating to actual and expected behaviour, priority as well as test data (if any). The test data (if any) is then used to perform automatic execution of the reported problem in order to confirm the reported behaviour as well as to obtain any additional information that may be possible to identify. The results of the automatic testing are then taken along with the data extracted from the input Support Request to generate a final report of actual and expected behaviour in an appropriate format. The data is used to search through the Knowledge Cache, which contains the most recent record of data relating to individual products, for data on the reported behaviour. If such a record is found completely or partially then the information is extracted and processed to furnish as a solution for this request, in an appropriate format. If the search fails then a search is carried out on the Multiproduct View Cache that executes related views and fetches data from the knowledge base in a like manner. If no match is obtained then the search is repeated on the Knowledge Base, which is a repository of all available data on supported products, not necessarily the most recent data. The data obtained in the case of a complete or partial match is processed to furnish a solution for this request, in an appropriate format. If however, no match is found then the problem is forwarded to a system expert for providing a manually derived solution.
The data in the knowledge bases, knowledge cache and the multiproduct view cache is updated whenever the expert system identifies the occurrence of new behaviour, or when a new product or a revision to an existing product are released into the system or when a solution is provided by the system expert to a problem that was forwarded by the automatic remote support system. In addition the self-learning abilities of the expert system are used to refine and modify the organisation of the data in order to improve the effectiveness of subsequent search operations, the updations being performed even if no input requests are received in a controlled manner,
In cases where multiple requests are received, each request is processed based on priority.
In order to minimize delays, at each stage of the system a request is operated upon as soon as the previous request has been cleared without waiting for the completion of the processing of one request based on priority,
Working
Support Requests ( 1 ) are received from a network or e-mail system (not shown) in a prescribed format that includes but is not limited to Environment, Description, Action, Next, Testcase by an Input Request Processing System ( 2 ), which comprises one or more interconnected computing systems and includes a Parser ( 3 ). The Input Request Processing System ( 2 ) prioritises the requests and then the Parser ( 3 ) analyses the Support Request ( 1 ) and extracts information relating to observed and expected behaviour, priority as well as test data, if provided. The test data, if provided in the Support Request ( 1 ), is extracted by the Parser ( 3 ) and forwarded by the Input Request Processing System ( 2 ) to a Test Execution System ( 4 ) which performs the tests with the data furnished to verify the behaviour and provide any other additional inputs that may not have been communicated in the Support Request. This information is fed back to the Input Request Processing System ( 2 ) which then prepares an output definition of the expected and observed behaviour in a defined format and forwards to a. Searching Means ( 5 ) which initiates a search in a database (DB). If a complete or partial match is found with a previously recorded request then the results of that analysis are retrieved and furnished to the Expert System ( 9 ), which then processes it and presents the solution in an appropriate format. If however, no such match is found then the Expert System ( 9 ) forwards the request to a system expert for manual analysis. The Expert System ( 9 ) uses its self-learning abilities to constantly refine the data organisation in the database (DB) in order to improve the effectiveness of subsequent search operations in a controlled manner.
In a specified embodiment, as shown in FIG. 2, Support Requests ( 1 ) are received from a network or e-mail system (not shown) in EDANT format by an Input Request Processing System ( 2 ), which comprises one or more interconnected computing systems and includes a Parser ( 3 ). The Input Request Processing System ( 2 ) prioritises the requests and then the Parser ( 3 ) analyses the Support Request ( 1 ) and extracts information relating to observed and expected behaviour, priority as well as test data, if provided. The test data, if provided in the Support Request ( 1 ), is extracted by the Parser ( 3 ) and forwarded by the Input Request Processing System ( 2 ) to a Test Execution System ( 4 ) which performs the tests with the data furnished to verify the behaviour and provide any other additional inputs that may not have been communicated in the Support Request. This information is fed back to the Input Request Processing System ( 2 ) which then prepares an output definition of the expected and observed behaviour in a defined format and forwards to an Searching Means ( 5 ) which initiates a search in the Knowledge Cache ( 6 ) containing the most recent data on individual products for a possible match. If no match is found then the Searching Means ( 5 ) initiates a search in the Multiproduct View Cache ( 7 ) containing the most recent data on views of various multiproduct product combinations, for a possible complete or partial match with a previously recorded data. If a match is found then the view obtained is used to extract the associated data from Knowledge Bases ( 8 ) which contain all available recorded data on supported products but not necessarily the most recent data. If however, no match is found then the Searching Means ( 5 ) initiates the search on the larger database in the Knowledge Bases ( 8 ). If a complete or partial match is found with a previously recorded request then the results of that analysis are retrieved and furnished to the Expert System ( 9 ), which then processes it and presents the solution in an appropriate format. If however, no such match is found then the Expert System ( 9 ) forwards the request to a system expert for manual analysis. The Expert System ( 9 ) uses its self-learning abilities to constantly refine the data organisation in the Knowledge Cache ( 6 ), Multiproduct View Cache ( 7 ) and Knowledge Bases ( 8 ) in order to improve the effectiveness of subsequent search operations in a controlled manner
The invention Will Be Further Illustrated By Means of the Following Examples:
1. Case-1:
Consider the case when a problem report is received for a particular product on a particular environment.
Let's say that:
Product p 1
Environment: e 1
Solution: s 1 (that has been found already)
Now, if this solution s 1 happens to involve either p 1 or e 1 or a combination of p 1 and e 1 , this knowledge could be used whenever there is a problem reported with (p 1 , e 2 ) or (p 2 , e 1 ). Now s 1 could be suggested as the new solution or a follow up question depending on the content of s 1 .
This can be used to refer to the multiproduct cache for the most probable hit.
The machine learning engine updates the multiproduct cache and the knowledge bases with the knowledge representations like (p 1 , e 2 , s 1 ), (p 2 ,e 1 ,s 3 ) etc.
Thus as the number of problems/solutions set increases. The multiproduct cache and the knowledge bases are updated with new information by the machine learning engine in a controlled manner, which comes with new associations of product, environment and solution combinations. The machine learning engine in the expert system ensures consistency and relevance of new data or knowledge generated with respect to product features, problems and solutions. It also ensures that such generation of new data or knowledge does not continue unchecked leading to an explosive condition where the system resources are exceeded and the system fails.
2. Case-2:
If the contents are in the EDANT form
2.1 We could have various components that constitute the environment.
E—e 1 , e 2 , e 3 , . . . , en
2.2 We could have various components that constitute the descriptions
D—d 1 , d 2 ,, d 3 , . . . , dn
2.3 Many action components could constitute the action taken
A—a 1 , a 2 , . . . ,, an
A solution s 1 may exist for a set (E,D,A)
The solution s 1 may include a change in any of the subcomponents of E,D or A. When a new problem information is received, each of the sub-components can be compared with the one associated with the existing solutions.
a. these can be suggested as probable solutions
b. These could be the basis of a follow up question.
The above examples are only illustrative of some features in the proposed implementation of the machine learning engine in the expert system. The machine learning engine is not limited by these features | This invention relates to a computer implemented automated remote support in a computing system that utilizes machine learning to provide constantly improving support capability. It comprises a means for parsing input requests, means for automatically executing test cases, a Database for storing data pertaining to behaviour of products and Multiproduct combinations, as well as searching means for searching through the Database for previous occurrences of similar requests. An Expert System utilizing machine learning capabilities generates the final solution and constantly updates the organization of the data in the Database in order to improve the effectiveness of subsequent searches. | 8 |
PRIOR RELATED APPLICATIONS
[0001] This application is a 371 U.S. National Phase Patent Application which claims priority to PCT Patent Application No. PCT/CU2012/000008, filed Dec. 27, 2012 and Cuba Patent Application CU/P/2011/0244, filed Dec. 27, 2011 and incorporates the above-referenced applications in their entireties by reference thereto.
DESCRIPTION OF THE INVENTION
[0002] This invention relates to the chemical and pharmaceutical branches, and more specifically with obtaining new molecular entities, synthetic variants of steranes fused steroids of a general formula:
[0000]
[0003] For compounds of general formula I, II, III and IV, R 1 , R 2 and R 4 represents H, hydroxyl, cetal, alcoxyl, alkanyloxyl, alkenoxyl and alkoxylcarbonyloxyl groups (preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof).
[0004] For compounds of general formula I, II, III and IV, R 1 , R 2 and R 4 also represents an amine group, preferable substituted with alkylamines, dialkylamines, alkenylamines, dialkenylamines, aminecarbonyloxyl, alkinylamines and dialkinylamines groups (preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof).
[0005] For compounds of general formula I, II, III and IV, R 1 , R 2 and R 4 also represents amide, thiol, sulphinyl, sulphonamide and sulphonyl groups, preferable substituted with alkylaryl, alkanoyloxyaryl, alkanoyloxyaryl and alkenylaryl groups (preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof).
[0006] For compounds of general formula I, II, III and IV, R 1 , R 2 and R 4 also represents an cyane, thiocyane, isothiocyane groups, preferable substituted with alkyl, acidalkyl, alkanyloxylalkyl, arylalkyl, heteroarylalkyl, arylalkenyl, heteroarylalkenyl, arylalkinyl, arylalkylalkinyl, alkanoyloxyarylalkylalkinyl, heteroaryloxyalkinyl, heteroaryloxyalkinyl, oxoalkinyl, or cetal groups, wherein the cyanilalkinyl substituents can be substituted in turn by heteroarylalkinyl, hydroxyalkinyl, alcoxyalkinyl, aminoalkinyl and acyloaminoalkinyl groups (preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof).
[0007] For compounds of general formula I, II, III and IV, R 1 , R 2 and R 4 also represents a phosphoryl group, preferable substituted with alkylaryl, alkanyloxyaryl, alkenyloxyaryl and alkenylaryl groups (preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof).
[0008] For compounds of general formula I, II, III and IV, R 3 represents an H or hydroxyl group.
[0009] For compounds of general formula I, II, III and IV, R 5 represents H, hydroxyl, cetal, amine, thiol and cyane groups.
[0010] For compounds of general formula I, II, III and IV, R 6 represents methyl, lipid chains derived from mono or polyunsaturated fatty acids having up to 24 carbon atoms and proteins union site groups.
[0011] For compounds of general formula III and IV, R x represents alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof, wherein x is different from zero.
[0012] For compounds of general formula III and IV, R x also represents alkylaryl, alkanyloxyaryl, alkenyloxyaryl and alkenylaryl groups, preferable alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof, wherein x is different from zero.
[0013] These novel compounds can serve as a basis for therapeutic drugs to treat anxiety, ischemia, epilepsy, hypertension and other cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric, and neurological disorders, as well as other disorders related to acute and chronic inflammation.
[0014] Compounds of I, II, III and IV type are obtained by tosylation of 3β-hydroxy group and hydroxylation of 6β-one group, in presence of carbonates. Oxidative reactions can employ Jones's reactive (CrO3-H2SO4), Collins's reactive (CrO3-acetone) or pyridinium chlorocromate, as oxidant agents according to Aburatani's method; or with oxoammonium-iodine salts.
[0015] Steroids were one of the first pharmacological entities denominated privileged anti-inflammatory structures. Generally, most steroid molecules act as immunosuppressive agents, through molecular mechanisms including rapid non-genomic and genomic effects. However some steroids, such as hydrocortisone, cortisone, prednisone, prednisolone, fludrocortisone, deoxycorticosterone, methylprednisolone, triamcinolone, paramethasone, betamethasone, dexamethasone, triamcinolone acetonide, acetoxyprenolone, among others, causes some toxicological effects in several organs. Therefore long-term clinical usage of those molecules induces different side effects, such as cellular metabolic disorders, osteoporosis, hypertension and gastrointestinal diseases.
[0016] In other words, the well-known neurosteroids have sedative, anesthetic and anti-convulsive affects in animals and humans. Such biological activity are due to the modulation of neuronal excitability, through the interaction between membrane receptors and ion channels, principally GABA A receptor, which acts in a bidirectional inhibitory system connected to different areas in the CNS.
[0017] Disclosed herein are new steroid compounds and compositions and their application as pharmaceuticals for the treatment of anxiety, ischemia, epilepsy, hypertension and other cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric, and neurological disorders, as well as other disorders related to acute and chronic inflammation.
[0018] After an analysis of the structure of the molecules tested and their effects on vitality of damaged PC12, as an indicator of their neuroprotective potential, the use of synthetic variants of steroids fused with spirostanes cycles for treating cerebrovascular, neurodegenerative, neuropsychiatric and neurological diseases is justified.
[0019] The novelty in this invention is obtaining a spirosteroid molecular system for potential application in the treatment of cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric and neurological diseases, as well as the possibility of obtaining these spirosteroid systems using a simple method of synthesis and steroid sapogenin-like diosgenin, hecogenin and solasodine as starting materials.
[0020] There are several patents describing steroids derivatives for treating CNS and inflammatory diseases. In such cases, however, no description is made of the fusion of these nucleuses or the inclusion of spirostanes cycles to form a new pharmacologic entity. Patents using different substituents of the spirosteroid nucleus, having no relation with the subject matter of our invention are listed below:
BACKGROUND OF THE PRIOR ART
[0021] Patents U.S. Pat. No. 6,909,007, U.S. Ser. No. 186,708 and U.S. Pat. No. 5,116,829 describe the process of obtaining steroid molecules as potential anti-inflammatory entities less toxic than conventional pharmaceuticals, but use hydrogen-type substituents, alkyl and alkenyl chains, and aromatic rings of the phenyl, carboxyphenyl, acetoxyphenly, methoxycarboxyphenyl and dimethylcarboxyphenyl type. U.S. Pat. No. 5,599,807 describes the process of obtaining steroid molecules with an ester group between carboxyl group of kinoloncarboxylic acid and alcoholic hydroxyl group in position 21, with anti-bacterial and anti-inflammatory activities without long-term immunosuppression.
[0022] Patent US20030092692 describes chemical production and application of known and novels 7α-hydroxy steroid molecules on in vitro cytoprotection of neuronal cells and for treatment of acute diseases affecting CNS. However, described substituents only includes H, hydroxyl, sterified hydroxyl, alkyl, amine, alkylamine and dialkylamine groups. The patents US200330186953, US20090227551 and US201001304559 also describes the process of obtaining, and application as treatment of neurological diseases, of 3-hydroxy-7β-hydroxy and some cetonide derivatives, but their described substituents omit spirostanes cycles.
[0023] Patent US20040072806 describes only the methods, combinations and applications for treatment and prevention of neurological diseases, of natural 22R-hydroxy steroid derivatives substituted with spirost-5-en-3-ol groups.
[0024] The spirosteroid synthetic variants, the subject matter of our invention, showed some kind of action upon neuronal cells. However, the degree of the action depends on the nature of the R substituent at the 3 and 6-positions and the nature of R 2 and R 4 substituents.
[0025] General experimental conditions: Fusion temperatures were determined with an Electrothermal 9100 capillary hot plate equipment. IR spectrums were registered by a Philips Analytical PU 9600 FTIR spectrophotometer in KBr tablets. The NMR 1H and NMR 13C were recorded by a Brucker ACF-250 spectrometer operating at 250.13 MHz and 62.50 MHz, respectively. All those records were determined at 26° C., with CDCl3 as solvent and TMS as internal reference. Spectral assignments in NMR were developed employing the correlating spectrum (HHCOSY y HCCOSY) for some compounds, edition DEPT technique, and comparing with spectral data of compounds reported from literature.
EXAMPLES OF PROCEDURE
Example 1
Synthesis of 6β-hydroxy 6-one poly-hydroxy Derivatives
[0026] Those compounds with 3α,5-cyclo-6-one structure, were obtained through Aburatani's method, which employs the 5-en-3β-ol system as starting material and consists in three principals stages. These experimental stages are performed in a continuous way and are the following:
Tosylation of diosgenin/hecogenin. Mesylation with MSCl, triethylamine and butanone. Isomerization with NaHCO 3 aqueous solution to form the i-steroid. Oxidation of C-6 hydroxyl group with Jones's reactive, to obtain the 3α,5-cyclo-6-one derivative. Isomerization of i-systems to Δ 2 spirostanic systems in presence of Li 2 CO 2 /CaCO 3 /DMFA/HMFTA. Dihydroxylation in catalytic conditions (CHCl 3 /NaOH/cetyltrimethylammonium bromide), and catalysis by solid bentonite acids and pyritic ashes. Catalytic esterification with niobyl-vanadyl acetate/acetic anhydride. Epoxide opening with bentonite-pyritic ashes and a reflux in water.
[0000]
Example 2
Chemical and Structural Characterization of 6R-hydroxy 6-one poly-hydroxy Derivatives
[0035] The spectroscopic reported data corroborates the proposed structures. In FTIR spectrums are observed the typical bands in 1350 to 850 cm −1 zones, due to vibrations of spiroketal systems, associated to narrowing in C—C and C—O bonds. These evidences demonstrate there were not structural degradation changes in E and F rings. Moreover, the band in 880-910 cm −1 is about twice more intense than the band in 925-910 cm −1 , therefore all synthesized compounds belongs to 25R series. The frequency zone 1713-1735 cm −1 , corresponding to acetoxy group CH 3 —CO—O—, is typical for synthesized acetoxy derivatives. The band in 1360 and 1170-1175 cm −1 , corresponding to asymmetric and symmetric vibrations of SO 2 group (v SO 2 s and as.), are characteristic for the tosyl derivative. To this grouping corresponds the band in 1588 cm −1 assignable to an aromatic v C═C.
[0036] The NMR- 1 H and 13 C spectroscopy were informative in order to elucidate the structure of synthesized compounds. Among common significant signals are those of protons from methyl groups (CH 3 ) 18, 19, 21 and 27, and those of protons H 2 -26 and H-16α. The H 2 -26 signal is complex and corresponds to both chemical shifts H-26α and H-26β, which practically does not vary in the series of studied compound. The axial H-26β is a triplet with δ=3.32 ppm; and its multiplicity results from a germinal quasi degenerate and vecinal axial-axial (J 2 ≅J 3 =10.6 Hz) double coupling. The H-26β signal is a double doublet with δ=3.5 ppm; and its multiplicity results from a germinal coupling (J 2 =10.6 Hz) and vecinal equatorial-axial (J 3 ea =2.6 Hz). With a chemical shift of γ=4.4 ppm, the appearance of a double doublet is typical for H-16α, due to its coupling with protons 15β (equatorial), 15α and 17β (quasi-equatorials).
[0037] The signals of olefinic protons H-2 and H-3 with δ=5.5 and 5.7 ppm, respectively, are characteristics for Δ 2 -6-oxo steroidal compounds. The signals of 7β and 5α protons appear superpose in 2.3-2.4 ppm. In NMR- 13 C C-2 and C-3 signals are unshielded to δ=124.4 and 124.5 ppm, respectively, while C-4 shields to 21.7 ppm.
[0000]
TABLE 1
Chemical shifts (δ, ppm) of carbon atoms from A and B rings,
and C-19 of (25R)-3α,5-cyclo-spirostan-6β-ol (G1) and
(25R)-2,3-dihydroxy-spirostan-6β-ona (G2).
Compounds
Carbons #
G1
G2
1
33.2
40.15
2
24.9
68.23
3
—
68.31
4
11.8
26.34
5
38.8
50.73
6
73.5
211.79
7
37.4
46.81
8
29.5
37.14
9
24.2
53.72
10
43.0
42.51
19
20.2
13.63
Example 2
Effects of the Synthetic Spirosteroids Series on Cellular Vitality of PC12 Exposed or Not to Glutamatergic Damage
[0038] PC12 constitute a neuron-like cell line widely employed in several models of neurological diseases. The patophysiological mechanisms which can be simulated in those in vitro models, allows the use of PC12 cells in evaluation of therapeutic candidates.
[0039] The synthetic spirosteroids series (10 μM of each molecule) was evaluated on PC12 cells exposed to L-glutamate (20 mM) for 24 h. Previously, those cells were routinely cultivated in RPMI 1640 medium, supplemented with equine serum (10%) and fetal bovine serum (5%) in a 37° C. and 5% CO 2 atmosphere. In the beginning of the experiment, cells were seeded in 96-well microplates at a cellular density of 150,000 cells/mL. After 24 h of exposition to glutamatergic damage and spirosteroids treatment, cellular vitality was determined with 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT), which is metabolized by mitochondrial deshydrogenases in living cells. Our results (Table 2) demonstrate an anti-glutamatergic and neuroprotector effect of several spirosteroids molecules (S) related to some structural features. Specifically, between the most active molecules was 2α,3α-dyhydroxy-(25R)-spirostan-6-one and 3,6-dione-(25R)-spirostan. All molecules of the synthetic spirosteroids series were non cytotoxic at the concentration employed for the in vitro anti-glutamatergic assay (data no shown).
[0000]
TABLE 2
Anti-glutamatergic effect of the synthetic spirosteroids series.
Experimental
Groups
Absorbance (540 nm)
Untreated
0.557
0.471
0.519
0.425
0.649
0.716
L-glutamate
0.342
0.341
0.347
0.534
0.271
0.385
S1
0.619
0.41
0.396
0.473
0.527
0.557
S2
0.562
0.372
0.343
0.42
0.452
0.536
S3
0.538
0.543
0.357
0.524
0.505
0.466
S4
0.653
0.605
0.489
0.607
0.484
0.643
S5
0.646
0.632
0.378
0.557
0.543
0.552
S6
0.58
0.592
0.545
0.562
0.435
0.589
S7
0.516
0.558
0.437
0.453
0.391
0.636
S8
0.467
0.28
0.311
0.547
0.448
0.482
S9
0.412
0.311
0.27
0.499
0.501
0.545
S10
0.301
0.257
0.262
0.499
0.513
0.41
S11
0.364
0.481
0.392
0.511
0.47
0.445
S12
0.384
0.423
0.58
0.501
0.625
0.486
S13
0.571
0.403
0.593
0.469
0.626
0.382
S14
0.415
0.381
0.4
0.586
0.657
0.659
S15
0.423
0.417
0.579
0.567
0.612
0.552
S16
0.348
0.394
0.438
0.53
0.567
0.563
S17
0.345
0.468
0.329
0.438
0.545
0.318
S18
0.284
0.346
0.346
0.44
0.411
0.464 | The present invention relates to the fields of chemistry and pharmacy and, in particular, to the production of novel molecular entities: esterane derivatives fused with spirostanes rings, acting upon the Central Nervous Systems (CNS). From diosgenin, a naturally occurring sapogenin, with some subsequent transformations thereof, spirosteroid derivatives of the I-IV general formula can be obtained, with a cyclopentaneperhydrophenantrene nucleus fused to a 25R-spirostanes nucleus. Such molecular entities have an anti-inflammatory and anti-glutamatergic actions that can be used to treat inflammatory, cerebrovascular, neurodegenerative, neuropsychiatric, and neurologic diseases. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This present application claims priority to TAIWAN Patent Application Serial Number 099126389, filed on Aug. 6, 2010, which are herein incorporated by reference.
TECHNICAL FIELD
[0002] The present invention is generally related to the field of a recycling PET, and more particularly to a method for manufacturing porous materials from waste PET bottle.
BACKGROUND OF THE RELATED ART
[0003] Polyethylene Terephthalate (PET) material is widely applied in various packs and containers of the food and other commodities. According to the statistics, the consumption of PET bottle is about ˜30 million tons every year around the world, which is equivalent to about 1 trillion PET bottles. In the face of such a large quantity of waste PET, how to recycle and reuse the PET bottle is an important issue for the industry.
[0004] For example, the prior art has used the recycled PET (also known as R-PET) for applying to the textile industry by the mechanical process, or for re-making the containers or the bottles (also known as R-PET bottle). Based on the carbon chain of the polymer is strong and, it is relatively difficult to break, weaken or degrade the carbon chain into small molecules. Thereby, there are only 4% PET recycling method use the chemical method to break down the PET into monomers directly, or add other oligomer, to form another polymer materials for applying to the petrochemical industry of the resin-coated. For example, the purpose of the prior art is to extract the monomer of terephthalic acid (TA) from recycled PET bottles which has more economic value.
[0005] However, no matter what the method is, the aforementioned processes consume more energy and additionally increase the carbon dioxide exhaustion. In addition, the processes had only limited the monomers recycling and the textile recycling, which has relatively lower economic value. Therefore, under the low profit situation to recycle the PET, it is a negative effect to promote the environmental protection.
[0006] As above mentioned, a recycling method for waste PET which has greater economy benefit is in demand. Therefore, the present invention provides a method for manufacturing porous material from waste PET bottle.
SUMMARY
[0007] One object of the present invention is to provide a method for manufacturing porous material from waste PET bottle to offer relatively higher economic value of recycling PET. In a preferred embodiment, the waste PET recycles to produce the white phosphor of single-emitting-component (SEC).
[0008] The present invention provides a method for manufacturing porous material from waste PET bottle, the method comprises steps of providing the transition metal or d 10 configuration metal source, amine source, PET source, phosphate derivative source, and water to be reacted in a closed container under temperature between 120 to 200° C., and pressure between 1 to 100 atm for between 48 to 168 hours, for forming a reaction mixture; and the porous material is precipitated from the reaction mixture.
[0009] The present invention provides a porous material, the porous material is made by the above mentioned method, wherein the transition metal or d 10 configuration metal source is Zinc source and the amine source contains pyridine group, such as 4,4′-trimethylenedipyridine (TMDP).
[0010] The present invention provides a porous material, the porous material is transition metal or made by the above mentioned method, wherein the d 10 metal source is Zinc source and the amine source is alkyl polyamine, such as Tris(2-aminoethyl)amine (TREN).
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A illustrates a diagram of the NTHU-2 chemical constitution of the prior art;
[0012] FIG. 1B illustrates a diagram of the NTHU-3 chemical constitution of the prior art;
[0013] FIG. 2 illustrates a method for manufacturing the porous material from waste PET bottle in accordance of the embodiment of the present invention;
[0014] FIG. 3A illustrates a diagram of the NTHU-2 PET chemical constitution in accordance of the embodiment of the present invention;
[0015] FIG. 3B illustrates a diagram of the TMDP which acts as protonated organic templates residing in extra-large channels within the NTHU-2 PET structure in accordance of the embodiment of the present invention;
[0016] FIG. 3C illustrates a diagram of the BDC(1,4-benzenedicarboxylate) ligands as pillars within the NTHU-2 PET structure in accordance of the embodiment of the present invention;
[0017] FIG. 3D illustrates a diagram of the NTHU-3 PET chemical constitution in accordance of the embodiment of the present invention;
[0018] FIG. 3E illustrates a diagram of the TREN which acts as protonated organic templates within the NTHU-3 PET structure in accordance of the embodiment of the present invention;
[0019] FIG. 3F illustrates a diagram of the TA of NTHU-3 PET chemical constitution in accordance of the embodiment of the present invention;
[0020] FIG. 4 illustrates a diagram of the TA recycling condition in accordance of the embodiment of the present invention;
[0021] FIG. 5 illustrates an X-ray diffraction pattern of NTHU-3 PET dissolved in different solvents in accordance of the embodiment of the present invention;
[0022] FIGS. 6A and 6B illustrates a photo-luminescent spectrometry diagram of NTHU-2 PET in accordance of the embodiment of the present invention.
DETAILED DESCRIPTION
[0023] The porous material mentioned herein is generally speaking only a material having void spaces (pores) inside and/or on surface. For example, the porous material includes but not limited the NTHU-X material which is named by National Tsing Hua University (NTHU). For example, the structure of NTHU-2 is shown as in FIG. 1 a and the structure of NTHU-3 is shown as in FIG. 1 b.
[0024] As shown in FIG. 2 , the embodiment of the present invention provides a method 100 for manufacturing porous material from waste PET bottle. The method includes the following steps of providing the transition metal or d 10 configuration metal source, amine source, PET source, phosphate derivative source, and water in a close container to act as reactants. The reaction of these reactants will be controlled under temperature between 120 to 200° C., and pressure between 1 to 100 atm for around 48 to 168 hours. A reaction mixture is finally prepared after the step 102. The porous material is subsequently precipitated from the reaction mixture at step 104. In another embodiment, the PET source is from reagent.
[0025] In preferred embodiment, in the step 104, hydrothermal process is introduced to the reaction mixture to crystallize the porous material, more particularly, the insoluble material will be digested by the aforementioned reaction conditions and through the temperature difference convection, and thereby the porous material emerges from the reaction mixture after a certain period of time.
[0026] In the preferred embodiment, the conditions for the method 100 is preferably under temperature 160° C. and about pressure >1 atm for about 72 hours.
[0027] In preferred embodiment, transition metal or d 10 configuration metal source includes zinc containing source, manganese containing source, chromium containing source or other d 10 configuration metal.
[0028] In a preferred embodiment, the zinc source includes Zn metal, ZnCl 2 , Zn(NO 3 ) 2 .6H 2 O, ZnO 2 or the like.
[0029] In a preferred embodiment, the amine source includes pyridine or alkyl polyamine, such as Tris(2-aminoethyl)amine (TREN), 4,4′-trimethylenedipyridine (TMDP) or the like.
[0030] In one preferred embodiment, the phosphate derivative source includes phosphoric acid, phosphorous acid, hypophosphorous acid, hypophosphorous acid or the like.
[0031] In preferred embodiment, the porous material (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA)(H 2 O) 2 (hereinafter referred to as NTHU-3 PET ) is manufactured at first. As shown in FIG. 3D , an organic-inorganic hybrid material-NTHU-3 PET which is composite of TREN (shown in FIG. 3E ) within the inorganic layer Zn 3 (PO 4 ) 2 . The tri-protonated TREN functions as a template and it achieves the status of charge balance with the inorganic layer Zn 3 (PO 4 ) 2 to form a pseudo neutral layer which is filled with TA shown in FIG. 3F and water.
[0032] In FIG. 3D , TA and water molecules separately exist in-between NTHU-3 layers. Furthermore, the manufactured porous material also could be (H 2 TMDP)[Zn 2 (HPO 4 ) 2 (BDC)] (hereinafter referred to as NTHU-2 PET ), as shown in FIG. 3A . Each ZnO 4 tetrahedron of the inorganic layer is corner-share with three HPO 4 tetrahedrons respectively by three oxygen atoms, A [4,8 2 ] two-dimensions inorganic layer is formed by the three connected tetrahedrons. In FIG. 3C , The framework structure consists of neutral sheets of metal phosphate which are pillared through BDC anions to form extra-large pore in which 4,4′-trimethylenedipiridine cations are located. For example, TMDP as shown in FIG. 3B , are filled in the inorganic layer to achieve the charge balance of whole structure. If the cations are removed, a nano-tunnel which is 1.30 nm×0.65 nm could be observed. The hydrogen atoms in FIG. 3A to 3F are omitted.
[0033] In an embodiment of the present invention, the chemical reaction for NTHU-3 PET is
[0000]
[0034] The above reaction is not limited to a specific dosage and ratio, wherein TREN is Tris(2-aminoethyl)amine. In a preferred embodiment, if ZnCl 2 1 mmol, TREN 4 mmol, PET 0.3 g, H 3 PO 4 solution 6 mmol (i.e. concentration 85%, 0.405 mL), H 2 O 5 mL, then (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA)(H 2 O) 2 0.3105 g can be generated. The yield of the embodiment is about 86.49% and the rate of PET consumption is about 100%. In most of the embodiment, the product is (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA)(H 2 O) 2 . If zinc source is Zn(NO 3 ) 2 .6H 2 O which has six lattice waters, it could generate (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA)(H 2 O) 2 and (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA), wherein (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA) (H 2 O) 2 is 0.3418 g.
[0035] In further embodiment of the present invention, the chemical reaction formula of NTHU-2 PET is:
[0000]
[0036] The above reaction formula is not limited to specific dosage and ratio, wherein BDC is 1,4-Benzenedicarboxylate and EG is ethylene glycol. In the preferred embodiment, if ZnCl 2 1 mol, TMDP 6.4 mol, PET 0.5 g, H 3 PO 4 solution 6 mmol (i.e. concentration 85%, 0.405 mL), H 2 O 5 mL, it could produce (H 2 TMDP)[Zn 2 (HPO 4 ) 2 (BDC)] and (TMDP)(BDC). The consumption rate of the PET is about 98%. The (TMDP)(BDC) byproduct is dissolved by HCl, and then it could recovered TA in 76%. More details about the (TMDP)(BDC) byproduct used to recycle the terephthalic acid (TA) are provided in following description.
[0037] Table 1 lists the crystal apparent, shape, size and reliability factors for the structures of NTHU-2 PET and NTHU-3 PET prepared from the method of the present invention. In order to provide comparison, NTHU-2 and NTHU-3TA.H 2 O made by conventional synthesis are enclosed. Table 1 as follows:
[0000]
TABLE 1
Reliability
Crystal mophology
size (mm 3 )
factors
NTHU-2
Lamellar; orange
0.28 × 0.53 × 0.03
R1 = 0.0766
R2 = 0.2230
NTHU-2 PET
Columnar; orange
0.5 × 1.2 × 0.23
R1 = 0.0514
wR2 = 0.1496
NTHU-
Lamellate hexagon;
0.35 × 0.43 × 0.01
R1 = 0.0463
3TA•H 2 O
colorless
wR2 = 0.1340
NTHU-3 PET
Lamellate hexagon;
1.48 × 1.6 × 0.25
R1 = 0.0341
colorless
wR2 = 0.0716
[0038] As shown in Table 1, the NTHU-2 PET made by the method 100 has better crystallization. The size of which is about 30 times the size of NTHU-2 and the actuarial structure reliability factors R1 and wR2 of NTHU-2 PET are also smaller than the ones of NTHU-2. Similarly, the NTHU-3 PET made by the method 100 has preferred crystallization. The size of which is about 400 times the size of NTHU-3TA.H 2 O and the actuarial reliability factors R1 and wR2 of NTHU-3 PET are both smaller than the R factors of NTHU-3TA.H 2 O.
[0039] In general, the crystal with larger size has better crystal quality. The smaller the R factors R1 and wR2 the more reliable the structure is. Therefore, Table 1 could evidence that the size and the reliability factors of the crystal, for instance, NTHU-2 PET and NTHU-3 PET made by the method 100 is better than the conventional crystallization method. In summary, although the chemical structure of NTHU-2 PET is essentially the same as NTHU-2, the crystal quality of NTHU-2 PET generated by the method 100 is largely improved as compared to NTHU-2.
[0040] In other words, the conventional method for manufacturing NTHU-2 could not obtain exactly the same the crystal quality as NTHU-2 PET . On the other hand, the crystal quality of NTHU-3 PET is not exactly the same as NTHU-3TA.H 2 O. Therefore, the present invention provides a porous material called NTHU-2 PET that is generated by the method 100. The present invention also offers the method for producing further porous material called NTHU-3 PET .
[0041] Take NTHU-2 PET as an example, the recycling economical value of a trivial waste PET bottle with 30 g and 600 mL is originally none, but under the present novel method, it could be effectively equivalent to about 300 mL EG and 24 g of terephthalic acid (TA) molecules for manufacturing porous material with higher economical value and producing the byproducts. FIG. 4 illustrates the byproduct (TMDP)(BDC) of the NTHU-2 PET made by the method 100 and the byproduct (TMDP)(BDC) is a co-crystal product. After dissolving by HCl, TA is precipitated and could be observed in the right one of FIG. 4 . Therefore, in the preferred embodiment of the present invention, the byproduct (co-crystal) recycle rate of TA is more than about 72%. In another words, under the method 100 for manufacturing the NTHU-2 PET , most of the residual TA could be precipitated from the byproduct to recycle TA. Comparatively, the conventional method for NTHU-2 fails to produce the byproduct mentioned above; it needs to soak NTHU-2 for more than about 5 days to crystallize the co-crystal.
[0042] As shown in above chemical reaction formula of NTHU-2 PET , in the preferred embodiment, 0.5 g waste PET may create 5 mL EG solvent and 0.4 g TA. In turning of the market values of TA and EG, the manufacture of NTHU-2 PET could save costs about US $8 by the usage of 600 mL waste PET bottles with mean weight of 30 g in chemical reaction.
[0043] In an embodiment, if the waste PET is prepared with specific ratio to replace the conventional TA by the present method to produce NTHU-3 PET , almost 100% PET would be consumed. As shown in above chemical reaction formula of NTHU-3 PET , in an embodiment, the economical value of 0.3 g waste PET is equal to the one of 1 mmol TA for forming 0.3105 g (H 3 TREN) 2 [Zn 3 (PO 4 ) 2 ](TA)(H 2 O) 2 . In turning of the market economical value of TA, it could save the cost of about 1 US dollars by using a 600 mL waste PET bottle with mean weight of about 30 g.
[0044] FIGS. 6A and 6B illustrate the photo-luminescent spectrometry diagram of NTHU-2 PET excited by various wavelength of the excitation light source from white light to yellow-orange light in accordance with different positions of the excitation spectrum.
[0045] As shown in FIGS. 6A and 6B , NTHU-2 PET generated by the method 100 could be applicable to broad wavelength range of the excitation light source. For example, the exciting light from 300 nm to 420 nm wavelength could allow the NTHU-2 PET emit the white light; and the exciting light from 440 nm to 480 nm could allow NTHU-2 PET emit the yellow light, wherein while the excitation light wavelength is about 365 nm, NTHU-2 PET emits the relatively pure white light. Hence, NTHU-2 PET generated by the method 100 has function as a white light phosphor LED of the single-emitting-component (SEC). The advantage of white light phosphor LED includes the characteristics of preventing the device from the internal color balance issues caused by mixing multi-color lights to generate the while light. At the time of the application, the existed SEC white phosphors are quite rare, and it could not be manufactured from waste PET as the present invention.
[0046] One of the advantages of the present invention is to provide a preferred way to recycle the waste PET, especially the bottles of plastic numbered by one.
[0047] Another advantage of the present invention is that the NTHU-2 PET has potential to functions as a white light phosphor LED of SEC. The cost for manufacturing the white light LED of SEC is significantly reduced due to the cost of the waste PET recycling is inexpensive.
[0048] Another advantage of the present invention is that the crystalline properties of NTHU-2 PET and NTHU-3 PET are superior to original NTHU-2 and NTHU-3. For example, both have the larger crystal size and the smaller reliability factors.
[0049] Another advantage of the present invention is that the method of recovering TA is easy for NTHU-2 PET and NTHU-3 PET . For example, the residual TA would form the co-crystal byproduct spontaneously to facilitate to recover TA. In some embodiments, there are about 72% TA could be recovered from co-crystals which are the byproduct in the method of manufacturing NTHU-2 PET .
[0050] On the other hand, TA recycle can be done in different solvents by ultrasonic energy at the room temperature rather than by using strong acid by the conventional process. FIG. 5 illustrates an X-ray diffraction pattern of NTHU-3 PET made by the method 100. In the lower two graphs, they illustrate respectively the X-ray diffraction patterns of NTHU-3TA.H 2 O and NTHU-3 which are made by conventional method and the upper three graphs illustrate the X-ray diffraction patterns of NTHU-3 PET powder which are dissolved respectively in dimethyl formamide (DMF), acetone and ethyl alcohol solution. The experimental conditions are generally that NTHU-3 PET is ground into powder and 0.04 g of the powder is put into different solvent (20 mL). Subsequently, the solution is vibrated by ultrasonic for 2 hours. As shown in FIG. 5 , dimethyl formamide (DMF), acetone and ethyl alcohol are chosen to be solvents and NTHU-3 PET is mixed with the solvents. Partial NTHU-3 PET phase are transferred to NTHU-3 through ultrasonic energy. Thus, TA is recovered by the present invention.
[0051] The above descriptions are the preferred embodiments of the present invention. They are intended to explain the present invention but not to limit the range of the present invention. For brevity, some well known components of steps may not be illustrated. The range of the present invention should base upon the claims and their equivalences. | A method for manufacturing porous material from waste PET bottle, the method comprising: providing transition metal or d 10 metal source, amine source, polyethylene terephthalate (PET) source, phosphate derivative source, and water to be reacted in a closed container under temperature between 120 to 200° C., and pressure between 1 to 100 atm for between 48 to 168 hours, for forming a reaction mixture; and precipitating the porous material from the reaction mixture. The method of the present invention uses the PET bottle polymers adequately to release two monomers in the reaction effectively and form porous or laminar material, such that the porous material can have photoluminescent phenomenon and can have light performance from white light to yellow-orange light under various excitation sources. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to structure venting, in particular, to a flood vent that opens to permit the flow of water in or out of a structure, such a house or garage, when the water level rises thereby avoiding an excessive pressure differential to develop between the interior and exterior of the structure as well as damage or failure of the structure.
[0003] 2. Description of the Related Art
[0004] To eliminate or at least reduce damage due to flooding, several building code entities as well as the federal government have developed rules and regulations requiring structures with enclosed spaces located below defined flood plain levels to include automatic equalization of interior and exterior hydrostatic pressure caused by floodwaters. The rules and regulations require structures to be designed and built to allow floodwaters to move in and out of a structure freely. The Federal Emergency Management Agency (FEMA) requires compliance with FEMA Technical Bulletin 1-93. Other governmental agencies required compliance with the International Building Code and/or ASME 24-05 and 24-98.
[0005] A number of devices have been developed to reduce or eliminate the pressure differential that may develop between the interior and exterior of a structure. In 1935, Hodge developed and was issued in 1938, U.S. Pat. No. 2,105,735 for a device that would relieve pressure that may develop within a closed chamber. The device focused upon the release of gas pressure from within the structure but provided for no means to reduce the pressure differential that could develop when the internal pressure of the closed chamber was less than the surrounding pressure. In 1954, Wolverton filed an application for a double acting relief valve and was issued a U.S. Pat. No. 2,774,116 in 1956. Wolverton's double acting relief valve addressed the shortfall for Hodge's device by double hinging a plate mounted in a structure's door that would activate to equalize the pressure differential, if any, between a storm door and main door. The Wolverton device did not address the issues associated with pressure differentials created by floodwaters, nor did the Wolverton device address ventilation.
[0006] In 1993, Wagedes filed an application for an improved louvered basement vent and was issued U.S. Pat. No. 5,293,920 in 1994. Wagedes' improved louvered basement vent included a frame and a screened opening. The louvers could be held open by engaging louver detents against frame tabs. The louvers open automatically to relieve excessive pressure in the structure and would remain open if the louvers engaged the frame tabs. While the Wagedes improved louvered basement vent was screened—where the prior discussed patents were not, it was limited to addressing only one type of pressure differentials—namely over pressurization of the structure. Furthermore, the Wagedes improved louvered basement vent required human intervention to reset the louvers in a closed position if the detents were engaged.
[0007] In 1994, Schedegger and others filed a patent application for a plastic foundation vent and were issued U.S. Pat. No. 5,487,701 in 1996. The Schedegger device is similar in construction to the Wagedes device, in that it comprised independent louvers that could be held in an open position as well as a screened opening. Like Wagedes' device, Schedegger's device was limited to addressing only one type of pressure differential and required human intervention to release opened louvers.
[0008] In 1999, Montgomery filed a patent application for a device and method for relieving flooding from an enclosed space. He was issued U.S. Pat. No. 5,944,445 in 1999. The Montgomery device includes a swinging door capable of swinging both in and out of the structure to permit tidal water flow in and out of the structure. The swinging door has a spring loaded hinge and is held in a closed position by a catch assembly. The catch assembly includes an adjustable screw, a catch spring, a ball bearing and threaded sleeve. The automatic opening of the device in response to floodwaters pressing against the door is a function of adjusting the catch assembly. Improper adjustment of the catch assembly could range from a premature door opening (by animals) to failure of the door to open. Furthermore the manufacturing and assembly of such a device require skilled labor. In the same year, Montgomery and other filed a patent application for a foundation flood gate with ventilation. U.S. Pat. No. 6,287,050 was issued in 2001 for the device. Like his previous device, the foundation flood gate with ventilation included a swinging door capable of swinging in both directions to allow water to flow in or out of the structure. Automatic activation of the door is performed by a catching assembly. The catching assembly included a float for sensing the level of the water and releasing the door when the level exceeds a preset height. Automatic opening of the door requires an intact and freely movable float within the device. While requiring fewer parts than his previous device, the catching assembly still requires skilled labor to manufacture and assemble. In 2001, Montgomery and others filed a similar application for a foundation flood gate with ventilation but the latch assembly senses fluid force acting upon the door rather than relying upon a float to sense water level. In 2002, the United States Patent and Trademark Office issued U.S. Pat. No. 6,485,231 for the device. The device included a latching assembly which requires skilled labor to manufacture and assemble for proper operation.
[0009] Sprengle and other filed an application in 2002 for a flood gate for a door. In 2004, U.S. Pat. No. 6,692,187 was issued for the device. The Sprengle device incorporated both the pressure and float sensing features of Montgomery's devices and further allowed for the gate to be used in an overhead door application without the door automatically swinging open when the overhead door is opened. Like the Montgomery devices, the Sprengle device requires skilled labor to manufacture and assemble for proper operation.
[0010] Finally, in 2007 Albanese was issued U.S. Pat. No. 7,270,498 for a flood vent which relies upon a door with floatation slideably mounted to a frame which automatically opens (or closes) based upon the level of the floodwaters. While Albanese reduces the number of moving parts and thereby reduces the need for skilled labor, the device still requires proper manufacturing tolerances and assembly to ensure free sliding movement of the door within its tracks. Furthermore the Albanese device has no means to automatically open in response to force upon the door.
[0011] As can be seen above the need for a flood vent that can open automatically, provide ventilation, yet have a minimal number of moving parts is desirable.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to a flood vent 10 comprising a shuttered duct 15 , with an upper and lower region, formed in a housing 20 fixed in a structure, such as a house, building, wall, door or overhead door at an elevation above ground level. See FIGS. 1 , 4 , and 6 . A lower region of duct 15 is angled down between two degrees)(2°) and eight degrees (8°) from a horizontal plane to form a sill 28 that sheds water to an exterior of the structure. See FIGS. 1 , 4 , and 6 . The present flood vent 10 includes a shutter 30 which is pivotally fixed in duct 15 . Duct 15 , sill 28 and shutter 30 are configured to allow the unimpeded movement of floodwaters in and out of the structure, when present; and further deter animals from using the flood vent 10 as a passageway in and out of the structure. Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The present invention is further described in connection with the accompanying drawings, in which:
[0014] FIG. 1 is an exploded isometric view of an embodiment of the flood vent.
[0015] FIG. 2 is an isometric view of a hood for said flood vent.
[0016] FIG. 3 is an isometric view of an embodiment of a flood vent shutter.
[0017] FIG. 4 is an isometric view of an embodiment of a flood vent housing.
[0018] FIG. 5 is an isometric detail view of another embodiment of a flood vent shutter.
[0019] FIG. 6 is an isometric view of an embodiment of a flood vent.
[0020] FIG. 7 is an isometric view of an embodiment of a flood vent.
DETAILED DESCRIPTION OF THE INVENTION
[0021] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0022] Certain terminology will be used in the following description for convenience and reference only and not for purposes of limitation. For example, the words “rightwardly”, “leftwardly”, “upwardly” and “downwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the structure being referred to. This terminology includes these words, specifically mentioned derivatives thereof, and words of similar import. Furthermore, elements may be recited as being “coupled”; this terminology's use anticipates elements being connected together in such a way that there may be other components interstitially located between the specified elements, and that the elements may be connected in fixed or movable relation one to the other. Certain components may be described as being adjacent to one another. In these instances, it is expected that such a relationship so described shall be interpreted to mean that the components are located proximate to one another, by not necessarily in contact with each other. Normally there will be an absence of other components positioned there between, but this is not a requirement. Still further, some structural relationships or orientations may be designated with the word “substantially”. In those cases, it is meant that the relationship or orientation is as described, with allowances for variations that do not effect the cooperation of the so described component or components.
[0023] The present flood vent 10 comprises a bezel 26 connected to two opposing walls 22 , an upper wall 22 and a sill 28 to form a duct 15 within a housing 20 . See FIGS. 1 , 4 and 6 . The flood vent 10 has an interior duct opening 17 on the inside of the structure and an exterior duct opening 19 on the outside of the structure. See FIG. 4 . Duct 15 allows fluid communication between the interior and exterior of the structure when floodwaters rise above sill 28 .
[0024] Bezel 26 surrounds a periphery of an exterior duct opening 19 and serves to attach housing 20 to structure by fasteners or adhesive. Housing 20 can have outer dimensions that correspond with the nominal dimensions of concrete masonry units (CMU). In a preferred embodiment, housing 20 has outer nominal dimensions that correspond to a CMU-8, namely eight inches (8″) high, sixteen inches (16″) long and eight (8″) wide (all nominal dimensions). Housing 20 , walls 22 , bezel 26 , and sill 28 can be constructed of materials such as metal, plastic, concrete, cement, composites or a combination thereof.
[0025] A shutter 30 is pivotally fixed to an upper region of duct 15 so that shutter 30 is capable of swinging in two directions, namely in and out of the structure. It is contemplated that shutter 30 can move about a swing arc that can be approximately one hundred and sixty degrees)(160°) to approximately two hundred and twenty five degrees (225°).
[0026] A lower region of shutter 30 is releasably coupled to a portion of sill 28 by a fin 50 . A coupling region is that portion of shutter 30 swing arc where fin 50 is in contact with a portion of sill 28 , at least one tab 40 fixed to and projecting away from sill 28 , or a combination of both. Movement of shutter 30 to, from or through a coupling region is hampered by the releasable coupling of shutter 30 to sill 28 by fin 50 . The presence of at least one tab 40 fixed to and projecting away from sill 28 hampers movement of shutter 30 to, from, or through a coupling region. The size of a coupling region varies with the width of fin 50 , angle of sill 28 and the presence of at least one tab 28 . It is contemplated in one embodiment, that when fin 50 is within a coupling region, shutter 50 is in a closed position that substantially obstructs duct 15 and deters animal use of flood vent 10 as a passage through the structure. Movement of shutter 30 about a swing arc can be in response to a floodwater pressure differential in or across duct 15 , movement of floodwater against shutter 30 , floatation of shutter 30 , or a combination thereof.
[0027] Shutter 30 can be pivotally fixed to an upper region of duct 15 by a variety of pivoting mechanism known to those skilled in the art of flood vents. In a preferred embodiment, a pair of opposing pin holes 24 is formed in an upper region of shutter 30 to receive a corresponding pin 32 fixed and projecting away from an upper region of duct 15 . See FIGS. 1 , 3 , 4 , 5 , and 7 . This arrangement allows a shutter 30 to rotate freely about a substantially horizontal axis above sill 28 .
[0028] Fin 50 can be fixed to shutter 30 , sill 28 or neither as set forth in the following descriptions. In a first embodiment, fasteners 07 fix fin 50 to a lower region of shutter 30 so that it projects away from a lower region of shutter 30 . See FIGS. 1 and 3 . In such an embodiment, fin 50 can be fixed to a lower region of shutter 30 by fasteners 07 or slidably fixed to a lower region of shutter 30 by fasteners 07 passing through corresponding slots 52 formed in fin 50 . See FIGS. 3 and 5 . As the reader can appreciate, a slideably fixation of fin 50 to a lower region of shutter 30 alters the coupling region without altering the width of fin 50 . In a preferred embodiment, at least one tab 40 is fixed to and projects away from sill 28 to releasably couple with fin 50 to hamper movement of shutter 30 to, from or through a closed position or a coupling region. See FIGS. 1 and 4 . In a second embodiment, fin 50 is fixed to and extends away from sill 28 to releasably couple with a receiver 42 formed in a lower region of shutter 30 . See FIGS. 6 and 7 . In such an embodiment, the size of a coupling region is a function of the cross sections of fin 50 and receiver 42 as well as the angle of sill 28 . In a third embodiment, fin 50 is releasably coupled to both shutter 30 and sill 28 by a first receiver 42 formed in a lower region of shutter 30 and a second receiver 42 formed in sill 28 . It is contemplated that such an embodiment would require a user to couple or re-couple shutter 30 with sill 28 after movement of shutter 30 beyond a coupling region.
[0029] It is contemplated that duct 15 and shutter 30 can be circular, arcuate, polygonal or a combination thereof in shape when viewed from a duct opening 17 or 19 .
[0030] In another embodiment, a plurality of holes 34 is formed in shutter 30 to allow movement of fluid through shutter 30 . Such holes 34 allow ventilation between the interior and exterior of the structure when shutter 30 is in a closed position. It is further contemplated that a hood 36 can be removably fixed to shutter 30 to impede the movement of fluid through shutter 30 .
[0031] It is contemplated that shutter 30 and hood 36 can be constructed from metal, plastic, composites or a combination thereof. Furthermore, shutter 30 can be constructed with material(s) with a low density such that at least a portion of shutter 30 is buoyant in floodwater of a sufficient depth within said duct 15 .
[0032] In any of the embodiments described above, the presence of a substantial amount of floodwater within at least a portion of duct 15 causes shutter 30 to move about its swing arc and allows the flow of floodwater between an interior and exterior of the structure. In the absence of a substantial amount of floodwater within duct 15 , shutter 30 is in a closed position or within a coupling region to substantially obstruct duct 15 and deter animal use of flood vent 10 as a passage through the structure. Finally, the number of parts used in the different embodiments of the present flood vent 10 is greatly reduced over existing devices which in turn reduces the cost of manufacturing and assembly. Likewise, the reduction in parts eliminates or reduces the likelihood of failure.
[0033] A flood vent 10 and its components have been described herein. These and other variations, which will be appreciated by those skilled in the art, are within the intended scope of this invention as claimed below. As previously stated, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. | A flood vent is provided that allows the unimpeded flow of floodwater in a shuttered duct formed in a housing installed in a structure such as a building. A lower region of the duct is angled down between two and eight degrees from a horizontal plane to form a sill that sheds water to an exterior of the structure, and an upper region of the duct is pivotally fixed to a shutter positioned within the duct. The shutter is capable of swinging between a closed position and an open position in response to the presence of floodwater within at least a portion of the duct. Movement of the shutter to, from or through a closed position is hampered by a releasable coupling of the shutter to the sill by a fin. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
In the following references of related patents, optical brighteners, optical brightening agents (OBA's) and fluorescent whitening agents (FWA's) refer to the same type of specialty chemical. The brightening chemicals present in these patents do not solve the problem of yellowing caused by overdosage of OBA/FWA. In addition, none of the patents below discuss the use of FWA #71 on the application of wet-end and coating papermaking process.
U.S. Pat. No. 7,812,156 proposes a modified OBA which maintains the high solubility and strong fluorescent whitening effects of previous OBA's while decreases the anionic load that stresses the papermaking system.
U.S. Pat. No. 7,566,349 explores the use of a new FWA of amphoteric bis-triazinylaminostilbene derivative on the process of whitening synthetic or natural organic materials such as paper. This new type of FWA is not usually suppressed in performance when put in the cationic papermaking environment or when combined with residual anionic FWA's.
U.S. Pat. No. 3,790,443 presents a technique of utilizing a water-soluble hydroxymethylaminonitrile salt in the form of dry powder on papermaking materials to quench the fluorescence of optical brightening agents present in the papermaking materials. By adding an acid along with the quencher, some undesirable whitening effects of the OBA's could be neutralized.
US20120211188 discloses the preparation techniques for a specific concentrated aqueous disulfo-stilbene based FWA for optically whitening paper.
U.S. Pat. No. 8,475,630 introduces an aromatic ring based additive that can increase the retention rate of OBA's on paper materials. By using the aromatic ring on the additive to associate with the OBA molecules chemically, capacity for retention is improved.
U.S. Pat. No. 7,789,917 reveals the composition of an amphoteric stilbene OBA, which consists of a substrate and the associated stilbene (one of 4,4′-diamino-2,2′-stilbene disulfonic acid, biarylsulfonate-4,4′-diamino-2,2′-stilbene disulfonic acid, biaryldisulfonate-4,4′-diamino-2,2′-stilbene disulfonic acid, derivatives thereof, salts thereof, and mixtures thereof).
U.S. Pat. No. 7,497,971 describes the use of a mixture of FWA's based on dicyano-1,4-bis-styrylbenzenes and bisbenzoxazoles. Such mixtures of two or more components may exhibit a higher degree of whiteness than that of the sum of the individual components alone.
U.S. Pat. No. 8,262,858 and U.S. Pat. No. 7,914,646 identify the use of oxidative agents for the paper process which enhances the performance of OBA's and chelants. By analyzing various stages of the papermaking process that involve oxidative compositions and processes that preserve and enhance the brightness and improve color of pulp or paper, it was found that the use of an oxidative agent could also reduce the photoyellowing of aged, bleached pulp materials.
U.S. Pat. No. 7,638,016 proposes a method of brightening pulp fibres with at least one stilbene-based OBA after the last bleaching/extraction stage with a chlorine based bleaching agent.
US20120199302 presents a new composition using at least two specific disulfo-stilbene based FWA for optically whitening paper or board.
U.S. Pat. No. 5,064,570 introduces a new preparation method for fluorescent brightener that involves the use of specific water-insoluble aromatic or carbon-substituted fatty alcohol auxiliaries.
EP1253191 and US 20030054969 present the composition of detergents, which includes stilbene-triazine-based optical brightener (FB #71).
CA 2576882 explores the use of stilbene-based OBA's on bleaching towers for pulp along with TAED for increasing pulp brightness.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM
Not applicable.
BACKGROUND OF THE INVENTION
In recent years, the consumers' pursuit for ultra-bright paper has pushed the market demands for more products with a brightness of 90-110 in ISO standards. In order to produce these ultra-high brightness products, optical brightener agents (OBA's) or fluorescent whitening agents (FWA's) must be utilized.
OBA's or FWA's have chemical properties that absorb light in the ultra-violet region (340-370 nm) and then re-emitting it back into the visible spectrum, usually in the color blue or indigo (420-470 nm). The absorption and re-emission happen at a rapid pace unlike the slow phosphorescence behaviour. The newly added blue light compensates the yellowness of paper products and produces a net whitening effect that is observable to the naked eye.
There is an ongoing need for improved brightness with low cost and with greater stability of the optical properties, i.e. decreased reversion such as yellowing (caused by overdosage), photoyellowing, and higher retention rates.
SUMMARY OF THE INVENTION
One of the biggest hurdles to using conventional FWA is the limit on overdosing, and low retention. This is especially prominent in lower brightness paper that has significant mechanical pulp present. As an increasing amount of excess conventional FWA has been input into the system, the paper materials coming off the machine would have more of a yellow tinge due to the natural appearance of the conventional FWA.
The new generation fluorescent brightener 71 (FB #71) does not encounter this problem as it has a slightly different molecular structure which exhibits an almost pure white appearance. There is a plateauing effect for brightness gain associated with injection (at which point the cost effectiveness decreases), but the paper products will no longer have a yellowish tinge. In short, the machine tender can inject as much FWA as needed to increase the brightness, without the risking yellowing caused by overdosing.
FB #71 has been historically used in the detergent industry as a brightener. However its application in papermaking process has not been successful due to the extremely low solubility in water caused by repulsions of its morpholino functional groups. Even though theoretically speaking, it is possible to be used to brighten paper, it was never commercially practical. Therefore FB #71 was not sought after by papermakers.
On the other hand, the low solubility of the FB #71 would yield a significantly higher retention rate on fibers than any other FWA's ever used in papermaking. By carefully optimizing the dosage in water of various temperatures, dissolution was achieved. FB #71 re-emits light in the range of 440-450 nm (indigo light).
The present invention relates to a novel, low-cost method of producing high final brightness values in paper production not previously achieved, and reducing brightness reversion of paper material.
According to the present invention there is provided an FWA for making high brightness paper. The usage of the FWA comprises of approximately 0.01%-1.0% by weight FB #71 based on dry weight at a temperature of 30° C.-80° C.
The invention provides several advantages over conventional FWA's:
1. Lower cost benefits due to the decreased addition of FWA while still achieving the same, or greater, ISO brightness values.
2. Increased brightness values and retention rates for paper materials over conventional FWA's. This increases the number and variety of applications for the product, significantly expanding its marketability.
The invention and its advantages will be illustrated in more detail by the examples below which however, are only intended to illustrate the invention without limiting the same. The percentage and parts stated in the description, claims and examples refer to percent by weight and parts by weight, respectively, unless otherwise stated.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be further described with reference to the following non-limiting examples:
Pulp brightness (ISO brightness) is measured with a brightness meter, which determines the brightness of a split sheet at a wavelength of 457 nm (ISO D65 Standard Method).
The FWA's described in this invention are the following:
1. FB #71 has a chemical name of 4,4′-bis[4-anilino-6-morpholino-1,3,5-triazin-2-yl]amino-2,2′-stilbene disodium salt (100% purity), and a CAS number of 16090-02-1.
2. Disulfo-stilbene based FWA has a chemical name of disodium 4,4′-bis[(4-anilino-6-hydroxyethylamino-1,3,5-triazin-2-yl)amino]stilbene-2,2′-disulphonate] (100% purity), and a CAS number of 12224-06-5.
3. Tetrasulfo-stilbene based FWA has a chemical name of tetrasodium 4,4′-bis[[4-[bis(2-hydroxyethyl)amino]-6-(4-sulphonatoanilino)-1,3,5-triazin-2-yl]amino]stilbene-2,2′-disulphonate] (100% purity), and a CAS number of 16470-24-9.
Example 1
Laboratory Studies
The incoming samples of 30% Kraft and 70% mechanical pulp mixture (from a pulp mill in British Columbia, Canada) with a brightness of 78 ISO and a concentration of 0.7%, was treated with three different FWA's at 40° C. and 5 minutes of retention time.
From the results shown in TABLE 1, it is evident that under the same dosage, FB #71 can obtain a significantly higher brightness value compared to the conventional FWA's when used on production that requires more mechanical pulp than Kraft pulp.
TABLE 1
Unbleached ISO
Disulfo-
Tetrasulfo-
FB #71
ISO
Brightness
OBA (%)
OBA (%)
(%)
Brightness
78
0.01
0
0
79
78
0.1
0
0
87
78
1.0
0
0
83
78
0
0.01
0
78.5
78
0
0.1
0
84
78
0
1.0
0
83
78
0
0
0.01
80
78
0
0
0.1
90
78
0
0
1.0
93
Example 2
Laboratory Studies
The incoming paper samples (from a paper mill in British Columbia, Canada) with a brightness of 84 ISO were coated with coating color and two different FWA's.
From the results shown in TABLE 2, it is evident that under the same dosage, FB #71 can obtain a significantly higher brightness compared to the conventional FWA's when used on production that requires coating materials.
TABLE 2
Uncoated Basesheet
Tetrasulfo-OBA
FB #71
Coated Paper
Paper ISO Brightness
(%)
(%)
ISO Brightness
84
0.01
0
85
84
0.1
0
90
84
1.0
0
87
84
0
0.01
89
84
0
0.1
96
84
0
1.0
102
Example 3
Laboratory Studies
The incoming samples of 100% Kraft pulp (from a pulp mill in British Columbia, Canada) with a brightness of 88 ISO and a concentration of 1.0%, was treated with three different FWA's at 40° C. and 5 minutes of retention time.
From the results shown in TABLE 3, it is evident that FB #71 has a plateauing effect with whiteness as the dosage is increased, whereas the two conventional FWA's causes yellowing once overdosing occurs.
TABLE 3
Unbleached ISO
Disulfo-
Tetrasulfo-
FB #71
ISO
Brightness
OBA (%)
OBA (%)
(%)
Brightness
88
0.1
0
0
105
88
0.2
0
0
112
88
0.3
0
0
115
88
0.4
0
0
113
88
0
0.1
0
100
88
0
0.2
0
108
88
0
0.3
0
110
88
0
0.4
0
108
88
0
0
0.1
107
88
0
0
0.2
116
88
0
0
0.3
120
88
0
0
0.4
123
Example 4
Mill-Trial
A plant test was performed at a pulp and paper mill in British, Columbia, Canada. Incoming pulp with 86 ISO brightness and a concentration of 0.7% was used to make paper products.
From the results shown in TABLE 4, it is clear that FB #71 is effective in stabilizing paper and has a high affinity for paper essential.
TABLE 4
Unbleached ISO
Disulfo-
Tetrasulfo-
FB #71
ISO
Brightness
OBA (%)
OBA (%)
(%)
Brightness
86
0.1
0
0
92
86
0.2
0
0
96
86
0.3
0
0
98
86
0.4
0
0
96
86
0
0.1
0
89
86
0
0.2
0
93
86
0
0.3
0
93
86
0
0.4
0
92
86
0
0
0.1
95
86
0
0
0.2
100
86
0
0
0.3
105
86
0
0
0.4
108 | Fluorescent whitening agent 71 (FB #71) 4,4′-bis[4-anilino-6-morpholino-1,3,5-triazin-2-yl]amino-2,2′-stilbene disodium salt (CAS #16090-02-1) is used on the wet-end papermaking process and coating papermaking process to increase the brightness of paper. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a slide fastener installation and in particular to an emergency opening device for such installations so as to be particularly adaptable for use with tents, sleeping bags, etc.
2. Description of the Prior Art
The prior art, as exemplified by U.S. Pat. Nos. 3,122,808 and 3,331,107, is cognizant of the general concept of quick release mechanisms for slide fastener installations. However, such prior art devices are constructed for use with slide fasteners having individual interlocking elements, a significant portion of which are cut out so as to provide a gap which receives a release pin of the quick release mechanism. In addition, such mechanisms have further disadvantages in that they require separate assembly during engagement of the slide fastener elements, they require the locating and pulling of a separate release handle in emergencies, and they have a complex arrangement of separate components resulting in an extremely uneconomical device.
The use of tents in camping areas has increased substantially in recent years and it is conventional that campsites also include wood fireplaces as well as cooking stoves utilizing highly inflammable fuel, such as liquid petroleum. The hazard of fire is thus enlarged, particularly as the campsite normally includes a number of children. When fire occurs at the campsite, it is imperative that anyone in a tent remove himself to a safe area; however, the above prior art devices do not provide for an immediate and instantaneous exit from a tent which has its door flaps closed by a slide fastener.
SUMMARY OF THE INVENTION
The present invention is summarized in quick opening device for a slide fastener having two portions of material closed by engaged interlocking elements on adjacent edges of the material portions, which device includes operating means having a first part adapted for mounting on one of said material portions and a second part adapted to extend over the interlocking elements, and projecting means extending from the second part toward the engaged interlocking elements and being movable inbetween the engaged interlocking elements by a predetermined applied force to cause separation of the engaged interlocking elements.
An object of the present invention is to construct a slide fastener installation with an emergency opening arrangement.
Another object of the invention is to release a slide fastener installation to an open position in a simple manner as quickly as possible without requiring any pulling, releasing or unlocking.
It is a further object of this invention to provide a slide fastener installation with an emergency opener that can be reassembled quickly and without any mechanical assembly or manipulation.
Other objects and advantages of the present invention will become apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of an emergency exit slide fastener installation embodying the present invention;
FIG. 2 is a bottom elevation view of FIG. 1;
FIG. 3 is a partial bottom plan view of FIG. 2 on an enlarged scale;
FIG. 4 is a partial bottom plan view similar to FIG. 3 but showing an embodiment of FIG. 3;
FIG. 5 is a cross section taken along line 5--5 of FIG. 4; and
FIG. 6 is a bottom elevation view of FIG. 4 with parts added.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is embodied in a slide fastener installation, indicated generally at 10 in FIG. 1, including a pair of carrier means having edges oppositely disposed to each other. In the embodiment of FIGS. 1 and 2, the pair of carrier means includes a pair of sheets 12 and 14 of material that may form an enclosure such as a tent, camper, sleeping bag, etc., and a corresponding pair of carrier tapes 16 and 18 secured to the sheets 12 and 14, respectively, adjacent the opposed edges thereof.
Continuous filamentary members 20 and 22 are respectively secured to the opposed edges of the carrier tapes 16 and 18 as by stitches (see FIGS. 1, 5 and 6), and form a plurality of interlocking elements 24 and 26, respectively. The continuous filaments 20 and 22 may be made of any suitable plastic material such as nylon, polyester, etc., and the interlocking elements 24 and 26 may be of any known filamentary configuration such as coil, meander and the like. A pull tab 28 is attached to a slider 30 that is moved longitudinally along the filaments 20 and 22 to engage and disengage the coupling elements 24 and 26 causing the slide fastener installation to be actuated between its respective closed and opened positions.
A backing or support sheet 32 made of stiffening material, such as canvas, is secured to the sheet 14 to provide support for a mounting or operating bracket, indicated generally at 34. The bracket 34 is secured to the support sheet 32 by any suitable fastener, such as rivets 36 and 38 which extend through the sheet 14 as well as the support sheet 32. The bracket 34 is made of any suitable flexible material, such as plastic, into a generally triangular configuration. A base portion of the bracket 34 defines its mounting end 40 and an intermediate portion 42 defines a flexible hinge between the mounting end 40 and an apex end 44 which serves as a presser pad portion that carries a movable member 46 on its undersurface. As is shown in FIGS. 1 and 2, the movable member 46 constitutes projection means shaped as an inverted cone with a rounded apex end disposed above the engaged interlocking elements 24 and 26.
To operate the emergency exit device of the present invention as embodied in FIGS. 1-3, the occupant of an enclosure or tent needs only to press against the presser pad section 44 thereby flexing the hinge 42, and forcing the movable projecting cone 46 inbetween a pair of coupling elements 24 and 26. Once a single pair of coupling elements 24 and 26 are disengaged, the opening created is easily expanded up and down the filaments 20 and 22 by only slight pressure on the bracket 34. Only slight pressure is needed to create the initial break between the filaments 20 and 22 and even less pressure is required to complete the separation.
Thus the installation of the present invention permits any easy and quick exit from any enclosure wherein the entrance is closed by a slide fastener installation. This is particularly advantageous since similar slide fastener installations are being increasingly used in a variety of applications, especially in such things as sleeping bags, campers and tents. In an emergency, any occupants of such an enclosure may need to effect a quick exit, particularly in the event of a fire. In a fire emergency there may be panic and operation of the conventional slide fastener slider may prove too slow and cumbersome. Thus the present invention is used to provide quick exit with one simple push and without requiring any pulling, unfastening or unlocking. The assembly is also extremely easy to reassemble since pulling the slider 30 down the filaments 20 and 22 to open the slide fastener and then pulling it back to reclose the coupling elements 24 and 26 will completely reassemble the entire installation.
Another embodiment of the invention is shown in FIGS. 4-6 wherein idential parts described above are given identical reference numbers, similar parts are given similar numbers with 100 added, and new parts are given new numbers in the 100 series; accordingly, only the differences of structure and operation in this embodiment are beind described in detail.
As is shown in FIGS. 4-6, the mounting or operating bracket 134 is an elongated rectangular plate with its mounting end 140 fastened as by rivets 38 to the carrier tape 18. In this instance, the emergency opening device is attached directly to the carrier tape 18; however, to facilitate its assembly onto sheet material, the rivets 28 are attached after the adjacent edge of the sheet material 14 has been sandwiched between the tape 18 and the mounting end 140. The projecting means includes a pair of spaced inverted conical members 145 and 147 carried on the undersurface of the presser pad portion 144 so as to be disposed above the engaged interlocking elements 24 and 26.
The operation of this embodiment is similar to that of the embodiment of FIGS. 1-3, again requiring only a simple push to open the slide fastener. This embodiment takes advantage of the inherent flexibility between a mounting tape 18 and a sheet such as 14, which bend freely with respect to each other. Additional flexibility may also be obtained by forming the bracket 134 of a more flexible material, such as cloth.
It should be readily apparent that any number of inverted cones may be provided on the bracket in accordance with the present invention. In addition the bracket may be secured to either one of the sheets joined together in any known manner such as sewing, ultrasonic welding, adhesives, etc., rather than riveting and may be secured to a mounting tape alone rather than to either sheet.
As is well known in the art, the filaments 20 and 22 may be formed in a variety of configurations other than the ladder or meander type illustrated in FIGS. 1-6. As shown in FIGS. 4-6, the projecting cones 145 and 147 are located along the longitudinal center line defined by the engaged interlocking elements 24 and 26 so as to engage the adjacent edges of the heads of adjacent interlocking elements 24 and 26.
While the location of the projecting means may vary to meet the requirements of a particular slide fastener, the off center line location shown in FIG. 3 has been tested with very satisfactory results; in this instance, the cone 46 is diposed to engage the adjacent legs of the same interlocking element 24. The projecting cone 46 is forced against the two legs of the interlocking element 24 causing separation of such legs whereby the head of the opposite element 26 is released.
Inasmuch as the present invention is subject to many modifications, variations and changes in detail, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A slide fastener installation is disclosed as including conventional slide fastener components such as interlocking elements which are engaged and disengaged by a movable slider element permitting the slide fastener intallation to be actuated between closed and opened portions; an emergency opening device also causes disengagement of the interlocking elements permitting rapid opening of the slide fastener installation. | 8 |
This invention relates to an orientable optical control appliance for a luminaire such as a refractor and more particularly to the mounting means therefor.
BACKGROUND OF THE INVENTION
Optical control appliances for luminaires such as refractors and reflectors which provide a non-symmetrical light distribution pattern may require a mounting scheme allowing orientation or angular adjustment about the mounting axis. For instance in a luminaire where the refractor provides two oppositely directed beams of light for lighting up and down a corridor, or a single broad beam for lighting away from a mounting wall, orientation is needed. Where the fixture does not have a fixed orientation relative to the task, angular adjustability of the optics is all the more necessary.
The feature of orientability is particularly desirable in retrofit type high intensity discharge (HID) lamp adapter fixtures. Typically such units replace an incandescent lamp of several hundred watts by an HID lamp of much smaller wattage, for instance a 300 watt incandescent lamp by a 35 or 50 watt high pressure sodium vapor lamp. The unit including ballast and lamp is mounted by screwing a screw base on the housing or fixture head into the socket that accommodated the incandescent lamp which it replaces. Such a mounting arrangement cannot effectively provide angular adjustment or orientation about the vertical axis. The thread pitch of 7 threads per inch in the conventional medium screw base is so coarse that the insertion tolerance is much less than 1 turn. In other words, one cannot resort to screwing in the housing tighter into the socket in order to achieve a particular orientation, and doing so may damage the base threads or the socket threads or both. It will be appreciated that the optics require individual adjustment to position the light beam with respect to the task. Providing a predetermined orientation relative to the socket is not enough because the sockets may be randomly oriented relative to the task.
SUMMARY OF THE INVENTION
The object of the invention is to provide a simple inexpensive mounting means for luminaire optical control appliances such as a refractor or a combination refractor-reflector which permits angular adjustment of the appliance relative to the luminaire.
In a mounting means embodying the invention, a rotatable mounting ring making an interference fit with a cylindrical neck portion of the appliance is provided, and angular adjustment of the appliance relative to the ring provides orientability.
In a preferred embodiment, appliance and mounting ring are made of light-transmitting material having a measure of flexibility and elasticity, such as polycarbonate or acrylic resins. A diametric interference is provided between a groove in one part and a mating ridge in the other part. Assembly is accomplished by forcing the parts together to snap them into place with the ridge seized in the groove. Shallow interfering ribs and valleys in the mating surfaces of the appliance and ring controllably lock the parts together while allowing angular indexing to provide orientability.
DESCRIPTION OF DRAWINGS
In the drawings
FIG. 1 is a pictorial view of a luminaire comprising wall mounting bracket, adapter type screw-in housing, and refractor embodying the invention.
FIG. 2 is a vertically exploded, pictorial view of the fixture showing the relationship between housing, mounting ring and refractor.
DETAILED DESCRIPTION
Referring to the drawings, there is shown a wall-mounted luminaire assembly in which the invention is embodied. The assembly comprises a wall mounting bracket 1, an adapter type housing 2, and a light-transmitting refractor 3. The bracket and the housing are suitably made of a molded engineering plastic such as nylon or fiberglass-reinforced polyester. A medium screw base 4 is incorporated into the housing top and screws into a conventional socket (not shown) in the projecting arm 5 of the bracket. Ratchet teeth 6 molded in the housing top are engaged by a spring blade 7 serving as an anti-pilfering device to secure the unit. The screw base also allows the housing to be mounted and suspended directly from an existing socket if preferred, which socket may be ceiling or wall hung. The housing contains a ballast capable of starting and operating an appropriate HID lamp which depends from the housing and is enclosed within the refractor. By way of preferred example, the lamp may be a 35 watt or a 50 watt high pressure sodium vapor lamp (not shown) and it is screwed into socket 8 in the housing bottom.
The illustrated refractor 3 is generally cylindrically shaped with a closed bottom and is preferably made of thin-walled clear polycarbonate plastic. The cylindrical wall has a pattern of optical surfaces such as prisms 9 molded into it. In addition to or in lieu of refracting prisms, reflecting coatings may be applied to the wall. The light control surfaces are preferably provided on the inside of the refractor in order to have a smooth outside surface less apt to collect soil and easily cleaned.
When the optical surfaces cause a non-symmetrical distribution of the transmitted light, it is necessary to orient the refractor relative to the task. The neck or upper end of the refractor is fitted with a mounting ring 10 which is shown raised above it in exploded fashion in FIG. 2. The ring is conveniently made of clear polycarbonate plastic like the refractor. The ring has a depending collar portion 11 whose outer diameter fits the inner diameter of the neck or upper end of the refractor. An external ridge 12 near the bottom of the collar mates with an internal groove 13 in the neck of the refractor. There is diametric interference between the ridge and the inner surface of the refractor neck next to the groove, for instance 0.040" for the case of 31/2" diameter refractor as illustrated. The non-rigid thin-walled plastic material of the neck will stretch when the collar with its ridge is forced into it, resulting in a snap fit. Retention of the parts in assembly and adequate sealing are achieved when ridge 12 is seated in groove 13. The mated ridge and groove allow angular rotation of the refractor and there is enough friction to maintain the setting in ordinary circumstances.
In a preferred construction, shallow radial depressions or valleys 14 on the inside of the refractor are engaged by matching protuberances or ribs 15 on the outside of the ring collar. The interengagement of ribs and valleys controllably resist rotation of the refractor with respect to the ring. Break-away torque to allow rotation is determined by the extent of interference and the proximity of the detenting ribs and valleys. It is set high enough to allow the refractor to be installed or removed from the housing, yet low enough to permit ready adjustment by the user without damage to any component by the application of excessive force.
The mounting ring is provided with six vertically rising tabs 16 which are disposed to penetrate slotted apertures 17 in the bottom wall of housing 2. Each tab has foot portion 18 directed radially inwards which engages a cooperating locking portion about the accommodating aperture when the refractor is twisted clockwise relative to the housing. The leading side 19 of the foot is inclined or ramped slightly in order to cause compression of a sealing gasket 20 when the refractor is mounted on the housing. A latch detent 21 on the ring in conjunction with a springy latch tab 22 depending from the lower face of the housing secures the refractor to the housing. This permits adjustment of the refractor relative to the mounting ring in both directions for orientation. The latch is easily disengaged to permit removal of the refractor without loss of orientation. A photoelectric controller for the lamp may conveniently be mounted on the wall bracket above the level of the housing as indicated at 23.
The preferred construction of mounting ring which has been illustrated uses tabs with feet portions for atattachment to the housing. Other attaching means such as conventional threads on the mounting ring may be used if preferred. However the particular mounting ring which has been described is so convenient and economical that it is used by applicant's assignee even with symmetrical refractors which do not require orientability.
While I have described my invention with reference to a specific embodiment, numerous modifications may be made without departing from the true scope of the invention and I intend by the appended claims to cover all such equivalent variations. | A polycarbonate orientable refractor for a luminaire comprises a mounting ring which has a collar portion fitting a neck portion of the refractor with matching diameters. A diametric interference is provided between a groove in one part and a mating ridge in the other part to an extent allowing a snap fit. Shallow interfering ribs and valleys in the mating surfaces controllably lock the parts together while allowing angular indexing for orienting the light distribution pattern of the refractor. | 5 |
RELATED PATENT APPLICATION
This is a division of application Ser. No. 08/930,228, filed Jan. 12, 1998, now U.S. Pat. No. 6,144,300, issued Nov. 7, 2000, which is the U.S. National stage of PCT/GB96/00823, filed Apr. 3, 1996.
BACKGROUND OF THE INVENTION
This invention relates to the exploitation of magnetic properties in a range of practical techniques, and utilizes a new technique of spatial magnetic interrogation in conjunction with a magnetic marker or identification tag. More particularly, but not exclusively, the invention relates to methods of determining the presence and/or the location of a magnetic marker or tag within an interrogation zone; to methods of identifying a magnetic tag (e.g. identifying a given tag in order to discriminate that tag from others); to systems for putting these methods into practice; to magnetic tags for use in such methods and systems; and to the storage of data in such tags, and the subsequent remote retrieval of data from such tags.
It should be understood that the terms “tag” and “marker” are used herein interchangeably; such devices may be used in many different applications and, depending on the magnetic qualities of the device, may serve to denote (a) the mere presence of the tag (and hence that of an article to which the tag is attached); or (b) the identity of the tag (and hence that of an article to which it is attached); or they may serve to define the precise position of the tag with respect to predetermined coordinates (and hence that of an article to which it is attached); or they may serve to provide access codes (e.g. for entry into secure premises; or for ticketing purposes, e.g. on public transport networks); or they may serve generally to discriminate one article or set of articles from other articles.
In addition, the terms “AC field” and “DC field” are used herein to denote magnetic fields whose characteristics are, respectively, those associated with an electrical conductor carrying an alternating current (AC) or a direct current (DC).
The tags, methods and systems of this invention have a wide variety of applications as indicated above. These include (but are not restricted to) inventory control, ticketing, automated shopping systems, monitoring work-in-progress, security tagging, access control, anti-counterfeiting, and location of objects (in particular the precise positioning of workpieces (e.g. probes in surgery)).
PRIOR ART
There are a number of passive data tag systems currently available. The most widely-used is based on optically-read printed patterns of lines, popularly known as barcodes. The tag element of such systems is very low-cost, being typically just ink and paper. The readers are also relatively low cost, typically employing scanning laser beams. For many major applications the only real drawback to barcodes is the need for line-of-sight between the reader and the tag.
For applications where line-of-sight is not possible, systems not employing optical transmission have been developed. The most popular employ magnetic induction for coupling between the tag and the interrogator electronics. These typically operate with alternating magnetic fields in the frequency range of 50 kHz to 1 MHz, and generally employ integrated electronic circuits (“chips”) to handle receive and transmit functions, and to provide data storage and manipulation. In order to avoid the need for a battery, power for the chip is obtained by rectification of the interrogating signal received by an antenna coil. In order to increase the power transferred, and to provide discrimination against unwanted signals and interference, the coil is usually resonated with a capacitor at the frequency of the interrogation signal carrier frequency. A typical product of this type is the TIRIS system manufactured by Texas Instruments Ltd.
Other multi-bit data tag systems have employed conventional h.f. radio technology, or technologies based on surface acoustic waves or magnetostriction phenomena.
FIELD OF THE INVENTION
The present invention involves, inter alia, the use of a new type of passive data tag system which employs small amounts of very high-permeability magnetic material, and a scanned magnetic field for interrogation. Since the magnetic material can be in the form of a thin foil, wire or film, it can be bonded directly to a substrate, e.g. paper or a plastics material, to form self-supporting tags.
Alternatively, the magnetic material may be incorporated into the structure of an article with which the tag is to be associated; thus a tag may be formed in situ with the article in question by applying the magnetic material to the surface of the article, or by embedding the magnetic material within the body of the article.
The invention exploits magnetic fields which contain a “magnetic null”—this term is used herein to mean a point, line, plane or volume in space at or within which the component of the magnetic field in a given linear direction is zero. The volume in space over which this condition is met can be very small—and this gives rise to certain embodiments of the invention in which precise position is determined. Typically the magnetic null will be extant over a relatively small linear range. It should be understood that, where there is a magnetic null, it is possible (and is often the case) that the magnetic field component in a direction orthogonal to the given linear direction will be substantial. In some embodiments of this invention, such a substantial orthogonal field is desirable.
One way of creating the magnetic null is to employ opposing magnetic field sources. These may be current-carrying coils of wire, or permanent magnets (these being well suited to small-scale systems), or combinations of coil(s) and permanent magnet(s). It is also possible to exploit the magnetic nulls which exist in specific directions when a single coil or permanent magnet is used.
For large scale applications, the magnetic field sources are preferably coils carrying direct current.
The invention also utilizes the relative movement between a magnetic marker and an applied magnetic field in order to effect passage over the marker of the magnetic null. This can be achieved by moving the marker with respect to the applied magnetic field, or by holding the marker in a fixed position while the magnetic field is scanned over it. Generally, the invention exploits the difference between the magnetic behavior of the marker in (i) a zero field (at the magnetic null), and (ii) in a high, generally saturating, magnetic field.
TAGS OF THIS INVENTION
According to one aspect of the present invention, there is provided a magnetic marker or tag which is characterized by carrying a plurality of discrete magnetically active regions in a linear array. The discrete magnetically active regions may be supported on a substrate, e.g. paper or a plastics material, or they may be self-supporting. Alternatively, the magnetic elements may be incorporated directly into or onto articles during manufacture of the articles themselves. This is appropriate, for example, when the articles are goods, e.g. retail goods, which carry the tags for inventory purposes; or when the articles are tickets or security passes.
A tag as defined above can also be formed from a continuous strip of high permeability material, discrete regions of which have their magnetic properties permanently or temporarily modified. It will be appreciated that such a process can begin with a high permeability strip selected regions of which are then treated so as to modify their magnetic properties, generally by removing or reducing their magnetic permeability; or with a strip of high permeability magnetic material accompanied by a magnetizable strip positioned close to the high permeability magnetic material, e.g. overlying it or adjacent to it, selected regions of which are magnetized. In relatively simple embodiments, each magnetically active region has the same magnetic characteristics; in more complex embodiments, each magnetically active region can possess a different magnetic characteristic, thus making it possible to assemble a large number of tags, each with unique magnetic properties and hence with a unique magnetic identity and signature (when processed by a suitable reader device).
Because the invention utilizes relative movement between a tag and an applied magnetic field, it will be appreciated that there will be a correspondence between the time domain of output signals from a tag reading device and the linear dimensions of the magnetically active regions of a tag and of the gaps between the magnetically active regions. In this sense, the active regions and the gaps between them function analogously to the elements of an optical bar code (black bar or white gap between adjacent bars). It follows from this that, just as variability of magnetic characteristics in the active regions can be used to generate part of a tag “identity”, so can the linear spacing between adjacent magnetically active regions. It will readily be understood that a vast number of tags, each with its own unique identity, can thus be produced in accordance with this invention.
Although the tags have been described as possessing a linear array of magnetically active regions, the tags may in fact have two or more such linear arrays. These may be disposed mutually parallel, or mutually orthogonal, or in any desired geometrical arrangement. For simplicity of reading such tags, arrays which are parallel and/or orthogonal are preferred.
Appropriate techniques for manufacturing the tags of this invention are well-known in conventional label (i.e. magnetic marker) manufacture. Suitable magnetic materials are also well-known and widely available; they are high-permeability materials which preferably have an extrinsic relative permeability of at least 10 3 . The coercivity of the magnetic material will depend on the tag's intended use. The magnetic material is preferably in the form of a long thin strip or of a thin film; these formats avoid major internal demagnetization effects. Suitable strip materials are readily available from commercial suppliers such as Vacuumschmeltze (Germany), Allied Signal Corp. (USA), and Unitika (Japan). Thin film material currently manufactured in high volume by IST (Belgium) for retail security tag applications is also suitable for use in this invention.
DETECTION/IDENTIFICATION METHODS
As well as the tags defined above, the present invention provides a variety of useful methods for detecting the presence of a magnetic marker and/or for identifying such a marker. While in many cases these methods will be intended for use in conjunction with the tags of the invention, this is not a necessary prerequisite in the methods of the invention.
According to a second aspect of the invention, there is provided a method of interrogating a magnetic tag or marker within a predetermined interrogation zone, the tag comprising a high permeability magnetic material, for example to read data stored magnetically in the tag or to use the response of the tag to detect its presence and/or to determine its position within the interrogation zone, characterized in that the interrogation process includes the step of subjecting the tag sequentially to: (1) a magnetic field sufficient in field strength to saturate the high permeability magnetic material, and (2) a magnetic null as herein defined.
Preferably the magnetic null is caused to sweep back and forth over a predetermined region within the interrogation zone. The scanning frequency (i.e. the sweep frequency of the magnetic null) is preferably relatively low, e.g. 1-500 Hz. Conveniently, the field pattern is arranged so that (a) said magnetic null lies in a plane; and (b) the saturating field occurs adjacent to said plane.
According to a third aspect of this invention, there is provided a method of determining the presence and/or the position of a magnetic element within a predetermined interrogation zone, the magnetic element having predetermined magnetic characteristics, which method is characterized by the steps of: (1) establishing within said interrogation zone a magnetic field pattern which comprises a relatively small region of zero magnetic field (a magnetic null) contiguous with regions where there is a magnetic field sufficient to saturate the, or a part of the, magnetic element (the saturating field), said relatively small region being coincident with a region through which the magnetic element is passing, or can pass, or is expected to pass; (2) causing relative movement between said magnetic field and said magnetic element such that said magnetic null is caused to traverse at least a part of the magnetic element in a predetermined manner; and (3) detecting the resultant magnetic response of the magnetic element during said relative movement.
According to a fourth aspect of the present invention, there is provided a method of identifying a magnetic element which possesses predetermined magnetic characteristics, which method is characterized by the steps of: (1) subjecting the magnetic element to a first magnetic field which is sufficient to induce magnetic saturation in at least a part of the magnetic element; (2) next subjecting the magnetic element to conditions of zero magnetic field (i.e. a magnetic null), the zero field occupying a relatively small volume and being contiguous with said first magnetic field; (3) causing relative movement between the applied magnetic field and said magnetic element such that said magnetic null is caused to traverse at least a part of the magnetic element in a predetermined manner; and (4) detecting the resultant magnetic response of the magnetic element during said relative movement.
In the identification method defined above, the magnetic element is advantageously caused to traverse an interrogation zone within which the required magnetic conditions are generated.
In a fifth aspect, the invention provides a method of identifying a magnetic element, the magnetic element having predetermined magnetic characteristics, which method is characterized by the steps of: (1) causing the magnetic element to enter an interrogation zone within which there is established a magnetic field pattern which comprises a relatively small region of zero magnetic field (a magnetic null) contiguous with regions where there is a magnetic field sufficient to saturate the, or a part of the, magnetic element (the saturating field); (2) causing the magnetic element to be moved through the saturating field until it reaches the magnetic null; (3) causing relative movement between said magnetic field and said magnetic element such that said magnetic null is caused to traverse at least a part of the magnetic element in a predetermined manner; and (4) detecting the resultant magnetic response of the magnetic element during said relative movement.
The relative movement between the magnetic element and the magnetic field may advantageously be produced by sweeping the applied magnetic field over the magnetic element. Alternatively, the relative movement can be achieved by the application of an alternating magnetic field to a generally static magnetic field pattern.
In carrying out the methods defined above, preferred embodiments of the magnetic element are either elongate, and the magnetic null is then arranged to extend along the major axis of said magnetic element;. or they are in the form of a thin film, in which case the magnetic null is arranged to extend to be aligned with the axis of magnetic sensitivity of the thin film material.
The magnetic field or field pattern utilized in the methods defined above may be established by the means of two magnetic fields of opposite polarity. This can conveniently be achieved by use of one or more coils carrying direct current; or by the use of one or more permanent magnets; or by a combination of coil(s) and magnet(s).
Where a coil is used, it may be arranged to carry a substantially constant current so as to maintain the magnetic null at a fixed point. Alternatively, the coil(s) carry/carries a current whose magnitude varies in a predetermined cycle so that the position of the magnetic null is caused to oscillate in a predetermined manner. We describe this as a “flying null”. A similar arrangement can be used to give a flying null when both a coil or coils and a permanent magnet are used.
According to a further aspect of the present invention, there is provided a method of determining the presence and/or the position of a magnetic element, which is characterized by the steps of: (1) applying a magnetic field to a region where the magnetic element is, or is expected to be, located, said magnetic field comprising two opposed field components, generated by magnetic field sources, which result in a null field (a magnetic null) at a position intermediate said magnetic field sources (which position is known or can be calculated); (2) causing relative movement between said magnetic field and said magnetic element; and (3) detecting the resultant magnetic response of the magnetic element during said relative movement.
Relative movement between the magnetic field and the magnetic element may be achieved by applying a relatively low amplitude alternating magnetic field superimposed on the DC filed. Typically, such a low amplitude alternating magnetic field has a frequency in the range from 10 Hz to 100 Hz, preferably from 50 Hz to 50 kHz, and most advantageously from 500 Hz to 5 kHz.
In one embodiment, the coils carry a substantially constant current so as to maintain the magnetic null at a fixed point. In another embodiment, the coils carry a current whose amplitude varies in a predetermined cycle so that the position of the magnetic null is caused to oscillate in a predetermined manner.
In the methods according to this invention, detection of the magnetic response of the magnetic element advantageously comprises observation of harmonics of the applied AC field which are generated by the magnetic element as its magnetization state is altered by passing through the magnetic null.
As indicated above, the system operates with a zero or very low frequency scanning field, and an HF (high frequency) in the range 50 Hz-50 kHz. This allows for good signal penetration through most materials including thin metal foils. In addition, international regulations allow high fields for transmission at these low frequencies.
Preferred embodiments of the invention provide a multi-bit data tag system which employs low-frequency inductive magnetic interrogation, and avoids the need for complex, expensive tags.
According to another aspect of the present invention, there is provided a method of coding and/or labeling individual articles within a predetermined set of articles by means of data characteristic of the articles, e.g. article price and/or the nature of the goods constituting the articles, which method is characterized by applying to each article a magnetic tag or marker carrying a predetermined arrangement of magnetic zones unique to that article or to that article and others sharing the same characteristic, e.g. article price or the nature of the goods constituting the article, said magnetic tag or marker being susceptible to interrogation by an applied magnetic field to generate a response indicative of the magnetic properties of the tag or marker and hence indicative of the nature of the article carrying the magnetic tag or marker.
FUNDAMENTALS OF THE INVENTION
Before describing further embodiments, it will be helpful to explain some fundamental aspects of the invention, giving reference where appropriate to relatively simple embodiments.
A key aspect of the invention is the form of the magnetic field created in the interrogation zone; as will become apparent later, this field allows very small spatial regions to be interrogated. The means for generating this magnetic field will be termed hereinafter an “interrogator”. In one simple form, the interrogator consists of a pair of closely-spaced identical coils arranged with their axes coincident. The coils are connected together such that their winding directions are opposed in sense, and a DC current is passed through them. This causes opposing magnetic fields to be set up on the coils' axis, such that a position of zero field—a magnetic null—is created along the coil axis, mid-way between the coils. The level of current in the coils is such as to heavily saturate a small sample of high permeability magnetic material placed at the center of either of the two coils. A much lower amplitude AC current is also caused to flow in opposite directions through the two coils, so that the AC fields produced sum together midway between the coils. This can easily be arranged by connecting a suitable current source to the junction of the two coils, with a ground return. The frequency of this AC current may typically be about 2 kHz, but its value is not critical, and suitable frequencies extend over a wide range. This AC current generates the interrogating field which interacts with a magnetic tag to generate a detectable response. Another effect of this AC current is to cause the position of zero field—the magnetic null—to oscillate about the mid-way position along the coils' axis by a small amount (this is a wobble or oscillation rather than an excursion of any significant extent).
In addition, a further, low frequency AC current may be fed to the coils so as to generate a low frequency scanning field (which may be zero). The frequency of the scanning field (when present) should be sufficiently low to allow many cycles of the relatively high frequency interrogation field to occur in the time that the magnetic null region passes over the tag; typically, the frequency ratio of interrogating field ((ω c ) to the scanning field (ω b ) is of the order of 100:1, although it will be appreciated that this ratio can vary over a considerable range without there being any deleterious effect on the performance of the invention.
When a tag containing a piece of high-permeability magnetic material is passed along the coils' axis through the region over which oscillation of the magnetic zero plane occurs, it will initially be completely saturated by the DC magnetic field. It will next briefly be driven over its B-H loop as it passes through the zero field region. Finally it will become saturated again. The region over which the magnetic material is “active”, i.e. is undergoing magnetic changes, will be physically small, and is determined by the amplitude of the DC field, the amplitude of the AC field, and the characteristics of the magnetic material. This region can easily be less than 1 mm in extent. If the level of the alternating field is well below that required to saturate the magnetic material in the tag, then harmonics of the AC signal will be generated by the tag as it enters the zero field region of interrogator field and responds to the changing field. As the tag straddles the narrow zero field region the tag will be driven on the linear part of its B-H loop, and will interact by re-radiating only the fundamental interrogation frequency. Then, as the tag leaves the zero field region, it will again emit harmonics of the interrogation field frequency. A receiver coil arranged to be sensitive to fields produced at the zero field region, but which does not couple directly to the interrogator coils, will receive only these signals. The variation of these signals with time as the tag passes along the coils axis gives a clear indication of the passage of the ends of the magnetic material through the zero field region.
It will be appreciated that because the interrogation zone can be very narrow, each individual piece of magnetic material can be distinguished from its neighbors, from which it is separated by a small distance. Naturally, the magnetic material will be selected to suit the particular application for which the tag is intended. Suitable magnetic materials are commercially available, as described hereinbefore.
If a tag containing a number of zones or pieces of magnetic material placed along the axis of the label is now considered, it will be appreciated that as each zone or piece of magnetic material passes through the zero-field region, its presence and the positions of its ends can be detected. It then becomes a simple matter to use the lengths and spacing of individual zones or pieces of magnetic material to represent particular code sequences. Many different coding schemes are possible: one efficient arrangement is to use an analogue of the coding scheme used for optical barcodes, where data is represented by the spacing and widths of the lines in the code.
The system so far described allows for the scanning of a single-axis tag (e.g. a wire or a thin strip of anisotropic material, having a magnetic axis along its length) as it physically moves through the coil assembly. It will be appreciated that relative movement between the tag and the interrogating field can be achieved either with the field stationary and the tag moving, or vice versa. If required, the arrangement can be made self-scanning, and thus able to interrogate a stationary tag, e.g. by modulating the d.c. drive currents to the two interrogator coils, so that the zero field region scans over an appropriate portion of the axis of the coils. The extent of this oscillation needs to be a: least equal to the maximum dimension of a tag, and should preferably be considerably greater, to avoid the need for precise tag positioning within the interrogation zone.
By using extra coils arranged on the 2 axes orthogonal to the original, tags in random orientations can be read by sequentially field scanning. This involves much greater complexity in the correlation of signals from the three planes, but because of the very high spatial resolution available would be capable of reading many tags simultaneously present in a common interrogation volume. This is of enormous benefit for applications such as tagging everyday retail shopping items, and, for example, would allow automated price totalization of a bag of shopping at the point of sale. Thus the invention has applicability to the price labeling of articles and to point-of-sale systems which generate a sales total (with or without accompanying inventory-related data processing)
The size of a simple linear tag is dependent on the length of the individual elements, their spacing and the number of data bits required. Using strips of the highest permeability material commercially available, such as the “spin-melt” alloy foils available from suppliers such as Vacuumschmeltze (Germany) and Allied Signal (USA), the minimum length of individual elements which can be used is probably of the order of a few millimeters. This is because the extrinsic permeability will be dominated by shape factors rather than by the very high intrinsic permeability (typically 10 5 ), and shorter lengths may have insufficient permeability for satisfactory operation.
For this reason it is attractive to use very thin films of high permeability magnetic material. Provided it is very thin, (ideally less than 1 μm), such material can be cut into small 2 dimensional pieces (squares, discs, etc.) with areas of just 20 mm 2 or less, yet still retain high permeability. This will enable shorter tags than possible with elements made from commercially available high-permeability foils. Suitable thin film materials are available commercially from IST (Belgium).
An extension to this type of programming can also be used to prevent the composite tag producing an alarm in a retail security system (such an alarm would be a false indication of theft, and would thus be an embarrassment both to the retailer and to the purchaser). If different regions of the tag are biased with different static field levels, they will produce signals at different times when they pass through retail security systems. This will complicate the label signature in such systems and prevent an alarm being caused. In the present invention, the reading system will be able to handle the time-shifted signals caused by such magnetic biasing.
Thus far tag coding has been described on the basis of physically separated magnetic elements. It is not essential, however, to physically separate the elements; programming of data onto a tag may be accomplished by destroying the high-permeability properties of a continuous magnetic element in selected regions thereof. This can be done, for example, by local heating to above the re-crystallization temperature of the amorphous alloy, or by stamping or otherwise working the material. Of even more importance is the ability to magnetically isolate regions of a continuous element of high permeability material by means of a magnetic pattern stored on an adjacent bias element made from medium or high coercivity magnetic material. Such a composite tag could then be simply coded by writing a magnetic pattern onto the bias element using a suitable magnetic recording head. If required, the tag could then be erased (by de-gaussing with an AC field) and re-programmed with new data.
The scheme described can also be extended to operate with tags storing data in two dimensions. This allows for much more compact tags, since as well as being a more convenient form, a tag made up from an N×N array of thin-film patches has much more coding potential than a linear array of the same number of patches. This is because there are many more unique patch inter-relationships that can be set up in a given area.
FURTHER EMBODIMENTS
Use of Spatial Magnetic Scanning for Position Sensing
In addition to interrogating space to read data tags, this new technique of moving planes of zero field through space (or moving things through the planes) can be used to provide accurate location information for small items of high permeability magnetic material.
Thus, according to another aspect, the invention provides a method of determining the precise location of an object, characterized in that the method comprises: (a) securing to the object a small piece of a magnetic material which is of high magnetic permeability; (b) applying to the region in which said object is located a magnetic field comprising two opposed field components, generated by magnetic field sources, which result in a null field at a position intermediate said magnetic field sources; (c) applying a low amplitude, high frequency interrogating field to said region; (d) causing the position of the null field to sweep slowly back and forth over a predetermined range of movement; (e) observing the magnetic interaction between said applied magnetic field and said small piece of magnetic material; and (f) calculating the position of the object from a consideration of said magnetic interaction and from the known magnetic parameters relating to said applied field and to said small piece of magnetic material. Advantageously, the small piece of high permeability magnetic material is in the form of a thin foil, a wire or a thin film.
This aspect of the invention is of particular interest when the object whose location is to be determined is a surgical instrument, for example a surgical probe or needle. The invention allows precise determination of the location of, for example, a surgical probe during an operation.
This technique is ideal for accurate location of very small markers within relatively confined volumes; it can separately resolve multiple markers. It also displays low sensitivity to extraneous metal objects.
The magnetic tag or marker can typically be a 1 cm length (longer if desired) of amorphous wire (non-corrosive, diameter 90 micron or less) similar to that used in EAS tags or, with suitable process development, a short length (e.g. 1 cm) of a needle sputter-coated with a thin layer of soft magnetic material.
In use around the head of a patient, resolution to 0.1 mm with the described markers can be achieved. Accuracy should also have the potential to approach this value if some precautions about calibration and use of other magnetic materials are observed, but for optimum performance a rigid but open structure close to the head would be desired. The magnetic field levels employed will be lower than those generated by everyday magnets (e.g. kitchen door catches, etc.).
This technique has particular application to brain surgery, where there is the requirement to locate the position of probes in three dimensions and with high precision. It is therefore possible, in accordance with this invention, to use small magnetic markers on such probes or needles. In this case, a key advantage is that the signal from the marker need only be detected and resolved in time; the resolution is determined by the location of the zero field plane, not by the signal-to-noise ratio of the detected marker signal. This permits a very small marker to be used.
A single axis position sensor may be implemented with a set of coils similar to the tag reading system described above. This comprises: a pair of opposed coils carrying DC current to generate a DC field gradient; a means of applying a relatively uniform low level AC field to drive the marker in and out of saturation in the small region where the DC field is close to zero; and a means of applying a relatively uniform DC field of variable strength and polarity to move the location of the plane of zero DC field around the volume to be interrogated.
An anisotropic marker—i.e. one having a preferential axis of magnetization—resolves the magnetic field along its length. Such a marker can be obtained, for example, by using a long, thin element of a magnetic material or by suitable treatment of an area of magnetic material having a much lower aspect ratio, e.g. by longitudinally annealing a generally rectangular patch of a spin-melt magnetic material. In the context of the single axis position sensor under discussion there are five degrees of freedom (x, y, z and two angles (rotation of the marker about its axis has no effect)). Three orthogonal complete sets of coils can capture sufficient information by doing three scans of the uniform DC field on each of the sets of coils in turn. The first scan with no field from the other sets, the second with a uniform DC field from one of the other sets, and the third with DC field from the other set. This gives nine scans in all; these may be represented as in the following table, in which the magnetic field sources are identified as a, b and c and the scans are numbered from 1-9 (scanning order being of no significance)
Orthog-
onal
field
source
1
2
3
4
5
6
7
8
9
a
ON
ON
ON
OFF
OFF
ON
OFF
OFF
ON
b
OFF
ON
OFF
ON
ON
ON
OFF
ON
OFF
c
OFF
OFF
ON
OFF
ON
OFF
ON
ON
ON
The only information required from each scan is the position of the center of the harmonic output from the marker within that scan. These nine DC field values can then be converted into the xyz-theta-phi coordinates of the marker. To start with, the system can simply be used by holding the marker in the desired position before the head is put into the coils; and then when the head is placed in the coils the marker can be moved until the same signals are obtained.
An alternative to sequential interrogation which has the advantage of requiring less time to scan the region of interest is to rotate the magnetic field gradient continuously so as to scan all directions of interest. This can be accomplished by driving three sets of coils with appropriate continuous waveforms. For example, a suitable scanning field will be created if coils in the x, y and z planes are driven with currents I x , I y and I z given by the equations:
I x =cos ω a t ( A cos ω b t −sin ω b t . sin ω c t )−sin ω a t . cos ω c t
I y =sin ω a t ( A cos ω b t −sin ω b t . sin ω c t )+cos ω a t . cos ω c t
I z =A sin ω b t +cos ω b t . sin ω c t
where:
ω a =overall frequency of rotation of applied magnetic field
ω b =null scanning frequency
ω c =interrogation frequency
A=amplitude ratio ω b :ω c .
Typical (but non-limiting) values of these parameters are:
A=10;
frequency ratio ω a :ω b ≡1:10; and
frequency ratio ω b :ω c ≡1:400.
DESCRIPTION OF THE DRAWINGS
The invention will now be illustrated with reference to the accompanying drawings, in which:
FIG. 1 illustrates the fundamental elements of a tag reading system of the invention;
FIG. 2 is a circuit diagram illustrating one mode of generating the desired magnetic field pattern with the arrangement of FIG. 1;
FIG. 3 relates the magnetic response of a tag to its position within the reading system of FIG. 1;
FIG. 4 illustrates where magnetic nulls occur with a permanent magnet;
FIG. 5 illustrates an embodiment of the invention which utilizes a coil and a permanent magnet to generate the desired field pattern;
FIG. 6 illustrates an embodiment of the invention which utilizes a pair of permanent magnets to generate the desired field pattern;
FIG. 7 illustrates an embodiment of the invention which utilizes a plurality of permanent magnets disposed in an annular array with a coil to generate the desired field pattern;
FIG. 8 is a schematic circuit diagram for one embodiment of a tag interrogator in accordance with the invention;
FIG. 9 illustrates a selection of tags in accordance with this invention; and
FIG. 10 illustrates an embodiment of the invention as applied to surgical operations.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a schematic arrangement is shown in which a tag 1 is positioned mid-way between two coils Tx 1 and Tx 2 . The tag is of the type shown in FIG. 9 a , i.e. a simple linear tag carrying a plurality of magnetic elements each of which is a high-permeability magnetic alloy material, for example Vacuumschmeltze 6025 spin melt ribbon having an intrinsic permeability of about 10 5 . The reader will appreciate that the values given in this description for the various parameters associated with the elements shown in FIG. 1 are given merely by way of example, and illustrate one working embodiment. The values of these parameters will inevitably vary according to the overall size of the system and its intended function. The magnetic elements which constitute the discrete magnetically active regions of the tag have dimensions 10 mm×1 mm×25 microns; the spacing between adjacent elements is 1 mm. The two coils are spaced apart by approximately 20 cm and each comprise 450 turns of 0.56 mm copper wire wound in a square configuration typically 45 cm×45 cm. Each coil has a resistance of GD and an inductance of 100 mH. Each of the coils Tx 1 and Tx 2 carries a direct current I superimposed upon which is a smaller alternating current i; typically, the direct current I is of the order of 3A while the superimposed alternating current I is of the order of 50 mA. The alternating current i is of relatively high frequency, typically about 2 kHz.
With a system such as that just described, the alternating and direct currents in the two coils generate a magnetic field pattern in which there is a magnetic null in the direction of arrow x at points lying in a plane parallel to the two coils and mid-way between them. In FIG. 1, the x- and y-coordinates of this mid-way plane are represented by the lines 2 and 3 , respectively.
If a magnetic tag of this invention is passed through the two coils shown in FIG. 1, travelling in direction x and generally along the longitudinal axis defined between the center points of the two coils, ft will pass through a magnetic field polarity inversion at the mid-way plane defined by coordinates 2 and 3 . The change in polarity of the magnetic field comes about because the DC current flows in one sense in the first of the coils and in the opposite sense in the other of the coils, as indicated by the bold arrows in FIG. 1 . At the mid-way plane, the magnetic field component generated by the direct current flowing in the first coil exactly cancels the magnetic field component generated by the direct current flowing in the other coil.
As the tag travels through the center of the first coil, it experiences a high magnetic field which is sufficient to saturate its magnetically active elements; as the field strength decreases on moving towards the mid-way plane, the magnetic material is influenced by the decreasing magnetic field in a way dictated by its hysteresis curve. In the vicinity of the magnetic null, the direction of magnetization of the magnetic elements of the tag is reversed.
The relatively high frequency alternating current i shown in FIG. 1 is identical in each of the coils Tx 1 and Tx 2 .
The alternating current can have a frequency within a wide range, as indicated hereinbefore; a typical operating value with the arrangement of FIG. 1 is about 2 kHz. The effect of this relatively low amplitude alternating current is to cause the mid-way plane defined by coordinates 2 , 3 to oscillate about the geometric midpoint along the longitudinal axis defined between the midpoints of the two coils. In other words, the plane containing the magnetic null oscillates or wobbles back and forth over a small spatial region at the frequency of the alternating current.
FIG. 2 shows a simple circuit for providing opposed DC fields combined with AC fields. Capacitor C 1 is selected to resonate with the inductance of coils Tx 1 and Tx 2 at the AC drive frequency; each of these coils has a resistance of 6 ohms and an inductance of 100 millihenries. A typical value for C 1 is 0.1 μF. C 2 is a capacitor selected to behave as an effective short-circuit at the AC drive frequency; a typical value for this component is 22 μF. The DC power supply will typically provide 30 volts at 3 amps; and the AC source will typically deliver an alternating current at a frequency of 2 kHz at 2 v rms.
FIG. 3 illustrates how the magnetization of a single magnetic element varies with time at different positions within the magnetic field pattern defined between the coils Tx 1 and Tx 2 of FIG. 1 . For ease of illustration, the oscillation of the plane containing the magnetic null is represented by the bold double-headed arrow (←→) 4 , the extreme positions of the plane being represented by dashed lines 5 and 6 , respectively, and the mid-point between limiting planes 5 and 6 being represented by dashed line 7 . In the right hand portion of FIG. 3, the applied AC field is shown varying with time between positive (H+) and negative (H−) field values. Beneath the graph of the applied AC field, there are five graphs depicting how the net magnetization of the magnetic element varies with time in each of five geometric positions indicated to the left as Position 1 , Position 2 , etc. Planes 5 and 6 define the limits of regions within which magnetic field polarity reversals occur. In practice, the separation between planes 5 and 6 is typically of the order of 1 mm; for a given magnetic material, this distance can be increased or decreased at will within certain limits by varying the amplitude of the AC current and/or the DC current in the coils.
At all times, the magnetic element has a linear magnetic axis which is orthogonal to the planes 5 , 6 and 7 .
In Position 1 , the end of the magnetic element is adjacent to plane 6 ; in this condition, it experiences a positive magnetic field at all times and its net magnetization is time-invariant. In Position 2 , the leading end of the element has reached the mid-way plane 7 . Most of the magnetic material, however, still remains outside limiting plane 6 . In consequence, the null plane is able to interact with only a portion of the magnetic material, resulting in a time-variable net magnetization having the repeat pattern shown, i.e. a straight line positive-value portion followed by a generally sinusoidal arc which dips towards zero and then rises to its original positive value.
In Position 3 , the magnetic material is positioned symmetrically with respect to the mid-way plane 7 . Here, the net magnetization versus time plot consists of a sine wave whose frequency corresponds to that of the applied AC field. In Position 4 , the majority of the magnetic element experiences a negative field at all times, while a smaller part of the element experiences polarity reversals; this leads to the net magnetization versus time plot as shown. The fact that Position 4 is in effect the inverse of Position 2 is reflected in the relationship between the magnetization plots for these two positions; as can be seen, the plot for Position 4 is effectively a mirror image of that for Position 2 but with the curved portions time-shifted.
Finally, that Position 5 , all of the tag experiences the negative field, and no part of the tag experiences field polarity reversal. In consequence, the net magnetization is time-invariant, being a constant negative value as shown.
When a tag containing such a magnetic element is passed along the coils' axis through the region of zero field, it will initially be completely saturated by the DC magnetic field. It will next briefly be driven over its B-H loop as it passes through the zero field region. Finally it will become saturated again. The portion of the traverse over which the magnetic material is “active”, i.e. is undergoing magnetic changes, is physically small, and is determined by the amplitude of the DC field, the amplitude of the AC field, and the characteristics of the magnetic material. This region can easily be less than 1 mm in extent. If the level of the alternating field is well below that required to saturate the magnetic material in the tag, then harmonics of the AC signal will be generated by the tag as it enters the zero field region (Positions 1 to 2 ) and responds to the changing field. As the tag straddles the narrow zero field region (Position 3 ) the tag will be driven on the linear part of its B-H loop, and will interact by re-radiating only the fundamental interrogation frequency. Then, as the tag leaves the zero field region, (Positions 4 to 5 ) it will again emit harmonics of the interrogation field frequency.
A receiver (Rx) coil arranged to be sensitive to fields produced at the zero field region, but which does not couple directly to the interrogator (Tx) coils, will receive only these signals. Such an arrangement can be achieved by using separate Tx and Rx coils physically arranged to have low mutual coupling; or by using a single coil (having both Tx and Rx functions) together with suitable filtering in the Tx and Rx paths. The variation of these signals with time as the tag passes along the coils' axis gives a clear indication of the passage of the ends of the magnetic material through the zero field region.
The result of this interaction between the tag and the magnetic field it experiences is shown in FIG. 3 b . Here, the region 4 over which the magnetic null oscillates is shown on a smaller scale, and the numbered dots represent the location of the mid-point of the tag in each of Positions 1 - 5 . The generation of a harmonic signal by the tag (illustrated by the second harmonic of the applied frequency) is apparent at positions where the tag enters the region defined by limiting planes 5 and 6 , i.e. the zone where magnetic field polarity reversals occur. Because of the symmetry of the system, a single magnetic element will generate a doublet peak 8 a and 8 b since Positions 2 and 4 are redundant.
Referring now to FIG. 4, this illustrates the lines of force (i.e. the magnetic contours) existing with a simple bar magnet. The plane X-Y which intersects the longitudinal axis of the bar magnet and which is orthogonal to the plane of the paper constitutes a magnetic null plane. Thus a magnetic element possessing a sensitive magnetic axis aligned orthogonally with respect to the null plane will experience a magnetic null as it traverses either path A-B or path C-D. Consequently a simple bar magnet can be used as part of an interrogation system to detect the presence of such a magnetic tag, or to read information carried by such a tag.
The generation of second harmonic signal can form the basis of a tag detection system. If, instead of just a single magnetic element the tag includes a linear array of n magnetic elements, the second harmonic output from the tag will comprise n duplet peaks, each of the type shown in FIG. 3 b . If the size and magnetic characteristics of the magnetic elements are all the same, the peaks will have the same profile and each peak will define an envelope of constant area. The spacing between individual magnetic elements will influence the relative positions of the duplet peaks on an amplitude versus time plot. It will be appreciated that the present invention is not restricted to the use of such simple tags as just described. The use of magnetic elements of different sizes and magnetic characteristics, and with non-uniform spacing along the length of the magnetic tag, will generate more complex signal patterns which nevertheless are characteristic of the given tag construction. By varying the number, the magnetic characteristics, and the positioning of a series of magnetic elements, it is possible to manufacture a very large number of magnetic tags each with its own unique characteristics which will accordingly generate a unique signal when used in conjunction with the system of FIGS. 1-3.
It will also be appreciated that the invention is not limited to observing the second harmonic of the applied alternating frequency; this particular harmonic has been selected for the purposes of illustration since it is relatively easy to generate a transmit signal (Tx output) which has no (or very little) second harmonic content, thus permitting good discrimination between the Tx signal and the response of the tag; and since it also contains a relatively high proportion of the total harmonic energy output from the tag.
Referring next to FIG. 5, there is shown a schematic arrangement for a simple tag reader in accordance with this invention, the reader utilizing a permanent magnet 10 and a coil 11 located adjacent to one face of the magnet. In this embodiment, a tag which is to be read can be passed along path C-D through coil 11 or along path A-B above the coil. The tags must be oriented with their magnetic axis aligned with the direction of tag movement. In FIG. 5, the magnetic null plane is positioned at 12 as shown.
Referring next to FIG. 6, the use of two permanent magnets positioned with their magnetic axes aligned and with like poles opposing one another is illustrated. Such an arrangement generates a null plane 13 ; the direction of tag motion required is indicated by arrows 14 . Again, the magnetic axis of the tag must be aligned with the direction of movement.
FIG. 7 shows a simple realization of a tag reader head using a plurality of permanent magnets to generate a magnetic null plane. As illustrated ten polymer-bonded ferrite magnets are disposed in an annular array with like poles facing inwards. A common transmit/receive coil L 1 sits within the annulus of magnets in the manner indicated. The tag is read as it passes through the null plane in the center of the loop of magnets.
Referring next to FIG. 8, there is shown one embodiment of an interrogation system in accordance with this invention. This is based on the use of a single coil L 1 to act as both transmitter (Tx) coil, which generates the desired magnetic field pattern, and as the receiver (Rx) coil. The system uses the second harmonic output of the tag as the oasis for tag detection/identification. Circuit components C 1 and L 2 form a resonant trap at frequency 2 f to reduce signals at this frequency in the Tx output to a very low level; C 2 resonates with L 1 at frequency f; and components C 3 , C 4 , L 1 and L 3 form a filter to pass wanted signals from the tag at frequency 2 f while rejecting signals at the transmitted frequency f.
The output obtained from this circuit passes through a low pass filter to an analogue to digital converter (ADC) and thence to a digital signal processor. These components, and in particular the signal processor, will be configured to suit the intended application of the interrogation unit. The nature of the signal processing, and the means by which it is achieved, are all conventional and therefore will not be described further here.
FIG. 9 illustrates the basic structure of magnetic tags in accordance with the invention. FIG. 9 a shows a tag 100 which comprises a support medium 101 (e.g. paper or a plastics material) and a linear array of magnetically active regions 102 , 103 , 104 , 105 and 106 . Each magnetically active region is formed from a patch of high-permeability magnetic material (e.g. Vacuumschmeltze 6025) having its magnetic axis aligned along the length of the tag. Each patch is about 10 mm 2 in area and is adhesively secured to the substrate 101 .
Patches 102 - 105 are identical in dimensions and magnetic properties, and are uniformly spaced apart, gaps 110 , 111 and 112 all being the same. The gap between patches 105 and 106 , however, is larger—as though there were one patch missing at the position indicated by dotted lines at 113 .
Tag 100 behaves as a six-bit tag, coded 111101 (the zero being area 113 ).
A functionally equivalent tag 120 is formed of a substrate 121 carrying magnetic elements 122 - 126 and having a “gap” 127 ; in this embodiment the magnetic elements are in the form of a strip or wire of high-permeability magnetic material (e.g. Vacuumschmeltze 6025), typically being about 5 mm long, 1 mm wide and about 15 microns in thickness.
FIG. 9 b illustrates an alternative construction for a six-bit, laminated tag 130 . This tag is coded 111101, as in FIG. 9 a . Here, a continuous layer or length of high permeability magnetic material 131 (in the form of wire, strip, thin film or foil) and a substrate 133 have sandwiched between them a magnetic bias layer 132 . The bias layer is magnetized in predetermined areas which influence the overlying high permeability material to generate magnetically active regions indicated as 134 , 135 , 136 , 137 and 138 . Region 139 is not active, and thus constitutes a magnetic zero. When read by an interrogation system such as that of FIG. 8, the output generated by tags 100 , 120 and 130 will be as shown in FIG. 9 d.
A more complex tag is shown in FIG. 9 c . Here there are a series of parallel linear arrays of magnetically active material, generating a 4×4 array of sites where the magnetically active material may be present (coding as ‘1’) or absent (coding as ‘0’).
FIG. 10 illustrates the general arrangement of three sets of coils as used in accordance with this invention for surgical applications. The three sets of coils are all mutually orthogonal and define a cavity into which the head 200 of a patient may be positioned. The first coil set consists of coils 201 a and 201 b ; the second set consists of coils 202 a and 202 b ; and the third set consists of coils 203 a and 203 b . In the drawing, two surgical probes 204 and 205 are shown schematically in position within the patient's cranium. The probes each have, at their distal ends, a magnetic tag 206 , 207 such as one of those described with reference to FIG. 9 above. Because the magnetic element of the tag is only required to provide information of its presence (rather than hold extensive data), relatively simple tags are preferred. A single magnetic element of high permeability magnetic material located at the tip of the probe is sufficient. The coils are operated in the manner described in detail hereinabove. By means of the present invention, it is possible to determine the positions of the ends of the probes with high precision—and thus to carry out delicate surgical procedures with accuracy and with minimum damage to healthy tissue. | Magnetic tags or markers are disclosed, together with a variety of techniques by means of which such tags may be interrogated. In one aspect, the magnetic marker or tag which is characterised by carrying a plurality of discrete magnetically active regions in a linear array. In another aspect, the invention provides a method of interrogating a magnetic tag or marker within a predetermined interrogation zone, the tag comprising a high permeability magnetic material, for example to read data stored magnetically in the tag or to use the response of the tag to detect its presence and/or to determine its position within the interrogation zone, characterized in that the interrogation process includes the step of subjecting the tag sequentially to: (1) a magnetic field sufficient in field strength to saturate the high permeability magnetic material, and (2) a magnetic null as herein defined. Applications of such techniques are described, inter alia, in relation to (a) identifying articles to which tags are attached; (b) accurate determination of position, as in the location of surgical probes; and (c) totalisation of purchases, where each item carries a tag coded with data representing its nature and its price. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of co-pending U.S. application Ser. No. 11/503,925 filed on Aug. 15, 2006, and China Patent Application Nos. 200510028795.8, 200510028796.2, 200510028797.7, and 200510028798.1, all of which filed on Aug. 15, 2005 on which priority is claimed under 35 U.S.C. § 120, 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 using a fluid-bed catalyst for the preparation of ethylene and propylene by catalytic cracking, and in particular, using a fluid-bed catalyst for the preparation of ethylene and propylene by catalytically cracking naphtha.
[0004] 2. Description of Background Art
[0005] Currently, steam thermocracking is the most popular method for preparing ethylene and propylene, and naphtha is the raw material used most frequently. However, steam pyrolysis of naphtha has the disadvantages including a high reaction temperature, strict process conditions, high requirements for devices, especially furnace pipe materials, a large amount of CO 2 that is released and big loss. It has become an issue attracting more and more attention to seek a suitable cracking catalyst, which does not effect the above disadvantages.
[0006] In the patents U.S. Pat. No. 4,620,051 and U.S. Pat. No. 4,705,769 of Royal Philips Electronics (US), an oxide catalyst comprising manganese oxide or ferric oxide as the active component, the rare earth element La and the alkaline earth metal Mg is used for cracking C 3 and C 4 raw materials. The Mn,Mg/Al 2 O 3 catalyst is put in a fixed-bed reactor in a laboratory, the temperature is 700° C., the mol ratio of water to butane is 1:1, the butane conversion may reach 80%, and the ethylene and propylene selectivities are 34% and 20%, respectively. It is alleged in said two patents that naphtha and fluid-bed reactors are also usable.
[0007] The patent CN1317546A of Enichem SPA (IT) relates to a catalyst of the chemical formula 12CaO.7Al 2 O 3 for steam pyrolysis reactions. The raw material may be naphtha, the operational temperature is from 720 to 800° C., the pressure is from 1.1 to 1.8 atm, the contact time is from 0.07 to 0.2 second, and the ethylene and propylene yield may reach 43%.
[0008] In the patent USSR Pat1298240.1987 (USSR), Zr 2 O 3 supported on a pumacite or ceramic is used, the temperature is from 660 to 780° C., the space velocity of the moderate device is from 2 to 5 h −1 , the weight ratio of water to naphtha is 1:1. The raw materials are N-paraffin C 7-17 , cyclohexane and straight gasoline, the ethylene yield may reach 46% and the propylene yield may reach 8.8%.
[0009] The patent CN1480255A (CN) introduces an oxide catalyst for the preparation of ethylene and propylene by catalytically cracking the raw material naphtha at a temperature of 780° C., wherein the ethylene and propylene yield may reach 47%.
[0010] To sum up, the current technology of preparation of ethylene and propylene by catalytic cracking requires a relatively high reaction temperature, but the yields of ethylene and propylene are not remarkably increased.
SUMMARY AND OBJECTS OF THE INVENTION
[0011] The technical problems to be solved by the present invention are to remove the disadvantages of the prior catalytic cracking technology, including a high reaction temperature, and low activities and poor selectivities of the catalyst at a low temperature. The present invention provides a novel fluid-bed catalyst for the preparation of ethylene and propylene by catalytic cracking. Said catalyst has the advantages of a low reaction temperature, superior catalytic activities, and high selectivity for ethylene and propylene.
[0012] In order to solve the above technical problems, the present invention employs the following technical solution: a fluid-bed catalyst for the preparation of ethylene and propylene by catalytic cracking, said fluid-bed catalyst comprising a support selected from at least one of SiO 2 , Al 2 O 3 , molecular sieves and composite molecular sieves, and a composition of the following chemical formula based on stoichiometric ratio:
[0000] Mo 1.0 V a A b B c C d O x ,
[0013] wherein A is selected from at least one element of Groups VIII, IB, IIB, VIIB, VIIB, IA and IIA;
[0014] B is selected from at least one of rare earth elements;
[0015] C is selected from at least one of Bi and P;
[0016] a is from 0.01 to 0.5;
[0017] b is from 0.01 to 0.5;
[0018] c is from 0.01 to 0.5;
[0019] d is from 0 to 0.5; and
[0020] X represents the total number of oxygen atoms that meets the valances of the elements in the catalyst,
[0021] wherein the molecular sieve is at least one of ZSM-5, Y, β, MCM-22, SAPO-34 and mordenite, and the composite molecular sieve is a composite grown together from at least two molecular sieves of ZSM-5, Y, β, MCM-22, SAPO-34 and mordenite, and wherein the amount of the catalyst support as used is from 20 to 80% by weight on the basis of the weight of the catalyst.
[0022] In this technical solution, a is preferably from 0.01 to 0.3, b is preferably from 0.01 to 0.3, c is preferably from 0.01 to 0.3 and d is preferably from 0.01 to 0.3. The element of Group VIII is preferably selected from at least one of Fe, Co and Ni, the element of Group IB is preferably selected from at least one of Cu and Ag, the element of Group IIB is preferably Zn, the element of Group VIIB is preferably selected from at least one of Mn and Re, the element of Group VIB is preferably selected from at least one of Cr, Mo and W, the element of Group IA is preferably selected from at least one of Li, Na and K, and the element of Group IIA is preferably selected from at least one of Ca, Mg, Sr and Ba. The rare earth element is preferably selected from at least one of La and Ce. When Cr is a component of the catalyst, the ratio of Mo:Cr is 1:0.01 to 0.5 based on stoichiometric ratio. In a preferred catalyst support, the molecular sieve is selected from at least one of ZSM-5, Y zeolite, mordenite and β zeolite, and the composite molecular sieve is selected from at least one of ZSM-5/mordenite, ZSM-5/Y zeolite and ZSM-5/β zeolite. The silica-alumina mol ratios, SiO 2 /Al 2 O 3 , of said molecular sieve and said composite molecular sieve are from 10 to 500, preferably from 20 to 300. The amount of the catalyst support as used is preferably from 30 to 50% by weight on the basis of the weight of the catalyst.
[0023] The fluid-bed catalyst of the present invention for the preparation of ethylene and propylene by catalytic cracking is useful for catalytically cracking heavy oil, light diesel oil, light gasoline, catalytically cracked gasoline, gas oil, condensate oil, C 4 olefin or C 5 olefin.
[0024] The catalyst of the present invention is prepared by the following process; the raw material Mo is from ammonium molybdate or phospho-molybdic acid, V is from ammonium metavanadate or vanadium pentoxide, Bi is from bismuth nitrate, A elements are from the corresponding nitrate, oxalate, acetate, oxide or soluble halide, B elements are from the corresponding nitrate, oxalate, acetate, oxide or soluble halide, and phosphorus is from phosphoric acid, triammonium phosphate, diammonium phosphate, ammonium biphosphate; the catalyst is shaped by heating and refluxing a slurry comprising the component elements and a support in a water bath at a temperature of 70 to 80° C. for 5 hours, spray drying the slurry, and sintering the resultant powder in a muffle furnace at a temperature of 600 to 750° C. for 3 to 10 hours.
[0025] In the present invention, a series of transition metals and rare earth metals having cryosorption property, oxidation reduction property and dual functional acidic and basic sites complexation are used, which have relatively high low-temperature activities and play an oxidation catalysis effect on the raw materials. At a relatively low temperature of 600 to 650° C., the catalyst is used in a reaction of catalytically cracking naphtha, resulting in a total yield of ethylene and propylene of up to 45.3% and achieving a better technical effect.
[0026] The relevant catalyst is checked and evaluated with naphtha as the raw material (see Table 1 for specific indices). The reaction temperature ranges from 600 to 650° C., the load of the catalyst is from 0.5 to 2 g naphtha/g catalyst h, and the weight ratio of water to naphtha is 1.5 to 3:1. The internal diameter of the fluid-bed reactor is 39 mm, and the reaction pressure is from 0 to 0.2 MPa.
[0000]
TABLE 1
Indices of the naphtha raw material
Items
Data
Density (at 20° C.) kg/m 3
704.6
Distillation range Initial distillation range ° C.
40
Final distillation range ° C.
160
Saturated vapor pressure (at 20° C.) kPa
50.2
Paraffin % (by weight)
65.2
N-paraffin %
32.5
Cycloparaffin %
28.4
Olefin % (by weight)
0.17
Aromatic hydrocarbon % (by weight)
6.2
[0027] 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.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
[0028] 5.89 g bismuth nitrate was measured, and dissolved in 10 ml 1:1 concentrated nitric acid to produce a yellow solution. 30 g ammonium molybdate was measured and dissolved in 200 ml water. The ammonium molybdate aqueous solution was then added into the bismuth nitrate solution. The resultant mixed solution was stirred to prepare solution (I).
[0029] 3 g ammonium metavanadate was measured and added in 100 ml water. Then, 2 ml 80% phosphoric acid was dripped and 3 g oxalic acid was added into the mixture of ammonium metavanadate and water. The resultant mixture was heated till ammonium metavanadate was completely dissolved, thus to prepare solution (II).
[0030] 7.86 g cobalt nitrate, 5.58 g cerium nitrate and 6.72 g calcium nitrate were measured and dissolved in 250 ml water to prepare solution (III).
[0031] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 26 g silica was measured and added into the mixed solution. The resultant solution was refluxed for 5 hours, and dried with a spray drier for shaping. The resultant powder was sieved, and put into a muffle furnace. The temperature was then elevated to 740° C. The powder was sintered for 5 hours. After it was cooled, the catalyst was sieved.
[0032] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Co 0.16 Ca 0.17 Ce 0.08 O x +30.6% support.
[0033] The activities of the catalyst were evaluated under the following conditions: a fluid-bed reactor having an internal diameter of 39 mm, a reaction temperature of 650° C., a pressure of 0.15 MPa, a weight ratio of water to naphtha of 3:1, a loading amount of the catalyst of 20 g, and a load of 1 g naphtha/g catalyst·h. The gaseous products were gathered for gas chromatography. The product distribution is shown in Table 2.
[0000]
TABLE 2
Distribution of main cracked products and yields of ethylene and
propylene
Products
Amounts (% by weight)
Methane
18.32
Ethane
3.54
Ethylene
33.47
Propane
0.56
Propylene
13.53
C 4
4.57
Conversion
87.5
Ethylene yield
31.53
Propylene yield
12.96
Ethylene + propylene yield
44.49
Example 2
[0034] Solutions (I) and (II) were prepared according to the steps described in Example 1. 10.91 g ferric nitrate, 3.73 g nickel nitrate, 5.85 g lanthanium nitrate and 1.1 g potassium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0035] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 26 g aluminium oxide was added into the solution.
[0036] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Fe 0.16 Ni 0.08 K 0.06 La 0.08 O x +30.06% support.
[0037] The activities of the catalyst were evaluated under the conditions described in Example 1. The product distribution is shown in Table 3.
[0000]
TABLE 3
Distribution of main cracked products and yields of ethylene and
propylene
Products
Amounts (% by weight)
Methane
18.34
Ethane
2.05
Ethylene
38.32
Propane
0.28
Propylene
10.53
C 4
3.31
Conversion
87.5
Ethylene yield
33.63
Propylene yield
9.38
Ethylene + propylene yield
43.01
Example 3
[0038] Solutions (I) and (II) were prepared according to the steps described in Example 1. 7.86 g cobalt nitrate, 1.68 g barium nitrate, 2.79 g cerium nitrate and 1.30 g potassium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0039] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 30 g silicon dioxide and 1.5 g aluminium oxide were added into the solution.
[0040] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Co 0.16 Ba 0.04 K 0.04 Ce 0.08 O x +37.5% support.
[0041] The activities of the catalyst were evaluated under the conditions described in Example 1. The yields of the products were as follows: an ethylene yield of 29.89%, a propylene yield of 7.37% and an ethylene+propylene yield of 37.25%.
Example 4
[0042] Solutions (I) and (II) were prepared according to the steps described in Example 1. 3.73 g cobalt nitrate, 3.10 g copper nitrate, 2.79 g cerium nitrate and 1.30 g potassium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0043] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 15 g silicon dioxide and 11 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 150 were added into the solution.
[0044] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Co 0.08 Cu 0.08 K 0.08 Ce 0.04 O x +34.3% support. The activities of the catalyst were evaluated under the conditions described in Example 1 The yields of the products were as follows: an ethylene yield of 25.55%, a propylene yield of 16.73% and an ethylene+propylene yield of 42.28%.
Example 5
[0045] Solutions (I) and (II) were prepared according to the steps described in Example 1. 7.86 g cobalt nitrate, 0.8 g zinc nitrate and 5.85 g lanthanium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0046] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 20 g silicon dioxide and 6 g H-mordenite having a silica-alumina ratio of 20 were added into the solution.
[0047] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Cu 0.16 Zn 0.2 La 0.08 O x +32.7% support. The activities of the catalyst were evaluated under the conditions described in Example 1. The yields of the products were as follows: an ethylene yield of 28.57%, a propylene yield of 13.69% and an ethylene+propylene yield of 42.26%.
Example 6
[0048] Solutions (I) and (II) were prepared according to the steps described in Example 1. 7.86 g cobalt nitrate, 3.10 g copper nitrate and 5.85 g lanthanium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0049] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 18 g aluminium oxide and 8 g H-β zeolite having a silica-alumina ratio of 30 were added into the solution.
[0050] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Co 0.16 Cu 0.08 La 0.08 O x +31.8% support. The activities of the catalyst were evaluated under the conditions described in Example 1. The yields of the products were as follows: an ethylene yield of 28.85%, a propylene yield of 12.58% and an ethylene+propylene yield of 41.43%.
Example 7
[0051] Solutions (I) and (II) were prepared according to the steps described in Example 1. 7.86 g cobalt nitrate, 6.39 g chromium nitrate, 5.86 g cerium nitrate and 2.60 g potassium nitrate were measure and dissolved in 250 ml water, thus to prepare solution (III).
[0052] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 18 g aluminium oxide and 8 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 40 were added into the solution.
[0053] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Cu 0.16 Cr 0.09 K 0.15 Ce 0.08 O x +30.6% support. The activities of the catalyst were evaluated under the conditions described in Example 1. The yields of the products were as follows: an ethylene yield of 33.74%, a propylene yield of 10.37% and an ethylene+propylene yield of 44.01%.
Example 8
[0054] Solutions (I) and (II) were prepared according to the steps described in Example 1. 10.91 g ferric nitrate, 0.80 g zinc nitrate and 2.2 g lanthanium oxide were measure and dissolved in 250 ml water. An appropriate amount of nitric acid was dripped into the mixture till the precipitates were completely dissolved, thus to prepare solution (III).
[0055] Solutions (I), (II) and (III) were mixed. The mixed solution was heated and stirred, and then 10 g silicon dioxide, 1 g aluminium oxide, 10 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 200, and 5 g H-mordenite having a silica-alumina ratio of 30 were added into the solution.
[0056] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.15 Fe 0.16 Zn 0.02 La 0.0.8 O x +33.0% support. The activities of the catalyst were evaluated under the conditions described in Example 1. The yields of the products were as follows: an ethylene yield of 32.29%, a propylene yield of 8.22% and an ethylene+propylene yield of 40.51%.
Example 9
[0057] 3 g ammonium metavanadate was measured and added in 100 ml water. Then, 2 ml 80% phosphoric acid was dripped and 3 g oxalic acid was added into the mixture of ammonium metavanadate and water. The resultant mixture was heated till ammonium metavanadate was completely dissolved, thus to prepare solution (I).
[0058] 30 g ammonium molybdate, 7.61 g ferric nitrate, 10.88 g chromium nitrate and 4.08 g lanthanium nitrate were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. After the diammonium phosphate aqueous solution was added into solution (II), precipitates were generated.
[0059] Solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 16 g silicon dioxide, 2 g aluminium oxide, 8 g H-MCM-22 molecular sieve having a silica-alumina ratio of 40 and 7 g H-β zeolite having a silica-alumina ratio of 30 were measured and added into the mixed solution. The resultant mixture were refluxed for 5 hours and dried with a spray drier for shaping.
[0060] The resultant powder was sieved and put into a muffle furnace. Then the temperature was elevated to 740° C. The powder was sintered for 5 hours. After it was cooled, the catalyst was ground into powder in a grinder and passed through a 100-mesh sieve.
[0061] The resultant catalyst was represented by the chemical formula: Mo 1.0 V 0.15 P 0.10 Fe 0.11 Cr 0.16 La 0.06 O x +34.1% support.
[0062] The activities of the catalyst were evaluated under the following conditions: a fluid-bed reactor having an internal diameter of 39 mm, a reaction temperature of 650° C., a pressure of 0.15 MPa, a weight ratio of water to naphtha of 3:1, a loading amount of the catalyst of 20 g, and a load of 1 g naphtha/g catalyst·h. The gaseous products were gathered for gas chromatography. The product distribution is shown in Table 4.
[0000]
TABLE 4
Distribution of main gas phrase products and yields of ethylene and
propylene
Amounts (H 2 : % by volume; others: % by
Products
weight)
Hydrogen gas (% by volume)
16.3
Methane
14.2
Ethane
2.10
Ethylene
32.24
Propane
0.51
Propylene
15.83
C 4
3.46
Others
15.20
Conversion
85.13
Ethylene yield
30.27
Propylene yield
14.88
Ethylene + propylene yield
45.15
Example 10
[0063] 284 g sodium metasilicate was measured and dissolved in 300 g distilled water to prepare solution A. 33.3 g aluminium sulphate was measured and dissolved in 100 g distilled water to prepare solution B. Solution B was slowly added into solution A. The mixed solution was stirred intensely. Then, 24.4 g ethylene diamine was added into the mixed solution. After stirring for some time, dilute sulphuric acid was added into the mixed solution to adjust the pH to 11.5. The mol proportion of the sol was controlled such that Si:Al:ethylene diamine:H 2 O is 1:0.1:0.4:40. The mixed solution was put into an autoclave and kept at a temperature of 180° C. for 40 hours. Then, it was taken out, washed with water, dried and sintered to produce a composite molecular sieve composed of ZSM-5 and mordenite. An ammonium nitrate solution having a concentration of 5% was used for interchange at 70° C. twice, and then sintering was carried out. The interchanging and sintering steps were repeated twice to produce a H-ZSM-5/mordenite composite molecular sieve.
[0064] Solution (I) was prepared according to the steps described in Example 9.
[0065] 30 g ammonium molybdate, 7.61 g ferric nitrate, 5.88 g zinc nitrate and 5.60 g cerium nitrate were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. The diammonium phosphate aqueous solution was added into solution (II), and then, solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 16 g silicon dioxide, 2 g aluminium oxide, and 18 g H-ZSM-5/mordenite composite molecular sieve having a silica-alumina ratio of 20, which was prepared above, were then added into the mixed solution.
[0066] The resultant catalyst was represented by the chemical formula: Mo 1.0 V 0.15 P 0.10 Fe 0.11 Zn 0.12 Ce 0.08 O x +37.8% support.
[0067] The activities of said catalyst were evaluated under the conditions described in Example 9. The product distribution and the yields of ethylene and propylene are shown in Table 5.
[0000]
TABLE 5
Distribution of main gas phrase products and yields of ethylene and
propylene
Amounts (H 2 : % by volume; others: % by
Products
weight)
Hydrogen gas (% by volume)
15.86
Methane
13.47
Ethane
2.03
Ethylene
32.65
Propane
0.45
Propylene
15.33
C 4
6.58
Others
13.11
Conversion
84.34
Ethylene yield
30.86
Propylene yield
14.53
Ethylene + propylene yield
45.39
Example 11
[0068] 284 g sodium metasilicate was measured and dissolved in 300 g distilled water to prepare solution A. 33.3 g aluminium sulphate was measured and dissolved in 100 g distilled water to prepare solution B. Solution B was slowly added into solution A. The mixed solution was stirred intensely. Then, 24.4 g ethylene diamine was added into the mixed solution. After stirring for some time, dilute sulphuric acid was added into the mixed solution to adjust the pH to about 11.5 g Y zeolite crystal seed was added into the mixed solution. The mol proportion of the sol was controlled such that Si:Al:ethylene diamine:H 2 O is 1:0.1:0.4:40. The mixed solution was put into an autoclave and kept at a temperature of 170° C. for 36 hours. Then, it was taken out, washed with water, dried and sintered to produce a composite molecular sieve composed of ZSM-5 and Y zeolite. An ammonium nitrate solution having a concentration of 5% was used for interchange at 70° C. twice, and then sintering was carried out. The interchanging and sintering steps were repeated twice to produce a H-ZSM-5/Y zeolite composite molecular sieve.
[0069] Solution (I) was prepared according to the steps described in Example 9.
[0070] 30 g ammonium molybdate, 7.61 g ferric nitrate, 7.29 g nickel nitrate, 5.60 g lanthanium nitrate and 5.18 g calcium nitrate were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. The diammonium phosphate aqueous solution was added into solution (II), and then, solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 16 g silicon dioxide, 2 g aluminium oxide, and 18 g H-ZSM-5/Y zeolite composite molecular sieve having a silica-alumina ratio of 20, which was prepared above, were then added into the mixed solution.
[0071] The resultant catalyst was represented by the chemical formula: Mo 1.0 V 0.15 P 0.10 Fe 0.11 Ni 0.15 Ca 0.13 La 0.08 O x +35.2% support.
[0072] The activities of said catalyst were evaluated under the conditions described in Example 9. The yields of the products were as follows: an ethylene yield of 25.97%, a propylene yield of 15.52% and an ethylene+propylene yield of 41.49%.
Example 12
[0073] 284 g sodium metasilicate was measured and dissolved in 300 g distilled water to prepare solution A. 33.3 g aluminium sulphate was measured and dissolved in 100 g distilled water to prepare solution B. Solution B was slowly added into solution A. The mixed solution was stirred intensely. Then, 24.4 g ethylene diamine and 10 g tetraethyl ammonium hydroxide were added into the mixed solution. After stirring for some time, dilute sulphuric acid was added into the mixed solution to adjust the pH to about 12.5 g β zeolite crystal seed was added into the mixed solution. The mol proportion of the sol was controlled such that Si:Al:ethylene diamine:H 2 O is 1:0.1:0.4:40. The mixed solution was put into an autoclave and kept at a temperature of 160° C. for 40 hours. Then, it was taken out, washed with water, dried and sintered to produce a composite molecular sieve composed of mordenite and P zeolite. An ammonium nitrate solution having a concentration of 5% was used for interchange at 70° C. twice, and then sintering was carried out. The interchanging and sintering steps were repeated twice to produce a mordenite/β zeolite composite molecular sieve.
[0074] Solution (I) was prepared according to the steps described in Example 9.
[0075] 30 g ammonium molybdate, 7.61 g ferric nitrate, 7.29 g nickel nitrate, 5.44 g cerium nitrate and 6.30 g copper nitrate were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. The diammonium phosphate aqueous solution was added into solution (II), and then, solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 16 g silicon dioxide, 2 g aluminium oxide, and 18 g mordenite/β zeolite composite molecular sieve having a silica-alumina ratio of 20, which was prepared above, were then added into the mixed solution.
[0076] The resultant catalyst was represented by the chemical formula: Mo 1.0 V 0.15 P 0.10 Fe 0.11 Ni 0.15 Cu 0.15 Ce 0.07 O x +35.2% support.
[0077] The activities of said catalyst were evaluated under the conditions described in Example 9. The yields of the products were as follows: an ethylene yield of 29.53%, a propylene yield of 12.69% and an ethylene+propylene yield of 42.22%.
Example 13
[0078] Solution (I) was prepared according to the steps described in Example 9.
[0079] 30 g ammonium molybdate, 5.49 g cobalt nitrate, 5.60 g zinc nitrate, 5.44 g cerium nitrate and 1.10 g potassium nitrate were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. The diammonium phosphate aqueous solution was added into solution (II), and then, solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 14 g silicon dioxide, 2 g aluminium oxide, 12 g H-ZSM-5/mordenite composite molecular sieve having a silica-alumina ratio of 20, which was prepared above, and 8 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 150 were then added into the mixed solution.
[0080] The resultant catalyst was represented by the chemical formula: Mo 1.0 V 0.15 P 0.10 C 0.11 Zn 0.11 K 0.06 Ce 0.07 O x +36.7% support.
[0081] The activities of said catalyst were evaluated under the conditions described in Example 9. The yields of the products were as follows: an ethylene yield of 36.53%, a propylene yield of 8.59% and an ethylene+propylene yield of 45.12%.
Example 14
[0082] Solution (I) was prepared according to the steps described in Example 9.
[0083] 30 g phospho-molybdic acid, 5.89 g bismuth nitrate, 5.49 g cobalt nitrate, 5.32 g nickel nitrate, 5.44 g cerium nitrate and 10.81 g 50% manganese nitrate solution were measured and dissolved in 250 ml water to prepare solution (II). 2.24 g diammonium phosphate was dissolved in 100 ml water. The diammonium phosphate aqueous solution was added into solution (II), and then, solution (I) was added into solution (II). The mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 30 g silicon dioxide and 2 g aluminium oxide were then added into the mixed solution.
[0084] The resultant catalyst was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.13 P 0.17 Co 0.1 Ni 0.1 Mn 0.16 Ce 0.07 O x +30.3% support.
[0085] The activities of said catalyst were evaluated under the conditions described in Example 9. The yields of the products were as follows: an ethylene yield of 36.12%, a propylene yield of 6.67% and an ethylene+propylene yield of 42.79%.
Example 15
[0086] Mixed solution (I) and diammonium phosphate-containing mixed solution (II) were prepared according to the steps described in Example 14. Said mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 36 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 150 were added into the mixed solution. After shaping by the same method, a catalyst was obtained, which was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.13 P 0.17 Co 0.1 Ni 0.1 Mn 0.16 Ce 0.07 O x +30.3% support.
[0087] The activities of said catalyst were evaluated under the conditions described in Example 9. In the resultant products, the ethylene yield was 36.54%, the propylene yield was 7.84%, and the total yield of ethylene and propylene was 44.38%.
Example 16
[0088] Mixed solution (I) and diammonium phosphate-containing mixed solution (II) were prepared according to the steps described in Example 14. Said mixed solution was heated and stirred in a water bath at a temperature of 70 to 80° C. 36 g H-ZSM-5/mordenite composite molecular sieve having a silica-alumina ratio of 30 were added into the mixed solution. After shaping by the same method, a catalyst was obtained, which was represented by the chemical formula: Mo 1.0 Bi 0.07 V 0.13 P 0.17 Co 0.1 Ni 0.1 Mn 0.16 Ce 0.07 O x +30.3% support.
[0089] The activities of said catalyst were evaluated under the conditions described in Example 9. In the resultant products, the ethylene yield was 37.27%, the propylene yield was 8.24%, and the total yield of ethylene and propylene was 45.51%.
Example 17
[0090] A mixed solution was prepared according to the steps described in Example 1.5 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 150 and 10 g silicon dioxide were added as support into the mixed solution. A catalyst represented by the chemical formula Mo 1.0 Bi 0.07 V 0.15 Co 0.16 Ca 0.17 Ce 0.08 O x +20.2% support was prepared according to the same method. It was checked and evaluated by the method described in Example 1. The results are shown in Table 6”, which is at the first line of the page 19 of the description, to “The ethylene yield was 15.25%, the propylene yield was 30.68% and the total yield of ethylene and propylene was 45.93%.
Example 18
[0091] A mixed solution was prepared according to the steps described in Example 1. 500 g distilled water was added to dilute the mixed solution. 60 g H-ZSM-5/mordenite composite molecular sieve having a silica-alumina ratio of 20, 100 g H-ZSM-5 molecular sieve having a silica-alumina ratio of 200, 40 g β zeolite having a silica-alumina ratio of 30 and 22 g silicon dioxide were added into the diluted mixed solution. A catalyst represented by the chemical formula Mo 1.0 Bi 0.07 V 0.15 Co 0.16 Ca 0.17 Ce 0.08 O x +79.2%. support was prepared according to the method described in Example 1. It was checked and evaluated by the method described in Example 1. The ethylene yield was 14.43%, the propylene yield was 32.17% and the total yield of ethylene and propylene was 46.60%.
Example 19
[0092] The catalyst prepared in Example 1 was used. Light diesel oil having a boiling point of lower than 350° C. was used as reaction material. Evaluation was carried out under the conditions described in Example 1. The ethylene yield was 29.14%, the propylene yield was 10.55% and the total yield of ethylene and propylene was 39.69
Example 20
[0093] The catalyst prepared in Example 1 was used. Mixed C 4 (paraffin:olefin=1:1) was used as reaction material. Evaluation was carried out under the following conditions: a temperature of 550° C., a water/oil ratio of 3:1 and a space velocity the same as the space velocity described in Example 1. The ethylene yield was 12.73%, the propylene yield was 39.13% and the total yield of ethylene and propylene was 51.86%.
[0094] 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 method for preparation of ethylene and propylene by catalytic cracking using a fluid-bed catalyst. The main technical problems to be solved are a relatively high reaction temperature, and low activities and poor selectivities of the catalyst at a low temperature, during the reaction for preparing ethylene and propylene by catalytically cracking naphtha. The fluid-bed catalyst is a composition of the chemical formula Mo 1.0 V a A b B c C d O x based on stoichiometric ratio. The method using the fluid-bed catalyst has satisfactorily solved the above-mentioned problems, and is useful in the industrial production of ethylene and propylene by catalytically cracking naphtha. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a wavelength conversion laser apparatus for converting wavelength by utilizing a nonlinear optical crystal, more specifically to a wavelength conversion laser apparatus in which the nonlinear optical crystal can be easily managed.
[0003] 2. Description of Related Art
[0004] In short wavelength laser apparatus, nonlinear optical crystals are generally utilized for wavelength conversion. Ultra violet solid state laser devices among such laser apparatus are generally constructed as follows. A fundamental wave laser light of 1064 nm in wavelength is oscillated by a Nd:YAG laser, Nd:YAG laser or the like. The nonlinear optical crystal generates a second harmonic wave of the fundamental wave laser light. Furthermore, third and fourth harmonic waves are also generated by nonlinear optical crystals. Crystals to be utilized for generating the second harmonic wave include an LBO crystal or a KIP crystal. Crystals to be utilized for generating the third harmonic wave include an LBO crystal, a BBO crystal or GdYCOB crystal. Crystals to be utilized for generating the fourth harmonic wave include a BBO crystal, a CLBO crystal or the like. Most of such nonlinear optical crystals are deliquescent. In order to prevent them from degrading by moisture absorption, it is required to pay special attention to atmosphere where the crystals are disposed, especially humidity where they are used.
[0005] Particularly, a CLBO crystal which is the nonlinear optical crystal to be utilized for generating the fourth harmonic wave exhibits significant crystal degradation in 30% or higher relative humidity. A crystal cell model no. 10031 commercially available from Crystal Association Inc. employs a method for filling a dry gas in the cell. Alternatively, there is an instance where a nonlinear optical crystal is used in dipping into oil. In Japanese patent non-examined publication no. 9-292638 (or JP-A-292638/94) entitled “High Output Ultra Violet Laser Light Generation Apparatus”, a deliquescent-free protection film is formed on the ultra violet light output end surface of the nonlinear optical crystal.
[0006] However, one problem associated with such conventional technique of simply filling a dry gas in a crystal cell is a limited lifetime. In other words, if any defect may occur in the sealing structure during a long time use, humidity in the sealed container tends to change. If the laser is continuously used in high humidity condition inside the cell, the nonlinear optical crystal is increasingly degraded and damaged. This accompanies with significant decrease in wavelength conversion efficiency and thus significant decrease in the laser output.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to provide a wavelength conversion laser apparatus that can be safely used for a long time by controlling the laser light generation operation by accurately detecting any humidity change in atmosphere of the nonlinear optical crystal.
[0008] In order to achieve the above object, the wavelength conversion laser apparatus according to the present invention includes harmonic wave generation means for receiving the laser light of a predetermined wavelength and generating the harmonic wave thereof, and the harmonic wave generation means comprises a sealed container formed with a through-hole through which the laser light propagates and windows at the laser light incident and output sides of the through-hole, a nonlinear optical crystal disposed in the through-hole and a humidity sensor disposed in the through-hole. In this arrangement, humidity change in atmosphere of the nonlinear optical crystal can be accurately detected.
[0009] Additionally, a control portion for controlling the laser light source is provided. When humidity in atmosphere of the nonlinear optical crystal is increased, the laser light source is interrupted to prevent the nonlinear optical crystal from being damaged.
[0010] In the wavelength conversion laser apparatus which is constructed as described hereinabove, the humidity sensor continuously and accurately monitors humidity in the cell in which the nonlinear optical crystal is accommodated, thereby enabling the user to use the wavelength conversion laser apparatus without any fear of damaging the nonlinear optical crystal. It is to be noted that the units for generating the harmonic wave are connected in series to generate sequentially higher order of harmonic waves.
[0011] Additionally, the provision of the control portion for controlling the laser light source by receiving the signal from the humidity sensor enables to stop the laser light source and prevent the nonlinear optical crystal from being damaged in case when humidity in atmosphere of the nonlinear optical crystal is increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a simplified side cross sectional view of one embodiment of the wavelength conversion laser apparatus according to the present invention;
[0013] [0013]FIG. 2 is a simplified cross section view of a nonlinear optical crystal cell in the embodiment of the wavelength conversion laser apparatus;
[0014] [0014]FIG. 3 is a simplified cross section view of a cover member for the nonlinear optical crystal cell of the embodiment of the wavelength conversion laser apparatus; and
[0015] [0015]FIG. 4 is a simplified block diagram of a humidity monitoring apparatus of the embodiment of the wavelength conversion laser apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Now, an embodiment of the present invention will be described in detail hereunder by reference to the accompanying drawings, namely FIG. 1 through FIG. 4.
[0017] An embodiment of the present invention is the wavelength conversion laser apparatus in which a humidity sensor for detecting humidity in a sealed container filled with a dry inert gas and for accommodating a nonlinear optical crystal which generates harmonic waves upon receiving a laser light having a predetermined wavelength, and the humidity sensor is connected to a laser control portion.
[0018] [0018]FIG. 1 illustrates a simplified side cross sectional view of one embodiment of the wavelength conversion apparatus according to the present invention. In FIG. 1, mirrors 1 and 2 are reflection mirrors which constitute a resonator for the fundamental wave laser light. A pumping chamber unit 3 is a unit including a solid state laser medium (such as Nd:YAG, Nd:YVO 4 , etc.) to be excited by a semiconductor laser. A Q switch 4 , a Brewster plate 5 , a shutter 6 and a first focusing lens 7 are basic elements constituting a solid state laser. Heaters 8 a , 8 b , 8 c are heating means for maintaining the solid state laser at constant temperature. A temperature sensor 9 is means for detecting temperature of the solid state laser. A case 11 is a case to constitute a container of the fundamental wave unit (A). The case 11 is U-shape in cross section and has a window for outputting the fundamental wave laser light. A cover member 12 is a cover of the container of the fundamental wave unit (A) for hermetically covering the upper face of the case 11 . The container 13 is a container for accomodating the fundamental wave unit (A) and comprises the case 11 and the cover member 12 .
[0019] A first nonlinear optical crystal unit 20 is a unit which contains an LBO crystal, a KTP crystal or the like for converting the fundamental wave laser light having the predetermined wavelength (angular oscillation frequency ω) into a second harmonic wave (angular oscillation frequency 2 ω). A second focusing lens 21 is a lens which focuses the second harmonic wave. A separation mirror 22 is a half mirror which separates the fundamental wave from the second harmonic wave. An output window 23 is a window through which the second harmonic wave is outputted. A unit case 24 is a case which accommodates a first wavelength conversion unit (B).
[0020] A second nonlinear optical crystal unit 30 is a unit which converts the laser light from the first wavelength conversion unit (B) into a third harmonic wave (or a fourth harmonic wave). A collimation lens 31 is a lens which converts the third harmonic wave (or fourth harmonic wave) into a parallel light. A separation mirror 32 is a half mirror which separates the second harmonic wave from the third (or fourth) harmonic wave. A power meter 33 is means which measures the output of the third or fourth harmonic wave. An output window 34 is a window through which the third (or fourth) harmonic wave is outputted outside the unit. A unit case 35 is a container which accommodates the second wavelength conversion unit (C).
[0021] The wavelength conversion laser apparatus as illustrated in FIG. 1 comprises the fundamental wave unit (A), the first wavelength conversion unit (B) and the second wavelength conversion unit (C). The fundamental wave unit (A) comprises basic optical units such as the mirrors 1 and 2 , the pumping chamber unit 3 , the Q switch 4 , the Brewster plate 5 , the shutter 6 , the first focusing lens 7 , etc. The elements constituting the fundamental wave unit ω) are accommodated in the container 13 . Filled in the container 13 is an inert gas such as nitrogen or the like. The heaters 8 a , 8 b , 8 c are suitably buried in the bottom portion 11 a of the case 11 . The temperature sensor 9 for monitoring temperature in the container 13 is disposed near the pumping chamber unit 3 . The first wavelength conversion unit (B) comprises the first nonlinear optical crystal unit 20 , the focusing lens 21 and the separation mirror 22 . The first nonlinear optical crystal unit 20 includes an LBO crystal, a KIP crystal or the like which converts the fundamental wave laser light which is focused by the focusing lens 7 and propagates through the window 14 into the second harmonic wave. The separation mirror 22 is a half mirror which separates the fundamental wave from the second harmonic wave. These optical devices are accommodated in the unit case 24 which is provided with the output window 23 .
[0022] On the other hand, the second wavelength conversion unit (C) comprises the second nonlinear optical crystal unit 30 , the collimation lens 31 , the separation mirror 32 and the power meter 33 . The optical devices such as the second nonlinear optical crystal unit 30 , the collimation lens 31 , the separation mirror 32 and the power meter 33 are accommodated in the unit case 35 which is provided with the output window 34 . The above described construction is the same as the conventional wavelength conversion laser apparatus.
[0023] [0023]FIG. 2 is a simplified cross section view of the nonlinear optical crystal cell of the embodiment of the wavelength conversion laser apparatus according to the present invention. In FIG. 2, the cell main body 40 corresponds to the first nonlinear optical crystal unit 20 or the second nonlinear optical crystal unit 30 . A foundation table 41 is a table on which the nonlinear optical crystal is placed. A through-hole 42 is a path through which the laser light propagates. A nonlinear optical crystal 43 is an LBO crystal or the like. A nonlinear optical crystal holder 44 is a member which holds down the nonlinear optical crystal on the table 41 . A heater 45 is heating means which keeps the cell at constant temperature.
[0024] An opening portion 46 is an opening in the cell main body 40 . A cell cover member 50 is a cover of the cell. A humidity sensor 51 is means which measures humidity of the cell. A hermetic seal terminal 52 is a pick-up port for a lead. A humidity detection circuit board 53 is a circuit board for a hygrometer. A recessed portion 54 is a portion in which the humidity sensor 51 is accommodated in the cell cover member 50 . A humidity detection amplifier circuit 55 as shown in FIG. 4 is a circuit of the hygrometer. Cell windows 60 a , 60 b are input and output ports for the laser light. Nonlinear optical crystal cell holders 70 a , 70 b are members which hold down the windows 60 a , 60 b . O-rings 80 a , 80 b , 80 c , 80 d , 80 e are hermetic sealing members.
[0025] Now, the first or second nonlinear optical crystal unit 20 , 30 is collectively referred to as a nonlinear optical crystal unit (NLU) hereinafter. The nonlinear optical crystal unit (NLU) comprises the cell main body 40 of U-shape in cross section and having the through-hole through which the laser light propagates in the horizontal direction and the cell cover member 50 which hermetically covers the opening portion 46 of the cell main body 40 . The foundation table 41 is provided at the center portion of the cell main body 40 which defines the through-hole 42 . Disposed on the foundation table 41 is the nonlinear optical crystal 43 which generates the harmonic wave. The nonlinear optical crystal 43 is secured on the cell main body 40 by the crystal holder 44 .
[0026] The recessed portion 54 is formed in the bottom surface of the cell cover member 50 , i.e., the surface which faces the through-hole 42 . The humidity sensor 51 is mounted inside the recessed portion 54 and at a location remote from the through-hole 42 so that the laser light is not interfered. In order to achieve electrical insulation, the humidity sensor 51 is connected through the hermetic seal terminal 52 to the humidity detection circuit board 53 which is provided outside the cell main body 40 (i.e., on the cell cover member 50 ).
[0027] Disposed at both left and right ends of the through-hole 42 are the cell windows 60 a , 60 b which hermetically seal the nonlinear optical crystal unit (NLU), the window holders 70 a , 70 b which secure the cell windows 60 a , 60 b onto the cell main body 40 by interposing the O-rings 80 a , 80 b , 80 c , 80 d , 80 e between the cell main body 40 and the cell cover member 50 . An inert gas such as Ar, N 2 or the like is filled in the sealed unit (NLU) which has the above construction. The heater 45 is buried in the cell main body 40 so as to maintain temperature of the unit constant.
[0028] The O-rings 80 a , 80 b , 80 c , 80 d , 80 e used herein are resistant to high temperature. Preferably, carlet material which is commercially available from DuPontDow Elastomer Inc. is used as the O-rings 80 because it has very low gas emission and gas permeability and yet provides a long sealing lifetime. Used as the cell windows 60 a , 60 b which are disposed in the propagation path of the laser light is synthetic quartz glass or CaF 2 which can resist high output laser.
[0029] Used as the humidity sensor 51 is an electrical capacity type humidity sensing device which is formed by vapor deposition on a glass substrate and emits no gas from the sensor portion. The humidity sensor 51 is highly durable. In order to detect humidity in the through-hole 42 , the humidity sensing device is mounted on one side surface portion of the cover member at the location which does not interrupt the through-hole 42 . Since the humidity sensor 51 is disposed in the medium which does not interrupt the propagation path of the laser light, it causes no adverse effect on the use of the laser apparatus. The humidity sensing device is connected to the humidity detection circuit board 53 which is disposed on the other side surface of the cover member 50 through the hermetic seal terminal 52 in order to electrically isolate the cell cover member 50 .
[0030] Now, illustrated in FIG. 3 is a simplified cross section view of the cover member of the nonlinear optical crystal cell which constitutes the embodiment of the wavelength conversion laser crystal cell. On the other hand, illustrated in FIG. 4 is a simplified block diagram of the humidity monitoring apparatus of the embodiment of the wavelength conversion laser apparatus according to the present invention. In FIG. 3 and FIG. 4, the hygrometer 56 is means which measures humidity. A switch 57 is one which turns the laser light on or off. A laser control portion 58 is an apparatus for controlling the laser light source. The output from the humidity sensor 51 in the unit (NLU) is supplied to the hygrometer 56 by way of the humidity detection amplifier circuit 55 which is provided on the humidity detection circuit board 53 . The output of the humidity detection amplifier circuit 55 is supplied by way of the switch 57 to the laser control portion 58 which shuts off the operation of the laser apparatus.
[0031] Now, operation of the embodiment of the wavelength conversion laser apparatus according to the present invention which has the abovementioned construction will be described hereunder. Firstly, the outline function of the wavelength conversion laser apparatus will be described by reference to FIG. 1. A solid state laser medium is utilized as the laser light source. The fundamental wave laser light of 1064 nm emitted from the pumping chamber unit 3 which is the fundamental laser light is focused by the focusing lens 7 and propagates into the first nonlinear optical crystal unit 20 through the window 14 . The first nonlinear optical crystal unit 20 is an LBO crystal, a KTP crystal or the like which converts the fundamental wave laser light which is focused by the focusing lens 7 and propagates through the window 14 into the second harmonic wave, i.e., the laser light of 532 nm in wavelength. A part of the fundamental wave laser light which is an incident light to the first optical crystal unit 20 is converted into the second harmonic wave by the first optical crystal unit 20 and is outputted from the nonlinear optical crystal. The separation mirror 22 separates the fundamental wave from the second harmonic wave.
[0032] Furthermore, the incident fundamental wave laser light and the second harmonic wave which are propagated through the focusing lens 21 and the output window 23 are inputted to the second nonlinear optical crystal unit 30 . The second nonlinear optical crystal unit 30 converts the laser light from the first wavelength conversion unit (B) into the third harmonic wave of 355 nm in wavelength (or the fourth harmonic wave of 266 nm in wavelength). The nonlinear optical crystal converts the laser light from the first wavelength conversion unit (B) into the third or fourth harmonic wave before being outputted from the output window 34 . The separation mirror 32 separates the second harmonic wave from the third (or fourth) harmonic wave. An LBO crystal, a BBO crystal or GdCOB crystal may be utilized as the nonlinear optical crystal which generates the third harmonic wave. On the other hand, a BBO crystal or a CLBO crystal may be utilized as the nonlinear optical crystal which generates the fourth harmonic wave. By controlling temperature of the heaters 8 a , 8 b , 8 c by way of a temperature controlling apparatus (not shown) based on the output from the temperature sensor 9 , temperature inside the container is always maintained at desired value. What is described hereinabove is the same as the conventional wavelength conversion laser apparatus.
[0033] Now, the operation of the nonlinear optical crystal unit (NLU) will be described hereunder by reference to FIG. 2 and FIG. 3. The incident laser light to the nonlinear optical crystal unit is converted into the harmonic wave and outputted from the nonlinear optical crystal. The heater 45 which is buried in the cell main body 40 is utilized to maintain temperature of the unit constant. The humidity sensor 51 detects humidity inside the through-hole 42 . It is possible to dispose the humidity sensor 51 in the cell main body 40 through the opening portion 46 in the cell main body 40 . Because the humidity sensor 51 and the humidity detection circuit board 53 are disposed on the cell cover member 50 , it is possible to mount the humidity sensor 51 at the appropriate location of the nonlinear optical crystal unit when the cover member 50 is assembled. It is also easy to inspect these devices.
[0034] Now, the operation of the humidity monitoring apparatus will be described by reference to FIG. 4. The output from the humidity sensor 51 in the unit (NLU) is supplied to the hygrometer 56 by way of the humidity detection amplifier circuit 55 which is provided in the humidity detection circuit board 53 . The output of the humidity detection amplifier circuit 55 is supplied by way of the switch 57 to the laser control portion 58 which interrupts the operation of the laser apparatus. Provision of the humidity sensor 51 in the nonlinear optical crystal unit (NLU) enables the user of the laser apparatus to monitor humidity inside the nonlinear optical crystal unit (NLU) by the hygrometer 56 . As a result, it is possible to manually (or automatically) turn off the switch 57 and to interrupt the laser oscillation when humidity exceeds a predetermined value.
[0035] As understood from the above description, the embodiment of the wavelength conversion laser apparatus according to the present invention features in that a dry inert gas is filled in the sealed container accommodating the nonlinear optical crystal which generates the harmonic wave of the laser light of a predetermined wavelength and that the humidity sensor which detects humidity inside the sealed container is provided and connected to the laser control portion. Accordingly, if the humidity sensor detects any humidity increase, the laser is immediately controlled to stop oscillation, thereby preventing the nonlinear optical crystal from being damaged. | The present invention is a wavelength conversion laser apparatus for converting wavelength by utilizing a nonlinear optical crystal and capable of safely using it over a long time. For this end, the fundamental wave laser light emitted from the pumping chamber unit 3 which is a solid state laser light source is converted into the second harmonic wave by the first nonlinear optical crystal unit 20 . And the second harmonic wave is, then, converted into the third (or fourth) harmonic wave by the second nonlinear optical crystal unit 30 . Filled in the container 24, 35 for each of the nonlinear optical crystal units 20, 30 is a dry inert gas. A humidity sensor 51 detects humidity inside the container. The output from the humidity sensor 51 is supplied to the laser control portion 58 . When the detected humidity exceeds a predetermined value, the laser oscillation is interrupted, thereby preventing the nonlinear optical crystal from being damaged in case of any defect in the sealing structure of the container. | 7 |
This application is a Divisional Application of pending U.S. application Ser. No. 11/805,786 filed May 24, 2007, which claims priority of U.S. Provisional Application Ser. No. 60/923,747 filed Apr. 17, 2007 and Provisional Application Ser. No. 60/930,646 filed May 18, 2007 now abandoned.
FIELD OF INVENTION
The present invention is concerned with rechargeable batteries, and in particular with the recharging of rechargeable batteries.
BACKGROUND OF THE INVENTION
1. For batteries to be used for applications such as vehicle starter, electric bikes, electric motorcycles, electric or hybrid vehicles, etc, high voltage is essential owing to the increase of efficiency and the decrease of cost. The increase of voltage requires batteries to be connected in series.
2. Problems associated with batteries in series are:
a. when one battery has a lower capacity, the capacity of the overall set of batteries is dictated by the capacity of the battery of lower capacity; b. if the battery possessing the lower capacity can not be charged to full capacity during charging, the performance of the entire battery set will be degraded owing to the lower capacity battery. This is known in the art as cell imbalance; c. the lower capacity of one specific battery can be caused by either high self discharge or defects during battery production.
3. Conventional ways to solve the cell imbalance problem are:
a. sorting the batteries in order to avoid inconsistency of the batteries to be connected in series; b. charging the batteries separately (e.g. U.S. Pat. No. 6,586,909), in order to overcome the problems mentioned above, however, low voltage is required for charging each battery to full (for example, the lithium iron battery is charged to 3.65V) and this low voltage charging is not energy efficient owing to conversions from normal high voltage AC power source to low voltage DC power.
Most prior art systems and methods utilized in making the batteries balanced during charging use complicated circuitry to detect and balance the uncharged batteries (e.g. U.S. Pat. No. 7,068,011, U.S. Pat. No. 7,061,207, U.S. Pat. No. 6,882,129, U.S. Pat. No. 6,841,971, U.S. Pat. No. 6,825,638, U.S. Pat. No. 6,801,014, U.S. Pat. No. 6,784,638, U.S. Pat. No. 6,777,908, U.S. Pat. No. 6,700,350, U.S. Pat. No. 6,642,693, U.S. Pat. No. 6,586,909, U.S. Pat. No. 6,511,764, U.S. Pat. No. 6,271,645).
OBJECT OF THE INVENTION
It is an object of the present invention to provide a simple device and method for charging a plurality of batteries electrically connected in a series circuit.
SUMMARY OF THE INVENTION
The present invention is a rechargeable battery assembly, having a rechargeable battery with a positive terminal and a negative terminal, and means for self-discharging the rechargeable battery when a voltage across the terminals is greater or equal to a preset value. The means for self-discharging is electrically connected in parallel with the battery terminals
DESCRIPTION OF THE DRAWINGS
The invention will become more readily apparent from the following description thereof shown, by way of example only, in the accompanying drawings, wherein:
FIGS. 1 a - e are schematic illustrations of various embodiments of battery assemblies of the invention;
FIG. 2 a is a schematic illustration of a battery assembly of the invention with an enlarged drawing of a self-discharging circuit of the invention;
FIG. 2 b is a schematic illustration the battery assembly of the invention with an enlarged drawing of another embodiment of a self-discharging circuit of the invention;
FIG. 3 is a schematic illustration of the battery assembly of the invention having the self-discharging circuit disposed on a case of the battery;
FIG. 4 is a schematic illustration of an electric power supply system having battery assemblies of the invention;
FIGS. 5 a - e are schematic illustrations of battery packs having battery assemblies of the invention
FIGS. 6 a - e are schematic illustrations of battery packs having battery assemblies of the invention differing from those of FIGS. 5 a - e;
FIGS. 7 a - e are schematic illustrations of battery packs having battery assemblies of the invention differing from those of FIGS. 5 a - e and 6 a - e;
FIGS. 8 a - e are schematic illustrations of battery packs having battery assemblies of the invention differing from those of FIGS. 5 a - e , 6 a - e and 7 a - e;
FIG. 9 is a schematic illustration of a battery pack assembly having battery assemblies of the invention;
FIG. 10 is a schematic illustration of a battery system having battery assemblies of the invention, as discussed in example 3; and
FIG. 11 is a schematic illustration of a battery system having battery assemblies of the invention, as discussed in example 5.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is especially important for resolving the problems caused by batteries connected in series. A cell imbalance problem during charging can be alleviated by creating a device and methods that allows the leakage of current (energy) from the batteries being overcharged. Instead of using very expensive devices or ways to prevent overcharging, to achieve battery equalization, as found in prior art devices and methods, the present invention uses a method and device that reduces the current being provided to a battery in the series circuit that is being overcharged. Such method and device can be implemented for each battery or battery set or battery pack being connected in series. The terminology “battery set” used throughout the specification means a plurality of batteries connected in parallel, or series, or parallel-series, or series-parallel. The terminology “battery pack” used throughout the specification means a plurality of battery sets connected in parallel, or series, or parallel-series, or series-parallel. The terminology “assembly” used throughout the specification means a battery, a battery set, or a battery pack accompanied with a means for self-discharge of the battery(s), battery set or battery pack when the battery(s) is(are) being overcharged
In the present invention a battery or batteries self-discharge when overcharged. Since each battery, battery set, or battery pack are provided with a “self-discharge” means, when voltage reaches a preset parameter during charging, or even after charging, a cell balance problem can be eliminated. This is the core idea of the present invention.
FIG. 1( a ) shows the structure of a “battery assembly”. FIG. 1( b ) shows the structure of a “parallel battery set assembly”; FIG. 1( c ) shows the structure of a “series battery set assembly”; FIG. 1( d ) shows the structure of a “parallel-series battery set assembly”; and FIG. 1( e ) shows the structure of a “series-parallel battery set assembly”. These assemblies are the basic units for use in providing the battery pack. In these figures, as well as in the remaining figures, an individual rechargeable battery is indicated at 1 , and a circuit for self-discharging the rechargeable battery(s) is indicated at 3 .
The present method of solving the cell imbalance problem is shown in FIG. 2( a ). As indicated in FIG. 2( a ), each battery is connected with a device 2 in parallel with the battery. Such device is comprised of a switching element 6 , a resistance element 7 , a voltage-detecting element 5 a , and a switching element controller 5 b that opens or closes the switching element 6 . The voltage-detecting element detects the voltage of the battery and along with the switching element controller controls the “opened” or “closed” state of the switching element. The switching element, resistance element, voltage-detecting element and switching element controller can be disposed on a printed circuit board. However, since a transistor can function as a combination of a voltage-detecting element, controller, switching element, and a resistance element, the device shown in FIG. 2( a ) can be replaced by a transistor, or a plurality of transistors connected in parallel (for adjusting the resistance). Other possibilities are one transistor 8 connected with a resistor 7 in series as shown in FIG. 2( b ). In the case of the transistor and resistor connected in series as indicated in FIG. 2( b ), the resistance of the resistor should be small in order to minimize the voltage drop caused by the resistor thus affecting the voltage detection of the transistor. The configuration of FIG. 2( b ) can also be applicable to diodes such as LEDs, or a printed circuit board consisting of the switching element and the controller only.
When batteries are charged, if the voltage of one of the batteries is above a preset upper limit, the switching element of the device electrically connected in parallel to the battery closes, therefore allowing current to flow through the resistor. Thus, the charging current for the battery that passed the preset upper limit voltage decreases, due to the presence of the device connected in parallel to the battery. Such decrease is shown in Example 1, below. Under such condition, other batteries are charged in a normal current flow but the one that passed the upper voltage limit has a decreased charging action. This is a basic mechanism of the invention for the prevention of battery overcharging. It should be mentioned that the resistance element can be any electronic component that possesses a satisfactory resistance. For example, a light bulb can be used as a source of resistance.
The elements of the device can be on a semiconductor chip 2 , which can be disposed anywhere close to the battery. FIG. 3 shows one possibility of the semiconductor chip 2 being built-in on the lid of a case of a battery. Also, for example, the chip can be disposed between the cathode (the case) 11 and the anode (the negative terminal) 12 . Also, the chip can be placed inside the battery case.
The resistor can be a variable one if further precise control of the resistance is necessary. Details of the current change for each battery during charging are further described below:
Example 1
Theoretical Demonstration of how cell Equalization can be Achieved
Assumptions:
1. Four battery assemblies are connected in series as indicated in FIG. 2( a ).
2. Batteries ( 1 ), ( 3 ), ( 4 ) have internal resistance of 5 mOhm, battery ( 2 ) has an internal resistance of 10 mOhm.
3. Batteries ( 1 ), ( 3 ), ( 4 ) have open circuit voltage of 3.3V, battery ( 2 ) has an open circuit voltage of 3.6V.
4. For each battery assembly, a resistor of 1.0 Ohm is connected parallel to the battery.
5. A power supply of 15V is applied to the four battery assemblies connected in series.
Calculation Case 1 (when Paralleled Resistors are all Open):
During charging of the four battery assemblies, the voltage of each battery can be represented as:
Battery ( 1 ): V 1 =Vo 1 +I 1 R 1 , V 1 is the voltage of the battery ( 1 ) during charging, Vo 1 is the open circuit voltage of battery ( 1 ), I 1 is the current passing through battery ( 1 ) and R 1 is the internal resistance of the battery ( 1 ).
Battery ( 2 ): V 2 =Vo 2 +I 2 R 2 ,
Battery ( 3 ): V 3 =Vo 3 +I 3 R 3 ,
Battery ( 4 ): V 4 =Vo 4 +I 4 R 4 ,
Since no other resistors are connected, I 1 =I 2 =I 3 =I 4 =I
15=( V 1 +V 2 +V 3 +V 4 )=( Vo 1 +Vo 2 +Vo 3 +Vo 4 )± I ( R 1 +R 2 +R 3 +R 4 )
15−( Vo 1 +Vo 2 +Vo 3 +Vo 4 )= I ( R 1 +R 2 +R 3 +R 4 )
15−3.3−3.6−3.3−3.3 =I (0.005+0.01+0.005+0.005)
I=60 Amp - - - The current that passes through each battery
Calculation Case 2, (when the Paralleled Resistor Circuit is Closed for Battery ( 2 )):
Assume I′ is the current passing through the resistor and R′ is the resistance of the resistor.
Then,
V 2 =I′R′,I′=V 2 /R′
V 2 =Vo 2 +I 2 R 2 ,
Considering the current balance: (I′+I 2 )=I 1 =I 3 =I 4 =I
So,
V 2 =Vo 2 +( I−I ′) R 2 =Vo 2 +( I−V 2 /R ′) R 2
Rearrange, then we get
V 2 =( Vo 2 +IR 2 )/(1 +R 2 /R ′)
Thus,
15=( V 1 +V 2 +V 3 +V 4 )=( Vo 1 +Vo 3 +Vo 4 )+ I ( R 1 +R 3 +R 4 )+( Vo 2 +IR 2 )/(1 +R 2 /R ′)
So,
I= 61.672(A),
V 2 =( Vo 2 +IR 2 )/(1 +R 2 /R ′)=4.175(V),
I′=V 2 /R′= 4.175(A),
I 2 =I−I′= 57.497(A)
If we substitute a resistor of 10 Ohm, then
I= 60.168(A),
V 2 =Vo 2 +( I−V 2 /R ′) R 2 =4.1975(V),
I′=V 2 /R′= 0.4198(A),
I 2 =I−I′= 59.748(A)
Conclusions from the Calculations:
1. With regards to battery assembly of FIG. 2( a ), when the switch of the resistor in the parallel circuit is closed, current flows through the resistor, and the charging current for battery ( 2 ) is decreased. 2. While the switch of the paralleled resistor circuit is closed for the battery assembly of FIG. 2( a ), the charging current for other batteries ( 1 , 3 , 4 ) is increased. 3. The resistance of the resistor dictates the magnitude of the current decrease for battery ( 2 ). The smaller the resistance, the bigger the magnitude of current decrease. 4. Thus, the idea of incorporating a resistor with each battery connected in series is effective in balancing the capacity of all batteries by decreasing the charging current of the battery that has a higher capacity, and by increasing the charging current of the other batteries that have a lower capacity. 5. It is clear that the resistor connected in parallel with the battery should possess satisfactory cell balancing function. Any electronic devices or components that satisfy the function of voltage sensing and providing the source of resistance are within the focus of the present invention.
Example 2
Theoretical Calculation Demonstrating a Method of Charging a Battery Assembly
Assumptions:
1. Four battery assemblies are connected in series as indicated in FIG. 2( a ).
2. Batteries ( 1 ), ( 3 ), ( 4 ) have internal resistance of 5 mOhm, battery ( 2 ) has an internal resistance of 10 mOhm.
3. Batteries ( 1 ), ( 3 ), ( 4 ) have open circuit voltage of 3.3V, battery ( 2 ) has an open circuit voltage of 3.6V.
4. Batteries ( 1 ), ( 2 ), ( 3 ), and ( 4 ) are subjected to a constant current charge. The current is 2 A.
5. For demonstration purpose, the battery being investigated, battery ( 2 ), a resistor of 1.0
Ohm is connected parallel to the battery and the circuit switch is closed.
Calculations:
Considering the current balance: (I′+I 2 )=I 1 I 3 =I 4 =I=2(A)
V 2 =Vo 2 +( I−I ′) R 2 =Vo 2 +( I−V 2 /R ′) R 2
Rearrange, then we get
V 2 =( Vo 2 +IR 2 )/(1 +R 2 /R ′)
Substituting Vo 2 =3.6(V), I=2 (A), R 2 =0.01 Ohm, R′=1 Ohm
We get:
V 2 =3.5842(V)
I′=V 2 /R′= 3.5842(A),
I 2 =I−I′= 2−3.5842=−1.5842(A)<0
Conclusions from the Calculations:
1. The battery that is overcharged will undergo discharging when the circuit current (I) is less than the current that passes the resistor (I′). That is, (I-I′<0). 2. When batteries being overcharged undergo discharge, cell balance can be achieved. 3. By combining the calculation results shown in Example 1 and 2, it can also be concluded that the cell balance charging method can be implemented as either a constant voltage mode (but the charging time required should be longer than the time required for the condition of I<I′), or a constant current mode by passing a current (I) that is less than the current that passes the resistor (I′). 4. It can further be concluded that the charger can be designed to have two modes for charging. One mode is the normal constant current/constant voltage charge mode for a battery system's normal use (end of charge executed by setting a certain charging time). The other mode is the cell balance mode (constant current charging) that can be used when a battery system possesses less capacity than their normal use.
Example 3
A Battery Pack and a Battery System
As mentioned above, a battery pack can be comprised of battery sets, or battery set assemblies as shown in FIG. 1( a )-( e ). In the present invention, a battery pack may also connect with a parallel circuit containing a switching element, a voltage-detecting element, a controller, and a resistance element to form a “battery pack assembly”. The possible structures of battery packs constructed using battery set assemblies are shown in FIGS. 5( a )-( e ), FIGS. 6( a )-( e ), FIGS. 7( a )-( e ), and FIGS. 8( a )-( e ). These figures represent the five unit structures shown in FIGS. 1( a )-( e ) being connected in various circuit arrangements. In series ( FIGS. 5( a )-( e )), in parallel ( FIGS. 6( a )- 6 ( e )), in parallel-series ( FIGS. 7( a )- 7 ( e )), and in series-parallel ( FIGS. 8( a )- 8 ( e )). Each of the cases shown in FIGS. 5 , 6 , 7 , and 8 can again be combined with a parallel circuit containing the switching element, the controller, the voltage-detecting element and the resistance element to form a “battery pack assembly”. An example of a “battery pack assembly” is shown in FIG. 9
Similar to the case as a battery pack that is comprised of battery sets or battery set assemblies, a battery system is comprised of battery packs or battery pack assemblies. Again, the possible structures of a battery system constructed using battery pack assemblies can be in series, parallel, parallel-series, and series-parallel. An example of a “battery system” is shown in FIG. 10 .
One practical case is described here, that is an example of the battery system for an electric motorcycle. Referring to FIG. 10 , a typical electric motorcycle uses a battery system having 53V, and 40 Ah. The battery system is comprised of four battery packs (13.3V) connected in series. Each of the battery packs consists of four lithium iron battery sets (3.33V) connected in series. And, each of the battery sets consists of four 10 Ah batteries connected in parallel. In this case, the best structure of the battery system is the utilization of battery pack assemblies and the battery set assemblies, as building blocks for the battery system. In such arrangement, overcharging of battery packs and overcharging of battery sets can be prevented. If the battery system is constructed using battery pack assemblies but the pack assemblies are constructed by battery sets only, some possible overcharging in the battery set may occur after long time cycling. If the battery system is constructed using battery packs only and the battery packs are constructed using battery sets rather than battery set assemblies, cell imbalance accompanied with overcharging during charging can occur.
Example 4
A Preferred Electric Power Supply System
An electric power supply system is the integration of components including a charger 4 , a battery system (packs or sets), a control board 10 , and a circuit breaker 9 , as shown in FIG. 4 . Again, four battery assemblies of the invention are connected in series as a simplest example for demonstration. Referring to FIG. 4 , it can be seen that each battery is connected in parallel with a circuit consisting of components as shown in FIG. 2( a ) or FIG. 2( b ). A control board is connected with electrical conductors to each terminal of each of the batteries. Those electrical conductors serve as a means for providing voltage detection. The other end of the control board is connected to a circuit breaker. The charger is connected directly to the two ends of the batteries electrically connected in series. During a normal charging (constant current/constant voltage), if any of the batteries exceeds a preset overcharge voltage, the control board sends a signal to the circuit breaker for charging termination. Similarly, during such discharging, if any of the batteries is below the preset termination voltage, the control board sends a signal to the circuit breaker for discharging termination. These two actions serve as battery protection to avoid overcharging and over discharging. During normal charging, a preset time period is allowed for the charging action (e.g. termination at 1.5 hours after constant voltage charging). At that time, the batteries may be more or less balanced. However, the batteries could be balanced after several chargings, or by just starting a balance charging (small current constant and current charge, current amplitude I<I′) mode, to allow constant current charging until all the batteries are balanced.
In the present case, the control board can be a very simple device for detecting the voltages of each battery connected in series and sending signals to the circuit breaker for charging or discharging action termination. The simplicity of the control board is thus benefited by the characteristics of the batteries of the invention since they possess current leakage during charging. In the present invention, the shutting off of the charging is preferably executed by a electromagnetic relay that turns off the power input or output. This electromagnetic relay preferably requires no power consumption during the idle state, and a pulse signal generated by the control board determines the close and open circuit status of the relay and therefore the on and off of the battery charging.
Example 5
Methods to Achieve Cell Equalization as Described in Example 1
Referring to FIG. 11 , in the present example, a total of eight 10 Ah lithium iron batteries are used for demonstrating the charging method and the cell balancing characteristic of the batteries during charging. Two cells are first connected in parallel to form a parallel battery set. Each set of the batteries are then connected with a circuit (a printed circuit board, for example) electrically connected in parallel with the battery set to form a battery assembly. Four battery assemblies are then connected in series. In the present case, the first set, second set, third set, and the fourth set are named for the four battery set assemblies connected in series for clarity. All four set assemblies are first charged to 100% full. The first battery set assembly is then subjected to discharge 10% capacity (2 Ah). After this procedure, all four battery set assemblies are connected in series and this setup is referred to as the battery pack. A preset self-discharge activation voltage is set at 3.75V in the present case. The self-discharge circuit that is parallel to each battery set has a resistance of 2 Ohm. After the above mentioned procedures, the battery pack is subjected to a constant current charge of 1.7 A. The voltage changes versus time for each set of the batteries are shown in Table I. From Table I it can be seen that the 2 nd , 3 rd , and 4 th battery set assembly had a voltage increase beyond 3.75V in the initial state. 5 minutes after, the 2 nd , 3 rd , and 4 th battery set assembly came back to be stabilized at 3.75V. At this time, the current passing through the resistor is measured to be 1.8 A.
The 1 st set of the battery set assembly increases its voltage gradually to 3.75V after 80 minutes and this is the end of the charge balance action. In the present experiment, I (power supply current) is set to be less than I′ (current passing resistor). As a result, the voltages for the 2 nd , 3 rd , and 4 th sets of battery set assemblies were stabilized at 3.75V during charging. Full balances of the four sets of battery set assemblies were achieved after a certain period of time. It was observed that if current I is set to be slightly larger than current I′ (1.8 A in this case), and the voltages of the 2 nd , 3 rd , and 4 th battery sets could be higher than 3.75V during the constant current charge. However, if the constant voltage charge is set at 15V as the second step charging, a voltage decrease of 2 nd , 3 rd , and 4 th battery sets can be observed (when current I starts decreasing below current I′) and the four sets of battery set assemblies can be balanced eventually, but requiring a longer time.
TABLE I
Voltage versus time for each set of the batteries.
40138 12V20Ah Lithium Iron Cell Balance
Charging Test
Constant current charge (current = 1.7A)
Set Number
1
2
3
4
Initial Voltage (V)
3.344
3.354
3.348
3.35
Time (minutes)
Voltage for each set (V)
0
3.401
3.883
3.852
3.861
5
3.457
3.761
3.757
3.759
10
3.462
3.752
3.761
3.762
15
3.473
3.753
3.755
3.757
20
3.481
3.756
3.751
3.754
30
3.499
3.759
3.752
3.757
40
3.558
3.753
3.756
3.755
50
3.633
3.758
3.754
3.756
60
3.757
3.751
3.753
3.754
70
3.752
3.757
3.756
3.752
80
3.759
3.751
3.754
3.755 | A rechargeable battery, battery set or battery pack having a circuit or a plurality of circuits for providing self-discharging thereof electrically connected in parallel are used to form rechargeable battery assemblies and electric power supply systems for use in electric and hybrid vehicles and the like. | 7 |
This is a continuation of application Ser. No. 443,422 filed Feb. 19, 1974, now abandoned, which is a continuation of application Ser. No. 278,540, filed Aug. 8, 1972, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to computer controlled data systems and, more particularly, to a programmed computer system for the production of embossed cards and retrievable data.
The primary application for the methods of this invention is the registration of attendees at large gatherings, such as trade shows or conventions. In many fields, periodic gatherings of large numbers of persons with the same interests or for same purpose are very common. For example, a trade association of companies in some particular field may stage each year a trade show of selected products manufactured or sold by its exhibiting member companies. Such a trade show is an important marketing method for the participating firms. New products may be introduced, old products advertised, and so forth.
Attendance at such gatherings may total many thousands of persons. Generally, the organization sponsoring the event wishes to have detailed information concerning the many attendees. This may include, for example, such usual data as attendee name, company name and address and such statistical information as company size, job title, area of interest, type of company and so forth. This data is of interest to both the sponsoring organization and the participating or exhibiting companies.
In order to collect the desired information, large meetings such as conventions and trade show generally utilize an attendee registration procedure. The registration procedure is the first of the two principal functions of the preferred embodiment of this invention. Current registration practices require an attendee to fill out a written document with the information desired by the sponsoring organization. The documents are then sorted and collated, quite often by hand, to obtain the desired information. Quite often, usually because of the time required to sort the data, the information is not available to the interested parties until after the conclusion of the meeting.
Many trade shows and conventions are used by exhibitors to provide information to attendees about their products or services. While some information may be obtained about a product or service at an exhibitor's booth, it very often is necessary for an attendee to give his name to an exhibitor so that requested information may be supplied to him at a later data. Traditionally, the information necessary to answer such an inquiry has been obtained from an attendee and copied out by hand by an exhibitor. As may be readily appreciated, such handling of an attendee inquiry is very time consuming. The practical result often is that many otherwise interested attendees never request information of an exhibitor because of the necessary wait at a busy exhibit. This is, of course, advantageous for both the exhibitor and the attendee.
An improvement in the traditional inquiry system described above has been used at some shows and conventions in recent years. Embossed plastic cards are produced, similar to the familiar credit card, which bear the attendee's name and address. Each exhibitor is provided with preprinted forms and a card imprinter. When an inquiry is received, the exhibitor imprints a form with the inquiring attendee's card and writes in only the requested information. The inquiry card procedure saves great amounts of the exhibitor's time, reduces the number of personnel necessary at the exhibit and reduces the time that each attendee must wait to record his inquiry. Production of the embossed card used in the inquiry procedure is the second of the two principal functions of the preferred embodiment of this invention.
While the inquiry card procedure described above is a considerable improvement over the traditional hand written method, there are many problems in its use. Each card must be embossed from data entered by hand. Since this process requires personnel to operate each card embosser, it is quite expensive. While the inquiry cards may be embossed for those persons who are expected at a show or convention, often the attendee must visit in a second line, following his registration, for his manually embossed card to be produced. If the line becomes too long, the attendee may be asked to return later to obtain his inquiry card. This is very unsatisfactory, since the attendee cannot make any inquiries during this period or the exhibitors must be prepared to record written inquiries.
In summary, the present registration and inquiry sytem in use at most trade shows and conventions is unsatisfactory for a number of reasons. Satistical data concerning attendees is often unavailable for considerable lenths of time after the conclusion of the show or convention. Since the data handling, both for registration and inquiry, must be performed by hand, it is both slow and expensive for the organizers and exhibitors. Finally, the very considerable periods of waiting required by the attendees is unsatisfactory to them.
SUMMARY OF THE INVENTION
In accordance with this invention, provision is made for a computer controlled process which combines the registration procedure for large trade shows or conventions and the production of embossed inquiry cards for attendees. Registration data is entered from terminal devices, which may take several forms but are cathode ray tube terminals in the preferred embodiment. A programmed general purpose computer edits and formats the entered data and transfers it to storage. Under computer control, selected statistical information may be retrieved from storage and read out to provide up-to-the-minute attendance statistics. Further, under computer control, certain of the entered registration information is extracted and transferred to card embossers which automatically produce inquiry cards under computer control.
Since registration information is retrievably stored in a computer system , desired statistics may be retrieved at will. Unlike the prior methods in which the information often does not become available for long periods of time, this invention provides for virtually instantaneous production of statistical information concerning attendees.
Except for the initial data input, all data handling in this invention is under computer control. As a result, fewer persons are required to operate the system which saves considerably on the costs of registration and inquiry card production as compared to the manual methods currently in use.
Finally, since show and convention attendees are registered and presented with their inquiry cards in a very short time, most of the previously experienced waiting is reduced or removed. For example, it has been found that in use of this invention at a large trade show, the total waiting time of each attendee after he presented his registration information to the operator of an input terminal device until he received his inquiry card was about thirty seconds. In that thirty second time period, registration information concerning the attendee was retrievably stored, certain data extracted and transferred to an automatic card embosser which produced his inquiry card.
Accordingly, it may be seen that the many problems attendant to the present method of trade show and convention registration and inquiry system have been alleviated by this invention. Further, the cost of operating such systems have been considerably reduced.
It should be noted at this point that the primary purpose of this invention is the handling of entered data and the production of embossed cards. The practical embodiment of this invention has been used in the registration and inquiry system described above. However, it should be realized that this is only an example of the application of the methods of this invention. Another very useful application of the invention is found in the production of embossed credit cards used in consumer credit businesses. Accordingly, while this invention will be described in connection with the operation of a registration and inquiry system, it is pointed out that the use of the invention is not limited to such an application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the hardware system of this invention, illustrating three of the maximum of ten input terminals and three of the maximum of five automatic card embossers, as well as the computer and peripheral equipment.
FIG. 2 is a high level flowchart of the system, showing the interconnection of the various software modules of this invention.
FIG. 3 is a flowchart of the initial portion of the Interrupt Monitor software module.
FIG. 4 is a flowchart of the cathode ray tube (CRT) Processor portion of the Interrupt Monitor module.
FIG. 5 is a flowchart of the Operator's Console Processor ((OPCP) portion of the Interrupt Monitor module.
FIG. 6 is a flowchart of the Embosser Processor (EMBP) portion of the Interrupt Monitor module.
FIG. 7 is a flowchart of the portion of the Interrupt Monitor module to which the flowcharts of FIGS. 4 , 5 and 6 return in order to determine whether there are pending interrupts from any portion of the system.
FIG. 8 is a flowchart of the Cathode Ray Tube Monitor (CRTM) software module which is called by the flowchart of FIG. 4 to service interrupts from the cathode ray tube terminals.
FIG. 9 is a flowchart of the initial portion of the Embosser Monitor (EMBM) software module which is called by the flowchart of FIG. 6 to service interrupts originating from the automatic card embossers.
FIG. 10 is a flowchart of a portion of the Embosser Monitor software module showing the first mode (EMOD 1) of operation (character after character) of the embosser hardware.
FIG. 11 is a flowchart of a portion of the Embosser Monitor software module showing the second mode (EMOD 2) of operation (function after character) of the embosser hardware.
FIG. 12 is a flowchart of a portion of the Embosser Monitor software module showing the third mode (EMOD 3) of operation (character or function after function) of the embosser hardware.
FIG. 13 is a flowchart of a portion (ECNTL) of the Embosser Monitor software module which is called from the flowchart of FIG. 9 for the purpose of counting ten millisecond interrupts to provide operation timing for the automatic card embossers.
FIG. 14 is a flowchart of a portion (EGETD) of the Embosser Monitor software called from the flowchart of FIG. 9 for the purpose of transferring data from an embosser buffer for use by an automatic card embosser.
FIG. 15 is a flowchart of the initial portion of the Master Controller software module which controls the transfer of data within the system and controls translation of the entered data to the proper embosser code.
FIG. 16 is a flowchart of a portion of the Master Controller software module called from the flowchart of FIG. 15 for the purpose of accepting inputs from the operator's control console.
FIG. 17 is a flowchart of a portion of the Master Controller software module called from the flowchart of FIG. 15 for the purpose of accepting data from input terminal storage buffers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A. Introduction
In the use of the methods of this invention as a registration and inquiry system, the hardware is arranged generally as shown in FIG. 1. Up to ten cathode ray tube terminals 20, in the preferred embodiment, are positioned at points of attendee entry into the convention or trade show sight. An operator is positioned at each terminal to accept information from each attendee. As the information is provided, the operator types the data into the terminal in the usual fashion. Before the information is displayed on the entering terminal display screen, it is routed to a central computer 21 where the entered characters are edited. As will be explained in detail in connection with the flowchart section herein, certain characters are not accepted by the card embossers and certain characters may not be used in designated locations on the embossed card. For example, the first line of data is generally the name of attendee and may not include a numeral. If the characters entered from the terminal are found acceptable by the computer, the data is routed back to the entering terminal 20 over the same connecting line 22. It should be noted here that while a terminal operator does not enter data directly onto the terminal screen, the data is written under computer control so quickly that it would appear to the operator that the data is directly written on the screen.
When the returned data is displayed at the terminal, both the terminal operator and the attendee may inspect it for accuracy. Any change in entered data, as, for example, the correction of a misspelling, is rerouted to the computer 21 for editing before the correct character is replaced at the terminal. When the attendee and the terminal operator are both satisfied that the entered data is accurate, an entry command is made at the terminal. The computer 21 transfers the entered data to a tape memory unit 23 and into buffer storage for CRT terminal entries, as will be explained below. When a CRT buffer is full and a card embosser 24 found to be available, the portion of the entered information which is to be embossed on a card is transferred a character at a time via parallel lines 25 to a specific embosser. The embosser accepts the transferred data characters and produces the inquiry card. The attendee then obtains his card at the embosser outlet and proceeds into the convention or trade show exhibit area.
A standard teleprinter console 26, which utilizes a Teletype device in the preferred embodiment is used by a system operator to give commands to the computer 21 and receive requested statistical information from the computer. While a Teletype console is used in the preferred embodiment, as may be readily appreciated, any standard keyboard device will suffice.
B. The Hardware System
Registration data supplied to the system of this invention is entered through up to ten cathode ray tube terminals. In the preferred embodiment, a Model VISTA-1, manufactured by Inforton, Inc., Burlington, Mass., is usd as the terminal device. The Infoton cathode ray tube terminal is equipped with the usual alphanumeric display screen and a keyboard for character and function entry. In the operation mode used in the preferred embodiment, as discussed previously, there is no direct communication between the terminal keyboard and the display screen. Each keyboard entry is immediately transmitted to the computer where it is edited. If the editing function determines that the entered character is one acceptable for display on the terminal screen and use in the system, the character is returned for display by the terminal. The time lapse between keyboard character entry and screen display is quite short so that an operator is not aware of the editing intervention of the computer. There is no buffer storage in the terminal utilized in the preferred embodiment. Accordingly, characters are transmitted to the computer as it may receive them.
While the particular terminal described above has been utilized in the preferred embodiment, it may be readily appreciated that any number of different alphanumeric display terminals or even non-displaying terminals, such as Teletype devices, may be utilized.
The teleprinter console utilized in the system of FIG. 1 is a Model 33 Teletype device manufactured by Teletype Corporation, Skokie, Ill. The console is a standard device and will not be described in detail here. All that is necessary for understanding of the operation of the system of FIG. 1 is to recognize that the Teletype console is a keyboard device capable of both sending and receiving data.
The programmable general purpose computer utilized in the preferred embodiment of the system illustrated in FIG. 1 is a NOVA 1200 minicomputer, manufactured by Data General Corporation, Southboro, Mass. The computer utilizes a sixteen bit word and includes a four thousand word core memory. Since the computer and descriptive information is readily available, no structural or programming details concerning it will be given. In the event further information is required about the computer, reference is made to manual DG NM-5, published by Data General Corporation in 1971.
It is understood, however, that virtually any make and type of programmable computer may be employed in this invention. Changes in the make and type of computer would necessitate only minor program language and structure changes, well within the skill of an average programmer.
Bulk memory utilized in the preferred embodiment of the system of FIG. 1 is a magnetic tape unit, Model 6X40, manufactured by Peripheral Equipment Corporation, Chatsworth, Calif. Data is stored on a twelve inch magnetic tape reel. Operation of the tape unit is standard. If further information concerning the details of the tape is necessary, reference is made Manual No. 100884, published by the Peripheral Equipment Corporation. As with the other hardware units employed herein, other makes of tape storage units or even other types of storage devices, such as discs, could be readily employed in this system.
A maximum of five card embossers may be utilized with the preferred embodiment of the system illustrated in FIG. 1. The embosser utilized in the preferred embodiment is a Model 6800 embosser manufactured by the Addressograph-Multigraph Corporation, Cleveland, Ohio.
As the embosser is used in this system, it automatically loads a plastic card from a supply of such cards. As characters are transferred to it from buffer storage under control of the computer, the characters are embossed in the plastic card. Since embossers utilize a special data code, the internal code used in the system is translated into a form acceptable to the card embossers under software control.
c. Software
1. Introduction
All functions of the hardware system which constitute this invention are performed under software control. The program listing is included herein following the descriptive portion of this specification. FIGS. 2-17 of the drawings contain flowcharts of the principal portions of the software according to this invention. In order that the methods of this invention be clearly understood, this specification will describe the software flowcharts illustrated in the drawings.
Before describing in detail the methods controlled by the software of this invention, it is believed that it would be helpful to understand the exact nature of the data entered in the preferred embodiment. Generally, five types of information are entered via a CRT terminal concerning each attendee. These are the attendee's name, company name, attendee and company address. In addition, statistical information such as title, company size, area of interest, types of products manufactured, and so forth, may be entered. In the preferred embodiment, up to five lines of information is embossed by the card embossers on a plastic inquiry card. This information consists of the attendee's name, title, company name and address. In the preferred embodiment, the card may contain a maximum of 132 characters. An additional twenty characters may be entered from the CRT terminal for statistical information.
Accordingly, a maximum entry for a single attendee would comprise 152 characters of data. The 152 characters comprises, on the magnetic tape memory unit, a logical record. The logical record size remains constant on the magnetic tape regardless of the actual number of characters entered concerning an attendee.
Generally, the software disclosed herein operates an interrupt system. The software processes interrupts from cathode ray tube terminals, the operator's console, the magnetic tape memory unit, the power failure automatic restart device and the computer real time clock. Upon detection of an interrupt, the software classifies the interrupt and calls the appropriate software module. On each machine interrupt, the machine's state is saved in a last-in-first-out table. After all higher priority interrupts are serviced, control is returned to the last entry in the table so that operation of the machine may take up at the point it was interrupted.
As in most interrupt systems, the interrupts are serviced by the system according to a previously determined priority schedule. The priority schedule, in descending order, is the CRT terminals, the operator's console, the embossers and the magnetic tape unit.
There are six primary modules in the software listing included in this specification: Interrupt Monitor; Master Controller; CRT Monitor; Tape Monitor; Operator's Console Monitor; and, Embosser Monitor. Of the six in the software listing, the four principal modules are represented in the flowcharts. The Interrupt Monitor module is disclosed in FIGS. 3-7; the CRT Monitor module is disclosed in FIG. 8; the Embosser Monitor module is disclosed in FIGS. 9-14; and, the Master Controller module is disclosed in FIGS. 15-17.
2. FIG. 2 Flowchart
An understanding of the overall method controlled by the software of this invention may be had by referring to FIG. 2 which illustrates, on a high level, the interrelationship of the various software modules. The background step 30 is the entry point into the software method. The first initialization step 31 is reached by a startup of the system from the operator's console via step 30 or an automatic restart of the system via start step 32 following a power failure. The first initialization step 31 controls such functions as initializing the computer's ten millisecond clock, which is utilized as an embosser interrupt, setting all code words in core to their initial values, zeroing the contents of the various buffers and enabling all interrupts.
The second initialization step 32 tends the start-up requirements of the embossers. The buffers and data lines on the embossers are cleared and a check is made for any pending embosser error. At this point, the system is prepared to operate, that is, to service interrupts from any of the four possible sources.
Following the two initialization steps, an interrupt decision step 36 checks the four possible sources of interrupts to determine if one is pending. If not, control is transferred to an initialization message decision step 37 which determines whether there is an input requiring re-initialization from the operator's console 26 (FIG. 1). If there is no such console message, the initialization message decision step 37 retransfers control to the interrupt decision step 36. If the initialization message decision step 37 finds wording initialization input from the operator's console, control is passed to the first initialization step 31 and the initialization procedure repeated.
In general, the software controls a two step looping operation between interrupt decision step 36 and initialization message decision step 37 until either an initialization message is received from the operator's console or an interrupt is detected from one of the four possible sources. When an interrupt is detected, control is immediately transferred via a foreground entry point 38 to the Interrupt Monitor module entry (INTM) 39.
The Interrupt Monitor software module is called whenever an interrupt is detected from any of the four possible sources of interrupts. The function of the Interrupt Monitor module is to disable all other interrupts, save the machine state at the time of the interrupt, determine which of the four types of interrupts has been received and pass control to the proper software module determined by the source of the interrupt. Finally, the Interrupt Monitor determines whether any interrupts are received during the processing of a previously received interrupt.
This process is broadly shown in FIG. 2 by a classification and branch step 40 which identifies the type of interrupt and transfers control to one of four processor branches 41, 42, 43, 44 dependent upon the prior identification. For example, if the interrupt detected by the interrupt decision step 36 had been an embosser interrupt, control would be passed to embosser processor step 43. It should be understood at this point that an "embosser interrupt" does not originate with an embosser. The interrupt is generated by a ten millisecond clock which is part of the computer. By software, the computer interprets the ten millisecond clock interrupt as one requiring servicing of the embossers.
It should also be noted here that the flowcharts in the following figures disclose details of the program steps for the CRT processor 41, the operator's console processor 42 and the embosser processor 43. The magnetic tape processor is operated in the usual fashion common to transfer of data to such memory devices. While the instructions for transfer of data to the magnetic tape memory unit are included in the program listing herein, no flowchart statement of the program is given.
Following the servicing of the device originating the interrupt detected by the interrupt decision step 36, control is transferred to more interrupts decision step 45. Basically, the purpose of decision step 45 is to determine whether further interrupt servicing is necessary. For example, an interrupt may have been received during the processing time of the prior interrupt detected by the interrupt decision step 36. In that event, decision step 45 will transfer control to the Interrupt Monitor entry step 39 and the above process will be repeated. Also, if a low priority interrupt is in the process of being serviced when a higher priority interrupt is received, the Interrupt Monitor will first service the higher priority interrupt. In such cases, more interrupt decision step 45 will also retransfer control to the Interrupt Monitor entry step 39.
As explained above, the four possible sources of interrupts according to this invention are assigned a relative priority. If, for example, the software is in the process of controlling transfer of a data record to the magnetic tape memory unit and a CRT terminal interrupt is received, the address of the next tape transfer instruction is saved in the last-in-first-out table, In such cases, the more interrupts decision step 45 controls the computer to return to the last table entry and complete servicing the prior but lower priority interrupt. In those instances where no intermediate interrupts nor any prior interrupts require servicing, control is transferred to the Master Controller Monitor module 46.
Generally, it is the function of the Master Controller module to examine a system status word to determine if data requires moving. The status word informs the Master Controller whether any cathode ray tube terminal buffers are full, whether any teleprinter console messages are waiting to be printed on the teleprinter, whether data is ready for transfer to the magnetic tape memory, or whether data is ready for transfer to one of the embossers for the production of an embossed card.
The Master Controller module determines in a messages decision step 47 whether any such data transfers are necessary and, if so, which data transfer is ready. When a data transfer is found to be appropriate by the message decision step 47, control is transferred to a processing step 48 which calls the proper message transfer routine to accomplish the transfer. Thereafter, control is retransferred to the any messages decision step 47 to determine whether further data transfers are ready. Finally, the Master Controller Monitor updates the system status word to reflect the data transfer which has just taken place.
In those instances where the any messages decision step 47 finds no data transfers ready, control is transferred to the background portion of the software to await the next interrupt or initialization message from the operator's console.
The above description concerning the steps of FIG. 2 describes the operation of the methods of this invention on a high level. FIGS. 3-17 will explain the software steps in more detail.
3. Interrupt Monitor
Referring to FIG. 3, the initial portions of the flowchart of the Interrupt Monitor software module is shown. When the background interrupt-initialization message loop (FIG. 2) finds an interrupt, control is transferred to an initial step 51 of the Interrupt Monitor. The initial step 51 first disables the other interrupts for the duration of the present Interrupt Monitor control. In addition, the initial step 51 enters the present machine state in the last-in-first-out table so that control may be returned to the proper point in those cases where a lower priority interrupt was stopped.
The first determination made in the Interrupt Monitor module is whether the interrupt was a system power failure by a power failure decision step 52. In those instances where a power failure occurs, control is transferred to a clearing step 53 which removes any data on the embosser input lines and sets the system for automatic restart. Thereafter, all operations are halted as commanded by a halt step 54.
In those instances when the background software steps detect an interrupt which is not a power failure, a fielding step 55 receives the interrupt flag and transfers contol to clock interrupt decision step 56. In the method according to this invention, a clock interrupt is generated in the system by the computer every ten milliseconds for the purpose of scanning and timing the embossers. Upon occurrence of each clock interrupt, a scanning of the condition of all embossers is initiated. Determinations are made during the embosser scanning of the condition of each embosser and whether card embossing commands are necessary. Also, as will be explained below in detail, operation of the embossers require numerous timed delays. All such delays controlled by software steps are based on counts of the number of ten millisecond clock interrupts.
Clock interrupt decision step 56 determines whether the sensed interrupt originated with the embosser ten millisecond clock. If so, the embossers must be serviced and control is transferred to the software steps of FIG. 6 via a transfer step 61.
If the interrupt sensed in the software background steps is found not to be a ten millisecond clock embosser interrupt, control is transferred to a tape entry interrupt decision step 57 which determines whether the interrupt was caused by a command to transfer stored data from the tape to the operator's console. If so, control is transferred to a tape processing step 58. The tape processing step controls transfer of the entered attendee registration information to the operator's console to provide attendance information. As the data is transferred, an error check is also controlled by processing step 58.
If the detected interrupt was neither a ten millisecond clock interrupt nor a tape entry interrupt or, following the processing of a tape entry interrupt, control is transferred to an operator's console interrupt decision step 59. If the interrupt is found to have originated with the operator's console, control is transferred to the software steps of FIG. 5 via a transfer step 60.
Finally, if the fielded interrupt is neither a power failure, ten millisecond clock, tape or operator's console interrupt, control is transferred to a CRT terminal interrupt decision step 62. As with the above classification steps, the decision step 62 determines whether the detected interrupt is from one of the CRT terminals. If it is found to be from one of the terminals, control is transferred to the software steps of FIG. 4 via transfer step 63.
Following the determination by decision step 62 of whether a CRT terminal interrupt is present, control is transferred to the software of FIG. 7 via a transfer step 64, labeled CKINT in FIG. 3, when no CRT terminal interrupt is found.
The steps of FIG. 7 are entered upon the completion of all interrupt determinations of FIG. 3 except when an interrupt is caused by a power failure. The basic purpose of the steps of FIG. 7 is to check for a pending interrupt which occurred during the processing of the last interrupt or which was in process when a higher priority interrupt occurred.
Referring to FIG. 7, after any pending interrupt is acknowledged by step 70, control is transferred to a decision step 71 which determines whether any interrupts are pending for any reason. If a pending interrupt is found, control is transferred to background decision step 72 which determines whether the last entry in the last-in-first-out table was a background step. The significance of the table entry being found to be background step is that the interrupt last serviced occurred while the software was controlling a background wait and, therefore, the pending interrupt occurred in the interim. In such an instance, the interrupt must be classified and serviced as previously described in connection with FIG. 3. Accordingly, if the last table entry was a background step, control is transferred via transfer a transfer step 73, labeled FLDIN in FIG. 7, to entry transfer step 74, similarly labeled, of FIG. 3. Thereafter, the interrupt which occurred after the servicing of the last interrupt started is classified by the steps of FIG. 3 as previously explained.
When the steps of FIG. 7 find a pending interrupt and find also that the last-in-first-out table entry was not in the backgound, control is transferred to a priority decision step 75 which determines whether the priority of the table entry, according to the interrupt priority schedule, was equal to or greater than the priority of the current interrupt. If the priority of the current interrupt is equal to or higher than the last table entry, control is again transferred to the software steps of FIG. 3 via a transfer step 76, labeled FLDIN in FIG. 7. As before, this serves to transfer control to the classification steps of FIG. 3 via an entry, transfer step 74.
In those cases where the priority of a pending interrupt found by the steps of FIG. 7 in higher or equal to that of the current interrupt, step 77 controls the fielding of the last table entry. Since the table entry contains, as is usual, the address of the interrupted procedure, restoring steps 80, 81 control the computer to return to the interrupted sequence. At the same time, the current interrupt and its assigned priority is entered in the last-in-first-out table so that it will be handled in the proper priority sequence.
If the software steps of FIG. 7 find no pending interrupt, control is transferred to a table decision step 83 to determine whether more than background entries are in the last-in-first-out table. If not, the current interrupt is determined to have been completely serviced and step 84 enables all interrupts. The purpose of this step is to offset the effect of the interrupt disabling which occurred in step 51 of FIG. 3. After the interrupts are enabled, all sources of interrupts, regardless of their priority, are capable of immediately interrupting operation of the system. After the interrupts are enabled, control is transferred to the Master Controller software module via a transfer step 85. The Master controller software flowcharts are disclosed in FIGS. 15-17 and will be described below.
If the table decision step 83 determines that there are more than background entries in the last-in-first-out table, the significance is that a prior processing sequence, not involving interrupts, was stopped and should be restarted. In order to accomplish this result, control is transferred to restoring steps 80 and 81 and proceeds as previously described.
As may be readily understood, the primary purpose of the software steps of FIG. 7 is to determine whether any pending interrupts are present and to set up the assigned priority schedule for the four possible sources of interrupts. It should be noted that, except for the tape entry process step 58 of FIG. 3, control is retransferred to the steps of FIG. 7 following the servicing of all interrupts.
Returning to FIG. 3, it is recalled that the software steps were for the purpose of classifying the type of current interrupt and transferring control to the proper device processor. For example, if the CRT interrupt decision step 62 determines that the origin of the current interrupt is one of the CRT terminal devices, control is transferred to the CRT processor step of FIG. 4 via transfer steps 63 and 88 (FIG. 4).
4. CRT Processor
The primary purposes of the steps of the CRT processor shown in FIG. 4 are to control the necessary buffer checks for transfer of entered data and to call the CRT Monitor software module.
Each CRT terminal device is assigned a code and has associated with it an input buffer. As each character or function key on the CRT keyboard is depressed, a CRT terminal interrupt is generated. When the interrupt is found to be the first following an enter code, the steps of FIG. 4 assign a packed buffer location to eventually receive the terminal entries. As each following interrupt occurs, control is transferred to the CRT Monitor steps of FIG. 8 which first identifies the type of input. If the input is a character, it is edited to ensure that it is a character acceptable to an embosser. If it is found acceptable, the character is returned to the entering terminal for display on its screen. At the same time, the character is entered into the terminals input buffer. When the terminal operator has completed the entries concerning a single attendee, an enter command causes the input buffer to transfer its contents to the assigned packed buffer. The Master Controller is then notified that data is ready for an embosser. These steps will be explained in detail in connection with the software steps of FIGS. 4 and 8.
Returning to FIG. 4, if a terminal decision step 91 determines that the CRT terminal is not busy, which would occur only upon the entry of the first character, a buffer decision step 95 determines whether a CRT packed buffer location is available. If not, the CRT terminal entry is not transferred to the entering terminal for display. The data entry, however, is saved. Thereafter, return is made via a transfer step 98 to the steps of FIG. 7.
When the buffer decision step 95 determines that a buffer location is available in the packed CRT buffer, step 99 controls the buffer locations to be cleared and the buffer flag set after which control is transferred to CRT Monitor calling step 92.
5. Operator's Console Processor
As explained in connection with FIG. 3, operator's console decision step 59 determines whether a detected interrupt originated with the operator's control console. If so, control is transferred to the Operator's Console Processor steps of FIG. 5 via a transfer step 60.
FIG. 5 illustrates the software steps of the Operator's Console Processor. Briefly, the purpose of the Operator's Control Processor is to transfer Teletype data and to notify the Master Controller module that a command is waiting to be processed.
Referring to FIG. 5, control is transferred to a read step 100 via transfer step 60 of FIG. 3 and entry step 101 of FIG. 5. Step 102 enables all interrupts from the various interrupt sources and transfers control to message waiting step 103. If it is determined that a console message is waiting, all other interrupts are disabled by step 104 after which transfer step 105 returns control to the steps of FIG. 7. After the FIG. 7 steps occur, the Master Controller module, as will be discussed below, controls the transfer of the waiting console message. If no console message is found to be waiting by decision step 103, control is transferred to step 107 which turns on a console message flag. Thereafter, control is transferred ultimately to the Master Controller module via transfer steps 105 and the software steps of FIG. 7, as above described.
6. Embosser Processor
As discussed in connection with the steps of FIG. 3, an embosser interrupt is generated in the system by a real time clock every ten milliseconds. When the ten millisecond interrupt occurs, interrupt decision step 56 of FIG. 3 detects the clock interrupt and transfers control to the Embosser Processor of FIG. 6 via transfer a step 61.
The primary purpose of the Embosser Processor steps of FIG. 6 are to call the Embosser Monitor software module, enable only the proper interrupts and control a scanning of each of the embossers in turn. Referring to FIG. 6, step 110 enables the CRT and Operator's Console interrupts. Step 111 identifies the first embosser to be checked after which step 112 calls the Embosser Monitor software module of FIGS. 9-14. The Embosser Monitor module controls the transfer of data from an embossor buffer to the corresponding embosser. Following the Embosser Monitor steps, which will be described in connection with those figures, restart step 113 of FIG. 6 causes the ten millisecond clock to be restarted and all interrupts to be disabled. Word step 114 then picks up the embosser communication word which states the status of the embosser just serviced and, via pointers, the present condition of the embosser.
Decision step 115 determines whether the embosser being looked at is busy, that is, embossing a card, or is idle. If the embosser is found to be either busy or idle, control is transferred to decision step 116 which determines whether there are more embossers in the system which must be serviced as a result of the current ten millisecond embosser interrupt. If decision step 116 determines that there are more embossers to be serviced, the above described process is repeated by transferring control back to the Embosser Monitor call step 112 via embosser set-up step 118. As may be readily appreciated, each time a ten millisecond embosser clock interrupt is received, the software steps of FIG. 6 are looped through until decision step 116 determines that all embossers connected to the system have been serviced. When step 116 determines that all embossers have been serviced, the steps of FIG. 6 is exited to the steps of FIG. 7 via transfer step 120. Each embosser in the system, is serviced every ten milliseconds or one hundred times each second.
Returning to the embosser busy or idle decision step 115, control is transferred to card finished decision step 121 if it is determined that the embosser being looked at is neither busy nor idle. In such a case, the embosser is either in an error condition, is turned off or has just completed embossing a card. Step 121 determines whether the embosser has finished embossing a card. If the embosser is finished, control is transferred to step 123 which frees the embosser buffer. This removes the embosser from a reference list of embosser buffers being utilized and frees it for receipt of further data. Thereafter, step 124 sets the embosser flag to idle and increments the embossed card count by one count. Control is then returned to step 116 which determines, as before, whether all embossers have been serviced. Again, if not, the looping process continues. If they have been serviced, the steps are exited via transfer step 120.
If the embosser busy and card finished decision steps 115, 121 determine that an embosser is neither busy nor idle and has not just completed the embossing of a card, control is transferred to decision step 125 which determines whether an error condition exists or the down switch is on. The down switch simply indicates that the system operator has turned the embosser off. In either case, message steps 126, 127 send the appropriate message to the operator's console. Following both of the message steps 126, 127, the embosser clock is restarted by step 128. Thereafter, control is retransferred to step 116 which, as described above, determines whether all embossers have been checked. When all embossers have been checked, control is transferred to the steps of FIG. 7 for a check of pending interrupts via transfer step 120.
7. CRT Monitor Module
As described above, interrupts from one of the CRT terminal devices may be detected in the background software. When a terminal interrupt is detected, control is transferred to the CRT Processor of FIG. 4. The steps of the processor, as described above, perform certain preliminary functions prior to calling the CRT Monitor module. The CRT Monitor steps, called by step 92 of FIG. 4, are shown in FIG. 8. Accordingly, the FIG. 8 steps occur each time a character or function key is depressed on one of the CRT terminals.
Referring to FIG. 8, step 130 causes the one data entry to be read from the terminal. After the appropriate table entries controlled by step 131, a cursor entry decision step 132 determines whether the entry is a cursor movement command. If so, cursor movement step 133 causes the cursor to be moved as directed and for cursor pointers to be updated, after which control is returned to the steps of FIG. 7 via transfer step 134.
If the cursor entry decision step 132 determines the current entry is not a cursor movement command, carriage return entry decision step 135 then determines whether the entry is a carriage return command. If the entry is a carriage return, decision step 137 determines whether it is a line 5 carriage return. The significance of a fifth line carriage return is that the end of the data destined for an embossed card has been reached upon the occurrence of the five lines of data which may be embossed on a card according to this invention; further statistical data entries relating to the same attendee are simply transferred to the magnetic tape memory along with the first five lines. In those cases where the entry is determined to be a fifth line carriage return, step 138 causes the entry to be replaced with an enter code. This is done to cause the block of data destined for the embossed card to be entered at that point. If the entered character is found to be a carriage return code, but not the fifth line carriage return, or following the replacement of a fifth line carriage return code with an enter code, control is transferred to data step 140 which causes data to be inserted and pointers and the status table to be updated. Following step 140, control is retransferred to the steps of FIG. 7 via transfer step 141.
If the entry is found to be neither a cursor control nor a carriage return command, enter code decision step 142 determines whether the character entered is an enter command. If so, control is transferred to step 143 which controls a transfer of the data from the CRT input buffer to the selected CRT packed buffer. Also, the appropriate flags are set and pointers are updated. After the data transfer control by step 143, control is retransferred to the steps of FIG. 7 via transfer step 144. If the first three entry decision steps 132, 135, 142 determine that the current entry is neither a cursor movement command, a carriage return command nor an enter code command, the only possibility remaining is that the current entry is a data character. Accordingly, step 146 then checks to determine whether the current entry results in too many characters in the line being currently entered. If so, control is transferred to the steps of FIG. 7 via a transfer step 148. If not, first line decision step 150 determines whether the current character is in the first line to be embossed. In view of the adopted convention that no numbers may appear in the first line of an embossed card, a number decision step 151 determines if the entered character is a number. If so, the convention is violated and control is transferred to the steps of FIG. 7. If the entered character is acceptable, control is transferred to validity checking step 154 which determines whether the entered character is a valid embosser character. This check is necessary because only certain alphanumeric characters may be utilized by an embosser. The decision is made by a table look-up procedure which refers to a list of acceptable embosser entries. If the validity decision step 154 finds an invalid character, control is transferred back to the steps of FIG. 7 via transfer step 158. In such a case, the character is not displayed on the terminal screen. If, on the other hand, the validity decision step 154 finds the entered character to be a valid embosser character, control is transferred to step 160 which causes the character to be transferred to the terminal screen for display. Storage step 161 enters the valid character into the CRT input buffer, after which control is returned to the steps of FIG. 7 via a transfer step 163.
8. Embosser Monitor Module
As described in connection with the Interrupt Monitor steps of FIG. 3, the system according to this invention generates a clock interrupt every ten milliseconds. The clock interrupt causes the Interrupt Monitor to call the Embosser Processor steps of FIG. 6, which, in turn, call the Embosser Monitor software module, disclosed herein in FIGS. 9-14.
The basic purpose of the Embosser monitor is to supply data to the system card embossers. The data is obtained from embosser buffers located in core which were filled from CRT terminal data entries. In response to each of the ten millisecond clock interrupts, the Embosser Monitor is called to check the status of each embosser connected to the system. The status of an embosser may be either busy embossing a card, finished with a card, completely idle or in an error condition. As will be explained in connection with the flowcharts of FIGS. 9-14, the steps taken by the Embosser Monitor are determined by the status of the checked card embosser.
Referring to FIG. 9, the initial entry decision step 170 first determines whether or not the current entry is the first since the system was set in operation. If so, initialize step 171 sets certain embosser control words to their proper values. Thereafter, via a transfer step 172, control is returned to step 113 of FIG. 6. It should be noted at this point that throughout the figures relating to the Embosser Monitor steps, the general return is via a transfer step and is labeled EMBM RETURN. In each case, the return is made to step 113 of FIG. 6. Hereafter, the return will be simply referred to as the Embosser Monitor return.
In those cases where the initial entry decision step 170 finds that the current entry into the Embosser Monitor steps is not the initial entry, card clear decision step 173 determines whether the card embosser presently being looked at is in its card clear stage. This refers to the operation in an embosser following the completion of an embossed card. If the decision step 173 determines that the card clear mode is on for the embosser being serviced, further buffer decision step 174 determines whether another buffer is ready. If not, step 175, the mode of operation referred to in the software listing as Mode 4, sets up card clear waits and commands on the basis of the card clear phase number. This refers to the timing requirements of the particular embosser used. Since the cards must be physically transported through the embosser, time delays of various lengths are required in the embossing operation. In the particular embosser utilized in the preferred embodiment, the card clear module consists of eight phases. One phase is controlled each time the embosser in card clear mode is addressed. That is, after each ten millisecond embosser interrupt, each embosser in the card clear mode will be stepped through one phase. One of the steps of each phase is to set up for the next phase following the next ten millisecond interrupt. At the end of each phase in the card clear mode, the usual Embosser Monitor return is made via transfer step 176.
If further buffer decision step 174 determines that another buffer is ready, step 178 turns off the card clear flag at the end of the current card clear mode phase.
If the card clear decision step 173 determines that the embosser being serviced is not in its card clear mode, then the Embosser Monitor software will switch to one of three other modes of operation. In such a case, buffer ready decision step 180 determines whether an embosser output buffer is ready to deliver data. If not, step 181 determines if a card clear routine is necessary. If so, step 182 turns on the software card clear flag. If no card clear is found to be required by step 181 or following the card clear flag being turned on by step 182, the usual Embosser Monitor return is made via transfer step 183.
If the buffer ready decision step 180 finds that data is ready for delivery to an embosser from the associated buffer location, waiting decision step 185 determines whether the Embosser Monitor is currently in a waiting stage. There are a number of instances where the timing requirements of the card embosser require that certain delays be set up between controlled steps. These are requirements of the card embosser itself and will vary as different embossers are used or embosser designs are changed. For example, in the first phase of the card clear mode described above, there is a requirement that a 520 millisecond wait be made. Instead of stopping the operation of the system during this wait, the system is programmed to count successive ten millisecond interrupts until 52 have been counted. Accordingly, all of the machine timing waits are set up as multiples of ten milliseconds. The waiting decision step 185 determines whether a waiting count has been begun on a prior operation of the Embosser Monitor for the embosser being serviced. If so, control is transferred to count done decision step 186 of FIG. 13 via transfer steps 187 and 188 (FIG. 13).
FIG. 13 discloses the flowchart for the ECNTL routine. The purpose of the routine is to count the number of ten millisecond interrupts for the timing requirements described above. Referring to FIG. 13, count done decision step 186 determines whether the previously commanded wait period has been completed. For example, in the case of the 520 millisecond wait described above, the count done decision step 186 would generate a NO answer for 51 consecutive ten millisecond interrupts. Following a NO answer, an Embosser Monitor return is made via transfer step 190. It is pointed out that until the count is found to be finished by count done decision step 186, the Embosser Monitor routine may be exited for the embosser being serviced.
If the count done decision step 186 determines that the count is done, that is, that the total waiting time has elapsed, control is transferred to step 191 which clears all data lines and turns off the count flag. Thereafter, plate discharge decision step 192 determines whether the last data entered was a plate discharge command. The function of a plate discharge command is to advance all cards within the card embosser one position each time a command is entered. Note that this differs from a card clear command in that the latter advances only cards which are within the card embosser. If the plate discharge decision step 192 finds that the last data step received was a plate discharge command, control is transferred to step 194 which is the eight phase card clear mode described in connection with step 175 of FIG. 9. As before, at the end of each phase an Embosser Monitor return is made via transfer step 195.
If the plate discharge decision step 192 determines that the last-received data entry was not a plate discharge, step 197 calls the procedure of FIG. 14 to obtain the next data bit from the embosser buffer. The data transfer steps of FIG. 14 will be described in connection with its entry from FIG. 9. Following the transfer of the next data bit from the embossed buffer, transfer step 198 (labeled CKCTB in FIG. 13) transfers control to step 173 of FIG. 9 via control entry step 199. Thereafter, the card clear, buffer ready and waiting decisions of FIG. 9 are made as before.
If the waiting decision step 185 of FIG. 9 determines that the embosser being looked at is not currently in a time delay, that is, is not currently waiting, control is transferred to data decision step 200 to determine whether a next data entry should be obtained from the embosser buffer. If so, control is transferred to the software steps of FIG. 14 via transfer steps 201 and 202 (FIG. 14) for the purpose of obtaining a data entry from the embosser buffer.
As before, the first step in the procedure is an initial entry decision step 203 which determines whether the current data entry is the initial entry for the embosser being serviced. If so, control is transferred to step 204 for the appropriate initialization procedure. If the current data transfer is not an initial entry or, following the intial entry initialization of step 204, control is transferred to data step 205 to transfer data from the address embosser buffer.
When the data is obtained, identification decision step 206 determines whether the data entry is a character or a function. If a character is found, prior decision step 207 determines whether the preceding data entry was a character or a function. This decision is necessary as a different procedure is followed when, for example, a function follows a character as opposed to a character following a character on an embossed card. If the prior entry decision step 207 determines that the prior entry was a character, control is transferred to step 208 which sets the proper flags for eventual transfer via the steps of FIG. 9 to the first phase of Mode 1. (FIG. 10) If the prior entry decision step 207 finds that the previous entry was a function, control is transferred to step 210 which sets the necessary flags for later entry into the first phase of Mode 3. (FIG. 12) After each set up, control is returned via transfer steps 211 and 212 (FIG. 9) to step 213 which transfers control to the mode previously set up.
Returning to FIG. 14, if entry identity decision step 206 determines that the entered data is a function, control is transferred to the second prior entry decision step 215 to determine, as in the case of the first prior entry step 207, the type of entry immediately proceeding. If it is found that the prior data entry was a character, control is transferred to step 216 which sets the necessary flags for later entry into the first phase of Mode 2. (FIG. 11) If the second prior entry decision step 215 finds that the prior entry was a function, control is transferred to step 217 for setting flags for later entry into the first phase of Mode 3. (FIG. 12) After either set up, control is transferred via transfer step 218 and entry 212 (FIG. 9) to branching step 213.
Referring to FIG. 9, it is noted that branching step 213 may be reached one of two ways. If the embosser being serviced after the current ten millisecond clock interrupt is in the process of embossing a card, the steps of FIG. 14 are entered via data decision step 200 (FIG. 9) to obtain the next piece of data. Thereafter, branching step 213 will transfer control to one of the first three modes determined by the comparison of the present and immediate prior data entry. On the other hand, if the embosser being serviced as a result of the current ten millisecond clock interrupt is found to be in a machine timing wait sequence, control is transferred to the steps of FIG. 13 via currently waiting decision step 185 of FIG. 9. The steps of FIG. 13 set up the flags for branching into the first phase of Mode 4 by branching step 213 of FIG. 9.
Referring to FIG. 9, branching step 213 determines which of the four modes have been previously set up. Dependent thereon, control is transferred to the Mode 1 steps of FIG. 10 via transfer step 220, the Mode 2 steps of FIG. 11 via transfer step 211, the Mode 3 steps of FIG. 12 via the transfer step 222 or into step 223 which defines the steps of Mode 4.
As described in connection with step 175 of FIG. 9, the card clear mode consists of eight phases. Each ten millisecond interrupt steps through one of the eight phases. The method controlled by step 223 and step 175 of FIG. 9 is identical.
In those cases where the steps of FIG. 14 determine that the current data entry is a character and the prior data entry was a character, control is transferred to the steps of Mode 1. Referring to FIG. 10, the character after character mode steps are divided into two phases. Accordingly, two successive ten millisecond clock interrupts are required to complete the steps of Mode 1. When Mode 1 is first entered during each pair of entries, steps 225 and 226 transfer control to phase 1 embosser error decision step 227. If an error has been previously made by the embosser, an error flag is set by step 228 and an Embosser Monitor return made via transfer step 229. The fact of an error is later sent to the operator's console via the Master Controller module as will be discussed below.
If no embosser error is encountered, K-1 decision step 230 determines whether the embosser has reached a timing position referred to as the K-1 position. The K-1 position occurs when the embosser's keyboard timing shaft is in its home position. If not, an Embosser Monitor return is made via transfer step 231. If so, control is transferred to step 232 which disables all interrupts and transfers the single character of data to the embosser. Thereafter, the interrupts are enabled and step 233 sets the flags for the second phase of Mode 1 when the current card embosser is next serviced after the following ten millisecond interrupt. Thereafter, an Embosser Monitor return is made via transfer step 234.
When the second phase of Mode 1 is entered by branching step 226, second embosser error decision step 235 determines whether an embosser error has been made. If so, step 236 sets the error flag and an Embosser Monitor return is made via transfer step 237.
If no embosser error is found, position decision step 238 determines whether the embosser has advanced to a time position termed the K-89 position. When the K-89 position is reached, all embosser functions, such as head move and hammer strike, have been completed. If not, an Embosser Monitor return is made via transfer step 240. If so, a fifty millisecond wait is commanded by waiting step 241 and the count flag is turned on. As explained before, this will result in the software steps of FIG. 13 being entered for the current card embosser following the next five ten millisecond interrupts. In this way, the current machine will be allowed to pause fifty milliseconds for the embossing of the currently entered character before new data is transferred to it. Following the fifty millisecond count started by step 241, an Embosser Monitor return is made via transfer step 242.
Referring again to FIG. 9, it will be recalled that branching step 213 transfers control to the Mode 2 function after character steps of FIG. 11 when the current data entry is a character and the prior data entry was a function. As with Mode 1, the second mode is divided into two phases and requires, therefore, two successive ten millisecond clock interrupts to complete.
Referring to FIG. 11, upon the first entry, branching step 250 transfers control to the first phase embosser error decision step 251. As before, an embosser error will cause flag step 252 to turn on the embosser error flag after which an Embosser Monitor return is made via transfer step 253. If no embosser is found, time decision step 255 determines whether the embosser is in the previously described K-1 position. If not, an Embosser Monitor return is made via transfer step 256. If the K-1 position is found currently, card clear decision step 247 determines whether the card clear command is currently in force. If not, control is transferred to step 258 which disables all interrupts and initiates the function in the card embosser. Thereafter, the interrupts are enabled and step 259 controls the flags to be set up for the second phase of Mode 2.
Upon the next entry into the Embosser Monitor for the card embosser currently being looked at, that is, following the next ten millisecond clock interrupt, the branching step 250 will transfer control to the second phase steps. After the second phase set up is made by step 259, an Embosser Monitor return is made via transfer step 260.
If card clear decision step 257 determines that a card clear command is in effect, decision steps 261 and 262 determine, respectively, whether the received function is a plate discharge or a carriage return. If either, an Embosser Monitor return is made via transfer steps 263, 264. If neither are found, control is transferred to step 258 and the process continues as described above.
When the Embosser Monitor steps are next entered after the first phase entry, branch step 250 transfer control to the second phase embosser error step 265. If an embosser error is found, step 266 sets the proper flag after which an Embosser Monitor return is made via transfer step 267. If no embosser error is found, timing step 268 determines whether the embosser is in the previously described K-89 timing position. Since the embosser must be in that position for the second phase of Mode 2 to continue, if it is found not to be in the K-89 position, an Embosser Monitor return is made via transfer step 269. Absent an error, the K-89 timing position should be reached upon the next ten millisecond clock interrupt for the embosser being serviced. If the embosser is found to be in the K-89 position control is transferred to step 270 which begins a fifty millisecond waiting period in order to allow the entered function to be carried out by the embosser. As described above, the waiting period is determined by counting the number of intervening ten millisecond clock interrupts. After the fifty millisecond clock is started, an Embosser Monitor return is made via transfer step 271.
Finally, as described above in connection with FIG. 9, branching step 213 calls the software steps of FIG. 12 for Mode 3 when a function is entered following a function. Referring to FIG. 12, entries into the Mode 3 steps first require an embosser error decision step 275. As before, if an error is found, the error flag is set by step 276 and an Embosser Monitor return made via transfer step 277. If no embosser error is found, a timing decision step 278 determines whether the embosser timing is in the K-1 and K-80 position. It is necessary that the embosser be in this condition for the Mode 3 step to continue. Accordingly, if the condition is not found, an Embosser Monitor return is made via transfer step 280.
If the timing step 278 finds the embosser in the proper timing position, entry identity decision step 281 determines whether the entered data is a character or a function. If a character, control is transferred to step 282 which disables the interrupts and sends the data character to the embosser. Thereafter, the interrups are enabled and control transferred to counter step 283 which initiates a fifty millisecond wait as described above. Thereafter, an Embosser Monitor return is made via transfer step 284.
If the entry identification step 281 determines that the entry is a function, control is transferred to step 285 which determines whether card clear is in effect. If it is not, step 286 sends the entered function code to the embosser after which counter step 283 initiates a fifty millisecond wait as before. If the card clar is found to be on, control is transferred to function decision step 290 for determination of whether the entered function is a plate discharge or carriage return command. If it is, an Embosser Monitor return is made via transfer step 291. If it is not, control is transferred to step 286 which functions as previously described.
9. Master Controller Module
FIGS. 15, 16 and 17 disclose the flowcharts for the Master Controller software module. As illuatrated in the high level flowchart of FIG. 2, the Master Controller steps are entered from the last routine (FIG. 7) of the Interrupt Monitor module. Data entered at a CRT terminal is stored in core under control of the CRT Monitor portion of the Interrupt Monitor software module. Except for this data transfer, the Master Controller handles all data flow within the system.
There are two inputs to the Master Controller software. Data inputs originate in core buffers which contain information entered concerning each attendee. In addition, the Master Controller monitors a system status word which contains a plurality of bits, each bit showing the status of a device in the system. As will be discussed in connection with FIGS. 15-17, the Master Controller continually checks for the readiness of the system to transfer data by examining individual bits in the system status word. Finally, the Master Controller software module calls a routine for translating the data code used within the system to a special code accepted by the card embossers. This translation is, of course, dependent upon the particular card embosser used.
Referring to FIG. 7, it is recalled that the Interrupt Monitor, as a last step, checks for pending interrupts following the servicing of each single interrupt. When all pending interrupts at one time have been serviced, and no further interrupts are pending, the steps of FIG. 7 transfer control to the Master Controller entry steps shown in FIG. 15.
Referring to FIG. 15, step 300 sets the appropriate interrupt priority and transfers control to message decision step 301. Decision step 301 examines the system status word to determine whether there are any Master Controller messages, that is, whether any data is ready for transfer. If there are no messages, control is transferred to translation decision step 302 for a determination of whether there are any embosser buffers with data ready for translation to the required embosser code. If not, a disabling step 303 disables the interrupts set by step 300 and exits the Master Controller software via transfer step 304. Step 304 is labeled BGRND for Background and transfers control to step 36 of the background program steps (FIG. 2). As described in connection with FIG. 2, at this point the looping begins between the decision steps awaiting an initialization message from the operator's console or an interrupt from one of the four interrupt sources.
If translation decision step 302 finds that buffer data is awaiting translation, control is transferred to step 305 which turns on an appropriate bit in the system status word. Control is then transferred to message decision step 301 which will recognize the change in status word controlled by step 305. Since a Master Controller message then exists, control is transferred to embosser message decision step 307. The embosser decision step 307 determines whether an embosser buffer is ready to deliver data to a card embosser. If so, control is transferred to step 308 which sets a flag recognizable by the Embosser Monitor buffer ready decision step (step 180 of FIG. 9) so that the next time the Interrupt Monitor steps are entered, the appropriate data transfer to the card embossers will begin. Also, step 308 turns off the bit in the system status word that was examined by embosser message decision step 307 to determine whether an embosser buffer was ready to deliver data. Thereafter, control is retransferred to Master Controller message decision step 301 via transfer steps 309 and 310.
If embosser message decision step 307 finds no embosser buffers ready to deliver data to a card embosser, control is transferred to console message decision step 312 which looks at the status word bit concerning the operator's console. If the console has data for entry, control is transferred to the software steps of FIG. 16 for acceptance of the message via transfer step 313.
If console message decision step finds no console message ready for transfer, control is transferred to CRT message decision step 315 which looks at the system status word bit corresponding to the CRT data packed buffers. If any of the packed buffers are ready to deliver data to an embosser buffer, control is transferred to the steps of FIG. 17 via a transfer step 316. IF there is no CRT message, control is transferred to step 302 which, as explained above, determines whether there are embosser buffers awaiting translation. If not, the Master Controller module is exited and the background looping is begun.
As described above, if console message decision step 312 finds that a message is ready for entry from the operator's console, control is transferred to the steps of FIG. 16. Referring to that FIGURE, an embosser running decision step 320 determines initially whether there is a card embosser running. If so, the message ready from the operator's console will not be accepted and control is retransferred to step 301 of FIG. 15 via transfer steps 321, 310.
If embosser running decision step 320 finds no embosser running, command step 323 causes the command from the operator's console to be loaded into core. A command decision step 324 determines whether the entered command relates to initialization. If so, an appropriate reply message is printed on the console by step 325 and the background steps started via START STEP 326 (step 32 FIG. 2).
When command decision step 324 finds that the command entered from the operator's console is not an initialization command, control is transferred to step 327 which causes an appropriate reply message to be sent to the console and the instructed function to be performed. Thereafter, the status word bit relating to the Master Controller's operator's console is turned off by step 328 and control is retransferred to step 301 of FIG. 15 via transfer steps 330, 310.
It will be recalled that step 315 of FIG. 15 examines the bit in the system status word relating to the CRT packed buffers to determine whether any buffer is ready to transfer data. In those cases where a buffer is found ready for data transfer, control is transferred via step 316 to the steps of FIG. 17. The function of the steps of FIG. 17 is to transfer attendee information from one of the CRT packed buffers to an embosser buffer in translated form. As described above, the translation that must take place is the change in the data to a form which is acceptable by the card embossers.
Referring to FIG. 17, data transfer step 333 transfers data from a packed CRT buffer. Thereafter, embosser decision step 334 determines whether an embosser buffer is available for receiving the packed buffer data after its translation. If not, the FIG. 17 routine is exited through transfer step 335 to step 301 of FIG. 15.
If embosser buffer decision step 334 finds an available embosser buffer, control is transferred to tape writing step 336. Step 336 represents the TAPEM instructions contained in the program listing herein. The purpose of the steps is to transfer the data obtained from the packed CRT buffer to the system magnetic tape storage. As discussed above, this storage is utilized as a data source for attendee statistics. Since the tape writing steps are standard, no detailed flowchart explanation is given herein.
Following the transfer of the attendee data to tape, translation step 337 controls the translation of the packed data to embosser code. Step 337 operates in a familiar table look up fashion. As with the tape transfer steps, instructions for the embosser code data translation are contained herein in the program listing. Since they comprise a standard table look up procedure, a detailed flowchart explanation concerning the translation will not be made.
Following the translation of the data to embosser code, step 338 sets a flag denoting a full embosser buffer, notes the change in status of the now empty CRT packed buffer and turns off the Master Controller CRT message which initiated the entry into the steps of FIG. 17. Thereafter, transfer step 340 transfers control to Master Controller message decision step 301 of FIG. 15.
Accordingly, it is noted that the Master Controller software module, when entered, performs a looping operation until all current data transfers have been accomplished. Thereafter, via transfer step 304 of FIG. 15, the background steps are entered for the interrupt and initialization message loop.
10. Program Listing
Following is the source listing of the entire program according to this invention. ##SPC1## ##SPC2## ##SPC3## ##SPC4## ##SPC5## ##SPC6## | A method of operating a hardware system, including a computer, for use in registering attendees at large gatherings, such as trade shows or conventions, and producing embossed identification and inquiry cards for each attendee. A plurality of data input terminals are used to supply information concerning each attendee to the programmed computer. Entered data is edited under software control before being stored by the computer. Appropriate portions of the entered data are transmitted to one of a plurality of card embossers where an identification and inquiry card is prepared. The entered data is retrieved from storage as desired to provide statistical information concerning attendance at the trade show or convention. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to methods for determining values relating to the reserve bilirubin-binding capacity of serum albumin containing aqueous specimens, and to compositions for use in such methods.
It is known that serum albumin has two high-affinity bilirubin-binding sites. For the first specific bilirubin-binding site the association constant for the reversible binding of bilirubin, K assoc ., is of the order of 10 8 liters/mole. For the second specific bilirubin-binding site, the association constant K assoc . is of the order of 10 6 liters/mole.
It is of interest to the clinician to determine a value for the reserve bilirubin-binding capacity that represents the proportion of the said first specific high-affinity bilirubin-binding sites that are available for binding bilirubin. This is especially important in the neonatal care of jaundiced newborns.
By "reserve bilirubin-binding capacity" is meant the reserve binding-capacity of the first specific high affinity bilirubin site of serum albumin, the maximum value of this capacity being 1. The blood of the jaundiced newborn contains excessively high levels of bilirubin. When the reserve bilirubin-binding capacity of the serum albumin is low, bilirubin may find its way into the brain of the new born and cause permanent damage which may required institutional care of the patient for the rest of his life. The only method which is available for avoiding this condition is blood transfusion, and such transfusions have to be made well before the reserve bilirubin-binding capacity becomes depleted, to avoid the possibility of permanent brain damage. At present, there is no satisfactory method for determining the reserve bilirubin-binding capacity. A satisfactory assay method would therefore be highly desirable and of important assistance to the care of new borns and especially in indicating when a blood transfusion is called for.
Known methods for determining the reserve bilirubin-binding capacity, such as the peroxidase technique, electrophoretic methods, Sephadex filtration, fluorescent techniques, and methods using dyes to duplicate the binding of bilirubin to albumin, are subject to various disadvantages. For instance, some of these methods require too large an amount of blood for each test, and so they cannot be used for following the rise and fall of the binding capacity since repeated tests would demand the withdrawal of an excessive quantity of blood from the neonate body. The methods that rely on dyes and on observing colorimetric changes cannot be applied to hemolysed blood samples, as the resultant coloration obscures the color changes that are to be observed.
SUMMARY OF THE INVENTION
The present invention provides a simple, accurate, and convenient assay for determining the reserve bilirubin-binding capacity of serum albumin which is, moreover, particularly advantageous in newborns because it requires only very small amounts of blood. The present invention also provides new spin labels which are singularly useful in the above assay.
The present invention uses a spin label in an assay method for determining the reserve binding capacity. The term "spin label" is well known and refers to relatively stable, water-soluble compounds that include within their molecule the structure of a free radical containing an unpaired electron.
Examples of typical spin labels include tetramethyl-substituted nitroxides of formula ##STR1## wherein R 1 and R 2 may complete a ring system. A large number of such compounds have been described in the literature. Spin labels that are useful for some previously known purposes are capable of binding reversibly to large molecules, e.g. proteins. By employing electron spin resonance spectroscopy it is possible to determine to a high degree of accuracy the amount of free and bound spin label in an aqueous solution containing a known amount of spin label and a molecule to which the label binds. On subjecting a sample of the solution to ESR spectroscopy, distinct spectral peaks resulting from the presence of free spin label are obtained. The height of these peaks, or, more rigorously, the area under the peaks, is proportional to the concentration of free spin label in the solution. Thus, by comparison with standard solutions of spin label, the amount of free spin label in the sample under test can be determined. The amount of bound spin label can then be obtained by subtraction from the total amount originally added.
Some spin labels have now been found that bind to the first specific high-affinity bilirubin-binding site of serum albumin and are quantitatively displaceable from this binding sites into solution on addition of bilirubin to the albumin. By "quantitative displacement" the present applicant refers to a displacement of spin label into solution which is proportional to the amount of bilirubin added. Moreover, the present applicant has found some new spin labels that have the desirable property of relatively strong affinity for the said first specific high-affinity bilirubin-binding site and have relatively high selectivity for binding at these sites, that is to say they have significantly larger affinity for the first specific high-affinity bilirubin-binding site than for other bilirubin-binding sites on the serum albumin molecule such as the second high-affinity bilirubin-binding sites and non-specific binding sites.
The assay method of this invention uses spin labels that bind to the first specific bilirubin-binding site of serum albumin, and which are quantitatively displaceable, on addition of bilirubin, from the said site into the solution, where their presence can be detected by the above-described ESR spectroscopy procedures.
In the assay method, a molar excess of the spin label is added to the serum albumin-containing sample, this excess amount of spin label being sufficient to occupy most of the available first specific high-affinity bilirubin-binding sites that are not previously occupied. The molar concentration of serum albumin in the specimen may be previously determined, using conventional methods, prior to conducting the assay. In theory, it should be sufficient to add 1 mole of spin label per mole of serum albumin, but in practice it is found that superior results are obtained when at least 3 moles of spin label per mole of serum albumin are added to the specimen. If lesser quantities of spin lable are added, the discontinuity in the spin label displacement curve, which will be described later, is found to be less sharp. Too great an excess should not be added, however, since this will tend to mask the subsequent increase in free spin label concentration resulting from displacement of the bound spin label into the solution. An amount in the range of about 3 to 6 mole of spin label per mole of serum albumin is preferred, more preferably about 4 to 5 mole per mole of serum albumin.
The specimen containing the excess spin label is then titrated with a standard bilirubin solution, and is subjected to ESR spectroscopy. Instead of adding increasing amounts of bilirubin to a single volume of the specimen, it will normally be more convenient to divide the specimen into aliquots and add a progressively greater quantity of the bilirubin to each. With addition of bilirubin, the amount of free spin label displaced into solution increases in proportion to the amount of bilirubin added, and this progressive increase can be followed by observing the height of the ESR spectral peak associated with free spin label. At a certain level of bilirubin addition, there occurs a discontinuity in the progressive release of free spin label, and beyond this level the rate of release of spin label with increasing bilirubin addition slows considerably. Thus, when the displacement of spin label is graphed against the molar ratio of bilirubin to serum albumin, there is a discontinuity in the curve. At this region of discontinuity, the first specific high-affinity sites of the serum albumin molecules have been occupied by the added bilirubin, which has replaced the spin label that was formerly bound. The remainder of the curve indicates displacement from sites other than the first specific binding site. Thus, the region at which this discontinuity occurs can serve to indicate what proportion of the first specific bilirubin-binding sites in the albumin of the specimen were unoccupied and available for binding with bilirubin.
In examining spin labels for their suitability for use in the above assay, the potentiality of the spin label for binding at the high-affinity bilirubin-binding sites can be investigated by mixing a standard solution of serum albumin, obtained in a form free from bilirubin with increasing amounts of the spin label, determining the proportions of free and bound spin label by the ESR techniques described above, and repeating the procedure using serum albumin to which has been added one equivalent of bilirubin per mole of albumin.
The procedures used and ESR techniques that may be used in the above investigation are in themselves generally known to those skilled in the art and need not be described in detail here. See Scatchard, G. (1949) Ann. N.Y. Acad Sci, 51, 660 to 672 and Swartz et al. (1972) Biological Applications to Electron Spin Resonance, Wiley-Interscience, New York. In analysing the data that are obtained, the conventional procedure of preparing a Scatchard plot may be followed. From the Scatchard plots, for the solutions with and without added bilirubin, an indication of the affinity from the spin label for the said first specific high-affinity bilirubin-binding site can be obtained. In an example of a suitable spin label, e.g. the compound TOPA-DNB described in more detail later, a Scatchard plot shows that the label has two binding sites on serum albumin, and that the first specific high affinity binding site is blocked on addition of bilirubin. The binding will in such case typically have two association constants associated with it, one of high affinity and one of lower affinity. From this it can be deduced that first specific high affinity binding site for the spin label is the first specific high affinity binding site for bilirubin.
From the data that are obtained in the above procedures, the K assoc . for the binding of the spin label to its first specific high affinity binding site can be obtained.
Preferably in the assay method of the invention there are used spin labels that exhibit a K assoc . for the first specific high-affinity site of not less than about 10 3 liters/mol. At values much less than 10 3 liters/mol, the amount of spin label that binds to the serum albumin, and that will be displaced into solution on addition of bilirubin during the assay, may in some circumstances be so small that the increase in free spin label concentration in the assay solution is insufficient to yield a reliable determination of the binding capacity.
The specificity of the spin label for binding at the first specific high-affinity sites as opposed to the second bilirubin-binding sites and non-specific binding sites can be investigated by taking a normal, bilirubin-free, serum albumin sample containing a known quantity of albumin, adding a suitable excess of the spin label and titrating the mixture with bilirubin while observing the displacement of bound spin label from the albumin through the ESR spectroscopic technique discussed above. An example of such an investigation is described in more detail later. With spin labels that exhibit good specificity, the displacement of spin label is proportional to the addition of bilirubin up to a region of discontinuity beyond which lesser quantities of free label are displaced. With spin labels that do not bind selectively to the first specific high-affinity sites in the presence of bilirubin but also bind readily to the second and non-specific binding sites, there is no proportionality between the displacement of spin label and the addition of bilirubin, and a discontinuity in the increase in free spin label concentration is not observable through ESR spectroscopic methods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some examples of preferred spin labels that can be employed in the assay can now be given.
It has been found that spin labels that are dianionic compounds exhibit markedly superior selectivity for binding at the first specific high-affinity site. Examples include dicarboxylic acids, diphenols or compounds that contain both phenolic and carboxylic groups. Without wishing to rely on any particular theoretical explanation, it is suggested the superiority of the dianionic compounds may be due to their ability to mimic the bilirubin molecule, which has two propionic acid residues in its structure.
Thus, for example, the known, mono-anionic, spin label 5-N (2,2,6,6-tetramethyl-1-oxyl-4 aminopiperidinyl) 2,4-dinitrophenol, referred to herein as TOP-DNP, of formula ##STR2## is, in its phenate form, bound to bind strongly to the high-affinity bilirubin-binding sites, but when tested for specificity it is found that this spin label is not quantitatively displaced into solution on addition of bilirubin, but instead is re-bound at binding sites other than the high-affinity binding sites.
Examples of useful dianionic spin labels that are preferably used in this invention include water soluble compounds of formula ##STR3## wherein p and q are each integers of from 0 to 5 and ##STR4## represents ##STR5## and water soluble salts and esters thereof. These compounds can be prepared by generally known synthetic preparative procedures for example through reaction of an appropriate dicarboxylic ester with a spin label containing a reactive carbonyl group followed by hydrolysis to yield the monoester of the dicarboxylic acid.
Thus, for example one preferred group of spin labels namely 2,2,6,6-tetramethyl-1-oxyl-4-piperidylidenesuccinic acid, referred to herein as TOPS, and its corresponding monoethyl ester, referred to herein as TOPSE, can be prepared by the following reaction. ##STR6##
As compared with TOP-DNP the compound TOPS exhibits greater specificity for the high-affinity binding sites and is displaced by bilirubin quantitatively into solution from serum albumin. However, the TOPS compound has a considerably lower K assoc . than TOP-DNP, of the order of 10 3 liters/mole as compared with a K assoc . of the order of 10 6 liters/mole for TOP-DNP. It is considered that compounds having an aromatic moiety in their molecular structure exhibit an increased affinity for the bilirubin-binding sites. Thus, the most preferred class of spin labels are novel dianionic compounds containing an aromatic moiety. Examples of this class include compounds of formula ##STR7## wherein p, q, and ##STR8## have the same meanings as above, r and s are integers of 0 to 6, A 1 and A 2 are NH, S, or O, and B is substituted or unsubstituted phenylene, preferably 1,5-phenylene, or substituted or unsubstituted diphenyl sulfone, and water-soluble salts, phenates and esters thereof.
These compounds are prepared by generally known preparative reactions. For example, compounds of formula (10) wherein B is a 1,5-substituted 2,4-dinitrobenzene or diphenylene sulfone can be prepared by reacting a 1,5-dihalo-2,4-dinitro benzene of the formula ##STR9## or 4,4'-dihalo-3,3'-dinitrophenylsulfone of the formula ##STR10## in which Hal is fluorine, chlorine, or bromine with a spin label of the formula ##STR11## to obtain a product of the formula ##STR12## and reacting the last-named product of formula (15) with a dicarboxylic acid, mercapto, or hydroxy acid of the formula ##STR13## and isolating the corresponding compound of formula (10).
Dianionic spin labels containing a phenolic group and a carboxylic group are prepared by reacting a spin label containing a carboxylic and an amino, mercapto, or hydroxy group of the formula ##STR14## with a 1,5-dihalo-2,4-dinitrobenzene of the formula (12) or a 4,4'-dihalo-3,3'-dinitro phenylsulfone of the formula (13) and treating the resulting compound of the formula ##STR15## with base to obtain the corresponding phenolic carboxylic acid as the phenate and carboxylate salt of formula ##STR16##
In each of the above compunds, a product containing a nitro phenylene residue can be reduced to the corresponding phenylene compound by conventional procedures, e.g. reduction of the nitro groups to amine followed by diazotization and reduction with hypophosphorous acid.
One preferred dianionic aromatic spin label is 4-[5-N-(aspartic acid)-2,4-dinitroanilino]-2,2,6,6-tetramethyl-1-piperidinooxyl or 1-N(2,2,6,6-tetramethyl-1-oxyl-4-aminopiperidinyl)-5-N(1-aspartic acid)-2,4-dinitrobenzene, herein referred to as TOPA-DNB, of formula ##STR17## This compound has relatively strong affinity for the bilirubin-binding sites of serum albumin and the Scatchard plot for the binding of TOPA-DNB to serum albumin in the absence of bilirubin reveals that the binding involves at least two sites and some non-specific binding The K assoc . for the first specific binding site is in the range 10 4 to 10 5 liters/mole. In the presence of bilirubin, TOPA-DNB is displaced quantitatively from first specific high-affinity bilirubin binding sites on serum albumin.
EXAMPLE 1
Preparation of 4-(5-fluoro-2,4-dinitroanilino)-2,2,6,6-tetramethyl-1-piperidinooxyl ##STR18## 1 mM of 1-oxyl-2,2,6,6-tetramethyl-4-aminopiperidine in 5 ml of chloroform is added dropwise into 1 mM of 1,5-difluoro-2,4-dinitrobenzene dissolved in 10 ml chloroform. Under vigorous magnetic stirring, it is allowed to react overnight shielded from light. After the solvent is stripped off, a yellow precipitate is chromatographed on a silicic acid column and eluted with chloroform. Fast moving yellow bands are collected and recrystallization is carried out in chloroform and ether and small amount of hexane. m.p. 198.5°-199°.
M.W. calc.: 355.34. Mass spectral analysis found: 355.
EXAMPLE 2
In the same manner as in Example 1, using 1 mM of 1-oxyl-2,2,5,5-tetramethyl-3-aminopyrrolidine in place of the aminopiperidine starting material, there is obtained 3-(5-fluoro-2,4-dinitroanilino)-2,2,5,5-tetramethyl-1-pyrrolidinooxyl.
EXAMPLE 3
In the same manner as in Example 1 using 1,5-dichloro-2,4-dinitrobenzene in place of 1,5-difluoro-2,4-dinitrobenzene there is obtained 4-(5-chloro-2,4-dinitroanilino-)-2,2,6,6-tetramethyl-1-piperidinooxyl.
EXAMPLE 4
Following the same method as in Example 1 and using 2,2,4,4-tetramethyl-3-oxyl-5-amino-1-oxazolidine in place of the aminopiperidine starting material, there is obtained 5-(5-fluoro-2,4-dinitroanilino)-2,2,4,4-tetramethyl-1-oxazolino-3-oxyl.
EXAMPLE 5
Following the method of Example 1 and using 1-oxyl-2,2,6,6-tetramethyl-4-hydroxy-piperidine instead of 1-oxyl-2,2,6,6-tetramethyl-4-aminopiperidine there is obtained 4-(5-fluoro-2,4-dinitroanilino)-2,2,6,6-tetramethyl-1-piperidinooxyl.
EXAMPLE 6
Following the method of Example 1 and using 1-oxyl-2,2,6,6-tetramethyl-4-mercaptopiperidine (hypothetical compound) instead of 1-oxyl-2,2,6,6-tetramethyl-4-aminopiperidine there is obtained 5-(5-fluoro-2,4-dinitro-thiobenzene)-2,2,6,6-tetramethyl-1-piperidinooxyl.
EXAMPLE 7
Employing 1,5-dibromo-2,4-dinitrobenzene in place of 1,5-difluoro-2,4-dinitrobenzene in the method of Example 1, there is obtained 4-(5-bromo--2,4-dinitrobenzene)-2,2,6,6-tetramethyl-1-piperidinooxyl.
EXAMPLE 8
Employing 4,4'-dichloro-3,3'-dinitrophenyl sulfone instead of 1,5-difluoro-2,4-dinitrobezene in the method of Example 1, there is obtained N-(2,2,6,6-tetramethyl-1-oxyl-4-piperidinyl)-4-amino-4'-chloro-3,3'-dinitrophenyl-sulfone.
EXAMPLE 9
Preparation of the spin label formula (20)
L-Aspartic acid (399 mg, approx. 3 mM) and Na 2 CO 3 (972 mg, approx. 9 mM) are dissolved in 25 ml of 40% aqueous ethanol solution. To this solution is added 4-(5-fluoro-2,4-dinitroanilino)-2,2,6,6-tetramethyl-1-piperidinooxyl of formula (21) (355 mg, 1 mM, prepared as in Example 1 above. The mixture is heated at 45°-50° C. overnight with stirring. The reaction mixture is cooled and diluted with H 2 O (15 ml) and filtered. The filtrate is extracted with CHCl 3 (2×30 ml). The aqueous layer is then acidified with dilute HCl (0.5 N) and precipitation occurs. The yellowish precipitate is filtered and washed with H 2 O until it is free of acid and then dried in air. The product is recrystallized from DMSO/H 2 O to give 250 mg of yellow crystals & yield 53%; R f value=0.56 (on silica gel with a solvent system CHCl 3 :CH 3 OH:acetic acid, 80:20:2); m.p.=220° C. (decomposed); UV, λmax=339 and 420 nm (respective molar extinction coefficients of 28,000 and 10,700) for a methanol solution of TOPA-DNB as a disodium salt, I.R. prominent features, 3350 cm -1 (--NH stretching), 1720 cm -1 (carboxylic acid>C=0 stretching), 1570 and 1330 cm -1 (conjugated nitro-group), 3200-2500 cm -1 (--OH stretching); could not obtain parent ion in mass spectrum.
EXAMPLES 10 to 16
In the same manner, employing the products of Examples 2 to 8 in place of the compound of formula (21) there are obtained the following products, respectively.
EXAMPLE NO.
10. 3-[5-N-(aspartic acid)-2,4-dinitroanilino]-2,2,5,5-tetramethyl-1-pyrrolidinooxyl.
11. Compound of formula (20).
12. 5-[5-N-(aspartic acid)-2,4-dinitroanilino]-2,2,4,4-tetramethyl-1-oxazolidino-3-oxyl.
13. 4-[5-N-(aspartic acid)-2,4-dinitroanilino]-2,2,6,6-tetramethyl-1-piperidinooxyl.
14. 4-[5-N-(aspartic acid)-2,4-dinitro-thiobenzene]-2,2,6,6--tetramethyl-1-piperidinooxyl.
15. N-[N'-(2,2,6,6-tetramethyl-1-oxyl-4-piperidinyl)4-amino-3,3'-dinitro-4'-diphenylsulfone] aspartic acid.
EXAMPLE 17
Determining specificity of spin label and example of assay
The procedure is conducted under a minimal amount of light to avoid photo-degradation of the bilirubin.
Initially, the bilirubin to be employed is converted to bilirubin disodium salt.
0.24 mg of bilirubin (obtained from Sigma Co., No. B.4126, derived from Bovine gall stones; crystalline) is weighed into a test tube (3 ml). 2 ml of 0.00044 M NaOH in methanol is pipetted into the test tube. The tube is swirled gently until all the bilirubin has dissolved and undissolved bilirubin is filtered through glass wool to obtain a clear bilirubin solution.
A quantitative bilirubin stock solution is then prepared from the solution of disodium salt. With a 25λ (micro liter) Hamilton syringe, 20λ of the bilirubin disodium solution is pipetted into a test tube (3 ml), and the solution is then evaporated to dryness under nitrogen. A 2 ml aliquot of 0.1 M phosphate buffer at pH 7.4 is pipetted into the dried bilirubin disodium salt sample. The concentration of bilirubin in this solution is determined using the known extinction coefficient of bilirubin. The determination is performed with a Unicam SP1800, Spectrophotometer. All measurements are done in triplicate.
The same absorbance should be taken immediately, and the sample removed from the cuvette holder within 30 seconds. Serum is obtained by centrifugation of the coagulated blood of an adult male volunteer, and the concentration of serum albumin is determined by conventional methods. For convenience, the serum is then diluted with 100 mM phosphate buffer pH 7.4 to achieve a convenient serum albumin concentration of 5×10 -5 M.
Appropriate amounts of the bilirubin stock solution are then pipetted into twelve numbered test tubes so that a range of bilirubin to albumin molar ratio from 0 to 2.0 will be obtainable on addition of a constant volume (50λ) of diluted buffered serum to each tube.
The whole set of tubes can then be dried under vacuum, if desired or stored in freezer below 0° C.
To a test tube containing a constant amount of dried TOPA-DNB, prepared from stock TOPA-DNB solution, and dried under nitrogen, a fixed volume (700λ) of the diluted serum sample is added to give a TOPA-DNB to albumin molar ratio of 5:1. The TOPA-DNB and albumin solution is left to stand for 15 minutes. 50λ of the TOPA-DNB/albumin solution is pipetted into each of the twelve numbered test tubes containing the bilirubin, making sure that all the dried bilirubin has dissolved. Each titration sample is then filled into a 25λ micro-pipette (Clay Adams, Micro Pet, Recorder No. 4619) by suction. The sealed micropipettes are subjected to ESR measurements.
A Varian E-6 X-band ESR spectrometer is used. The instrument settings are as follows:
(a) Gain: a convenient setting (1250-3200) is selected within the limits of the microprocessors.
(b) Frequency/power: 9.065 GHZ/40 mw
(c) Modulation (Grass): 2.5
(d) T.C./S.T. (sec/min) 0.3/4.0
(e) Field and Range: 3230±20 Gauss
(f) Temp.: 22°±1° C.
Some of the free TOPA-DNB signals that are obtained are shown in FIG. 1. Each of these peaks is a peak associated with free spin label and its height is proportional to the amount of free spin label in solution. The peak heights are calibrated against known standard solutions of TOPA-DNB and the percent increase in free TOPA-DNB is plotted against the mole percent of added bilirubin or in mg% which yield the reserve bilirubin loading capacity.
The result is as shown in FIG. 2 (curve I). As shown, at bilirubin levels of up to 1 mole per mole of albumin, the displacement of spin label into the solution is linear.
In order to demonstrate an assay procedure, the above is repeated using serum to which has been added 0.5 equivalent of bilirubin (0.5 mole) per mole of albumin. The result is as shown by curve II. The region of discontinuity of the curve has been shifted left-wards by the presence of bilirubin in the serum specimen, the shift indicating the extent to which the first specific high-affinity bilirubin-binding site is occupied in the specimen.
In the case of the specimen assayed in curve II, the reserve bilirubin-binding capacity is indicated as being smaller than the maximum possible by an amount of 0.5 equivalent of bilirubin.
In the application of assay, if the albumin concentration of the serum sample is known, an absolute value representing the reserve bilirubin-binding capcity (RBBC) can then be obtained from the region of discontinuity on the TOPA-DNB displacement curve. However, if the albumin concentration is not available, the percent increase in free TOPA-DNB is then plotted against the added bilirubin in mg per 100 ml of specimen, the region of discontinuity of the displacement curve is defined as the reserve bilirubin loading capacity (RBLC) in units of mg per 100 ml of specimen. This value can be calculated but is not illustrated in FIG. 2.
The assay method described above has the advantages that since free radicals are rare in physiological specimens, there is little risk of spurious values being obtained from any extraneous contribution to the ESR spectral peaks, it can be applied to cloudy or hemolyzed serum specimens, the assay takes advantage of the complete and instantaneous separation of the bound and free spin labels so that there is instantaneous determination of the equilibrium state, the spin label is itself relatively stable and does not deteriorate over extensive periods, the position of the resonance peaks on the ESR spectrum indicates whether the peak is associated with a bound or a free spin label, the concentration of free spin label can be quantified directly merely by observation of the spectral peak height, and the volume of specimen required is very small, less than 50λ of serum being needed per test, e.g. when the specimen is diluted with an appropriate diluent, a phosphate buffer, the test is performed with considerably small volume of the specimen. | Spin labels, especially dianionic aromatic spin labels which can bind to the first specific high-affinity bilirubin-binding site on serum albumin, and which are quantitatively displaceable into solution from said site in the presence of bilirubin, can be used in an assay for bilirubin-binding capacity. In the assay, an excess of spin label is mixed with the serum albumin or serum and is titrated with standard bilirubin. ESR spectroscopy indicates a change in the rate of spin label release with addition of bilirubin, giving a value indicative of bilirubin-binding capacity. Novel dianionic aromatic spin labels are also disclosed. | 8 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to systems and methods for controlling and scheduling equipment in HVAC systems by predicting cooling loads, heating loads and equipment efficiencies using historical load and efficiency data recorded in situ by building sensors, a building automation system (BAS), an equipment automation system or some combination thereof.
BACKGROUND
[0002] Many buildings employ an HVAC system to maintain a comfortable environment. The HVAC system provides heating and cooling for the buildings. Conventionally, local engineering knowledge is used to produce a sequencing that arranges equipment (chillers, pumps, etc.) by their energy efficiency such as using the least efficient equipment only under the most extreme circumstances. To achieve a better energy efficiency and energy savings for the HVAC system, it is typically advantageous to use the equipment with the higher efficiency before bringing on other equipment that uses more energy to do the same job.
[0003] HVAC systems are designed with multiple pieces of equipment, some to do the same job as other identical pieces of equipment, like chillers in which there may be two or more water chillers as part of the building or campus HVAC system. During low cooling season only one of the chillers would be operating; whereas during high cooling season maybe all of these chillers would be operating. In addition, one or more chillers may be purposefully kept off line for a variety of reasons such as, but not limited, repairs, maintenance, etc.
[0004] Even though these chillers may be similar or identical (e.g., same manufacture, same model, etc.), the chillers may often have different efficiency's for performing the same heating or cooling task. By way of example, a chiller efficiency is typically measured as kW/ton (or other HVAC equipment efficiency measurements like Co-efficient of Performance (COP), Energy Efficiency Ratio (EER), Seasonal Energy Efficiency Ration (SEER)), which is the amount of energy (measured in kW) used by the chiller to produce cooling (measured in tons). A lower kW/ton rating indicates higher efficiency (tons=one ton of cooling is the amount of heat absorbed by one ton of ice melting in one day, which is equivalent to 12,000 Btus per hour, or 3.516 kilowatts (kW) (thermal energy)).
[0005] A number of different methods have been developed to measure equipment efficiency and stage equipment by their efficiency ratings. These methods include observation and manual modeling of equipment efficiency for certain building conditions (usually including wet bulb air temperature, building load, etc.) along with use of a manufacturer's specification for equipment efficiencies. These parameters are combined with engineering knowledge to provide a static sequencing order that may be used over a period of time to keep energy efficiency high.
[0006] While equipment like a chiller is operating, the efficiency of each operating chiller may be measured and compared by an engineer, a building automation system (BAS) or an energy management system (EMS) with the correct instrumentation. By way of example, some engineers may specify the most efficient sequence to run the equipment and that sequence may be controlled manually by operators or it may be hard coded within the BAS to run in that particular sequence in an automated manner.
[0007] Many of the conventional sequencing methods involve many hours of labor on the part of a knowledgeable engineer and the sequence modeling typically occurs only at the outset when the equipment is initially commissioned. The “stage and forget” process may be problematic since equipment energy efficiencies can drift over time as parts or components wear, critical operating fluids leak or are used up, and/or conditions change in the system as a whole. Such operational changes directly affect the energy usage of individual pieces of equipment.
[0008] The reasons that equipment like chillers, pumps, fans, cooling towers or boilers may have different efficiencies may be due to (1) manufacturing differences (large or small); (2) poor equipment (3) equipment wear or broken parts; (4) contamination or loss of refrigerant within a chiller; and/or (5) fouling or buildup of material on working surfaces.
[0009] FIG. 1 shows a chart 10 in which energy efficiency 12 is recorded over time 14 for two separate, but otherwise identical chillers 16 , 18 , respectively. The upper curve 20 shows how the efficiency of first chiller 16 varies over time while the lower curve 22 shows how the efficiency of second chiller 18 varies over time.
[0010] Additionally, while the manual sequencing process may capture trends in equipment efficiency it is often unable to observe small fluctuations in efficiency. Since manufacturer specifications are often used in the manual sequencing process it can also be difficult to perceive differences in equipment energy efficiencies for the same model. This may result in operating less efficient equipment, using excess energy that may be “left on the table.”
[0011] The most predominant and common method to operate and stage equipment involves operating the equipment in an equal runtime rotation scheme. This method rotates the operating sequence of a group of equipment based on the accumulated running hours (or days, or minutes) of each piece of equipment. When one piece of equipment has accumulated a certain number of operational hours than another piece of equipment the operating sequence is rotated. The equipment having the lowest logged hours is rotated in the operating sequence to turn on first, while the equipment having the highest logged hours will be turned on last in the sequence.
[0012] Another method to operate and stage equipment involves using a minimum runtime sequence in which the equipment is staged to ensure that each piece of equipment runs for a certain amount of hours every rotation period, which is commonly done to make sure that the equipment does not sit inoperable for a long period. When equipment is left inoperable for long periods of time, the equipment may decay or lose critical operating fluids to leakage or evaporation.
[0013] FIG. 2 shows another chart 24 in measured energy efficiencies 26 are plotted over time 28 . Each curve 30 , 32 , 34 represents the energy efficiencies 26 of three similar chillers respectively, over time. An upward facing arrow 36 indicates that chiller 30 had the best operating efficiency for a period of time, but then began operating at a poorer operating efficiency over a later period of time as indicated by arrow 38 .
[0014] Over time, the energy efficiencies of the equipment may drift as shown in FIG. 2 , and such drifts may be result in a reduced or poorer energy efficiency for that particular equipment. On the flip side, a piece of equipment with a poor energy efficiency may be improved through maintenance, repair, or cleaning, for example.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention is generally directed toward systems and methods for sequencing HVAC equipment of an HVAC system using data recorded in situ to build a model capable of making predictions about equipment efficiency and using that information, in combination with predictions about building load, to produce an operational sequence for the HVAC equipment that promotes an improved or optimized overall energy efficiency for the HVAC system.
[0016] In addition, this data, prediction and modeling can be used to determine which pieces of HVAC equipment work more efficiently with other pieces of HVAC equipment, taking into account the covariance between the different pieces of HVAC equipment, producing further sequencing that will operate the HVAC equipment together in efficient covariance combinations, that promotes an improved or optimized overall energy efficiency for the HVAC system.
[0017] In addition, this data, prediction and modeling can be used to optimize when best to stage additional HVAC equipment on or off, based on the future load prediction of the HVAC equipment, which promotes an improved or an optimized overall energy efficiency for the HVAC system.
[0018] In addition, this data, prediction and modeling can be used to determine at which loads the HVAC equipment operates at its best efficiency, allowing for the load balancing of the different similar pieces of operating HVAC equipment, to keep them operating in their ‘Sweet Spot’, for example if one chiller operates most efficiently at a load of 500 tons, it can be load balanced via water flow, valves or control set points, to remain operating at that “sweet spot” of 500 tons in parallel with another operating chiller which operates efficiently at 700 tons, also load balanced to operate producing 700 tons via water flow, valves or control set points, to remain operating at that “sweet spot”, which promotes an improved or optimized overall energy efficiency for the HVAC system.
[0019] In one embodiment, the process is automated and utilizes Bayesian computational models or algorithms to generate an initial sequence. The process reduces engineering hours and may advantageously provide a means to predict potential sequencing problems for similar types of HVAC equipment.
[0020] In one aspect of the present invention, a method for sequencing HVAC equipment in an HVAC system includes the steps of (1) acquiring a plurality of inputs including historical data points and predicted data points; (2) determining energy efficiencies for the HVAC equipment; (3) acquiring weather prediction data; (4) using the inputs, energy efficiencies and weather prediction data, computing an expected future load for the HVAC equipment; (5) using the inputs, energy efficiencies, weather prediction data and expected future load, employing an analytical computational model to determine predicted energy efficiencies for the HVAC equipment; (6) determining an initial order of the HVAC equipment configured to provide an optimized energy efficiency for the HVAC system; (7) filtering the initial order based on an operating status for one or more of the HVAC equipment; (8) determining a final sequence of the HVAC equipment; and (9) providing the final sequence to a building automation system for controlling the HVAC system in accordance with the final sequence.
[0021] In another aspect of the present invention, a method for sequencing HVAC equipment in an HVAC system includes the steps of (1) acquiring a plurality of inputs including historical data points and predicted data points; (2) determining energy efficiencies for the HVAC equipment; (3) acquiring leather prediction data; (4) using the inputs, energy efficiencies and weather prediction data, computing an expected future load for the HVAC equipment; (5) using the inputs, energy efficiencies, weather prediction data and expected future load, employing a linear regression model to determine predicted energy efficiencies for the HVAC equipment; (6) determining an initial order of the HVAC equipment configured to provide an optimized energy efficiency for the HVAC system; (7) filtering the initial order based on an operating status for one or more of the HVAC equipment; (8) determining a final sequence of the HVAC equipment; and (9) providing the final sequence to a building automation system for controlling the HVAC system in accordance with the final sequence.
[0022] In yet another aspect of the present invention, a method for sequencing HVAC equipment in an HVAC system includes the steps of (1) acquiring a plurality of inputs including historical data points and predicted data points; (2) determining energy efficiencies for the HVAC equipment; (3) acquiring weather prediction data; (4) using the inputs, energy efficiencies and weather prediction data, computing an expected future load for the HVAC equipment; (5) using the inputs, energy efficiencies, weather prediction data and expected future load, employing a k-nearest neighbors model to determine predicted energy efficiencies for the HVAC equipment; (6) determining an initial order of the HVAC equipment configured to provide an optimized energy efficiency for the HVAC system; (7) filtering the initial order based on an operating status for one or more of the HVAC equipment; (8) determining a final sequence of the HVAC equipment; and (9) providing the final sequence to a building automation system for controlling the HVAC system in accordance with the final sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings:
[0024] FIG. 1 is a chart showing two similar pieces of HVAC equipment operating at different energy efficiencies over time;
[0025] FIG. 2 is a chart showing three similar pieces of HVAC equipment operating at different efficiencies over time;
[0026] FIG. 3 is a schematic system diagram of an equipment sequencing program in on-site communication with a building automation system (BAS) that controls an HVAC system according to an embodiment of the present invention; and
[0027] FIG. 4 is a schematic system diagram of an equipment sequencing program that remotely obtains weather data from a weather service provider and where the equipment sequencing program is in remote communication with an external optimization application that provides a communications interface for a building automation system (BAS) that controls an HVAC system according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures associated with HVAC systems; automation systems (e.g., building automation systems referred to as BASs) air handler units (AHUs) such as, but not limited to terminal units (also called fan coil units), packaged units or rooftop units, and various equipment used in HVAC systems such as, but not limited to, controllable valves, heating and cooling coils, various types of sensors; controllers and processors; communication networks; various computing and/or processing systems; chillers, fans, various HVAC system equipment operational parameters and set points, data points or data points; and methods of operating any of the above with respect to one or more buildings have not necessarily been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments of the invention.
[0029] One systemic and on-going problem in the HVAV industry is the inability to continually model ongoing dynamic efficiency changes of the HVAC equipment, and then react to such changes in a meaningful manner such as re-ordering the equipment sequencing to improve overall efficiency and reduce operating costs of the HVAC system.
[0030] Even if the labor intensive and time intensive manual sequencing process could be done quickly, putting the data to use would be expensive without an automatic method of generating sequencing orders while considering local operating conditions. Any method that models energy efficiency on a per equipment basis should preferably include an automation method that produces a sequencing order.
[0031] An embodiment of the present invention includes a method for automatically and dynamically predicting energy efficiency on a per equipment basis and using that information along with local conditions to choose a sequencing order that increases energy efficiency. Further, the chosen sequencing order may allow for the observation of various HVAC equipment efficiencies over time, which in turn may provide a technician or engineer with a better insight about the HVAC system. The automation of such a method would advantageously rebalance equipment loads without requiring direct management, oversight or observation by a knowledgeable technicians or engineer. Further, such a method may produce reports that highlight any glaring changes in energy efficiency in a timely manner.
[0032] FIG. 3 shows a system diagram 100 for providing intelligent equipment sequencing to a various sets or groups of similar HVAC equipment such as, but not limited to, chillers, boilers, fans, pumps and cooling towers. The term “similar” as used herein means the equipment is of a similar design and size relative to the other equipment. In the illustrated embodiment, the intelligent equipment sequencing occurs on-site, for example on a building site or a campus site (e.g., a site having more than one building or HVAC system). The system diagram 100 shows the overall process for sequencing similar HVAC equipment by their respective energy efficiencies which includes the inputs for the major modules to complete said sequencing.
[0033] The outline or border 102 represents a building or a campus, which in turn includes at least one HVAC system 104 having two or more pieces of similar HVAC equipment 106 . In the illustrated embodiment and by way of example, the HVAC equipment 106 may take the form of three chillers operating in parallel, but of necessarily all operating at the same time.
[0034] In the illustrated embodiment, the HVAC system 104 exchanges data to/from the pieces of equipment 106 with a building automation system (BAS) 108 . The BAS 108 controls and runs the equipment 106 to meet a load or demand of the building or campus 102 . Further, the BAS 108 operates as a communications interface between an equipment sequencing program 110 and the HVAC system 104 .
[0035] In operation, data is gathered, in real-time from the equipment 106 and the HVAC system 104 . The data is stored in an equipment and sensor database 112 of the BAS 108 and communicated to the equipment sequencing program 110 as operating data 114 , which uses a Bayesian method to sequence the equipment 106 as will be explained in further detail below,
[0036] In the illustrated embodiment, the equipment sequencing program 110 utilizes a plurality of inputs 116 such as, but not limited to, historical data points 118 , per equipment efficiency 120 , predicted data points 122 and weather prediction data 124 . The historical data points 118 have been recorded, observed, measured or otherwise documented at a prior time.
[0037] One type of historical data point 118 may include a historical time at which the data point was recorded. This historical time may be in the form of a universal time code (UTC), a time stamp, or a record of the time in minutes and hours (either 12-hour or 24-hour format). The historical time provides various snapshots and periodic thermal dynamics of the HVAC equipment 106 . Another type of historical data point 118 may be a historical date for when the data point was recorded. The historical date preferably may further indicate whether the data point was recorded on a weekend or a weekday, and whether the weekday was a holiday. The historical date information captures load dependency information pertaining to the work schedule of the HVAC system 104 and the similar HVAC equipment 106 to be sequenced. Other historical data points 118 may include a wet bulb outside air temperature, a dry bulb air temperature, and load information of the building or campus. The load information is used by the equipment sequencing program 110 to bind the aforementioned historical data points to a specific load value for the equipment sequencing program.
[0038] The per equipment efficiency input 120 is a record of the efficiency of each piece of HVAC equipment, which in turn provides specific efficiency values so that future efficiencies may be predicted. In one embodiment, the per equipment efficiency input 120 is recorded in kilowatt per tons of ice equivalent (it could also be recorded in any other energy efficiency measurement like COP, EER, SEER or IEER).
[0039] The inputs 116 further include predicted data points 122 . One of the predicted data points 122 includes predicted time information with time stamps or boundaries fur a predetermined future time period under consideration. Another one of the predicted data points 122 includes predicted date information and whether such date or dates include a weekend day, a weekday or a holiday.
[0040] Lastly, the inputs 116 include weather prediction information that includes a predicted outside air wet bulb temperature, a predicted outside air humidity and a predicted outside air dry bulb temperature, both for the future time period under consideration.
[0041] The inputs 116 are communicated or otherwise transmitted to a load predictor module 126 , which computes a future load or loads for the HVAC equipment 106 using said inputs 116 . In practice, the future load is typically computed for the next day, or for the next 24 hours, but it is appreciated that the future load may be predicted for any reasonable, foreseeable period of time. The load predictor module 126 may assist in predicting equipment efficiency and may also be used to predict a total energy used by the entire HVAC system.
[0042] The inputs 116 are also communicated to or transmitted to an equipment efficiency predictor 128 , which generates an efficiency model for all of the HVAC equipment 106 to be sequenced. In one embodiment, the equipment efficiency predictor 128 may take the form of a self-learning module that continually updates the efficiency model.
[0043] The equipment efficiency predictor 128 may be configured to predict an energy efficiency of the equipment 106 using data from the inputs 116 and load predictor 126 . In one embodiment, the equipment efficiency predictor 128 takes the form of a linear regression model that accepts at least the historical data points 118 and the prediction data points 122 to build a model of the HVAC equipment's 106 energy efficiency. The equipment efficiency predictor 128 predicts the energy efficiency for each piece of HVAC equipment 106 at each predicted data point 122 . The linear regression model scalarizes the data points 118 , 122 by transforming the data points from its native or baseline encoded format to a scalar value that can be manipulated as a number. Next, a linear regression analysis is performed on the inputs 116 with the time information, the date information, the temperature data, and the load as independent variables and the equipment's energy efficiency as the dependent variables. The linear regression model accepts the predicted data 122 and uses the line regression to make predictions about equipment energy efficiency. Each piece of HVAC equipment 106 may have its own model. The predicted data points 122 along with the predicted efficiency of the HVAC equipment at each predicted data point is then output to an order equipment module 130 .
[0044] in another embodiment, the equipment efficiency predictor 128 takes the form of a K-nearest neighbors (KNN) model efficiency predictor. This KNN predictor accepts the historical data points 118 and the predicted data points 127 to build a model of the equipment's energy efficiency. The model predicts the energy efficiency for each piece of HVAC equipment 106 at each predicted data point 122 . The KNN model scalarizes the data points 118 , 122 similar to the linear regression model. Next, the KNN model removes data points that contain invalid data values from both the historical 118 and predicted data points 122 . Each dimension of each historical data point 118 is treated as a random distribution of points, The standard deviation and average of this random distribution is computed. All dimensions of each historical data point 118 are normalized by subtracting the average Obtained for that dimension and then dividing by the standard deviation for that dimension. This process is repeated on the predicted data points 122 , except that the same average and standard deviation derived from the normalizing the historical data points 118 are used to normalize the predicted data points 122 . The value of each dimension is re-weighted by multiplying each value for that dimension in both the historical and predicted data points by a constant re-weighting constant.
[0045] The KNN model then accepts the historical data points 118 and places them into a KNN space that returns the K neighbors of each input prediction data point that most closely resemble that point. The model returns the average efficiency of the k neighbors for the HVAC equipment along with the original predicted data points 122 . For each prediction data point and each piece of HVAC equipment 106 , the respective energy efficiency is predicted using the prepared KNN model. Next, the weighting process used is reversed or de-weighted such that each dimension should have the same weight after thereinafter. Lastly, the normalization process is also reversed. Each dimension (along with the predictions of equipment energy efficiency) may be re-scalarized with correct values. The predicted data points 122 along with the predicted efficiency of the HVAC equipment 106 at each predicted data point is then output to the order equipment module 130 .
[0046] Both the load predictor 126 and equipment efficiency predictor 128 forward their data to the order equipment module 130 , which uses this information along with the predicted data points 122 to determine an order of the HVAC equipment 106 by their respective energy efficiency, best operating combinations, best covariance operation and efficient load balancing.
[0047] The order equipment module then forwards the order of the HVAC equipment 106 to a filter equipment module 132 , which determines what equipment is actually available to be sequenced, as some may not be able to run due to unavailability, minimum runtime, etc. After the HVAC equipment 106 is ordered and filtered, that information is transmitted to an output sequencing module 134 .
[0048] In the output sequencing module, the data is formatted for consumption by a receiving device or system and is then transmitted to an equipment staging sequence module 136 of the BAS 108 . The BAS 108 will take the sequence and use it in conjunction with a BAS equipment control program 138 to operate the HVAC equipment 106 in the most efficient way possible.
[0049] Summarizing, one or more embodiments of the present invention provide methods for sequencing HVAC equipment by their respective energy efficiencies. The method accepts two time series as inputs and returns an equipment ordering. The first time series includes historical data recorded at the building or campus. The second time series is a set of predicted data points. These prediction data points are time series predictions for each of the dimensions contained in the historical data points over some future time period under consideration by the load predictor.
[0050] The historical data and prediction data is then fed into a load predictor, which in turn uses the historical data to build a model that can predict the future load of HVAC equipment given a time series that contains a prediction of the environmental conditions for the HVAC system in the future. This model is used, along with the predicted data points, to predict the building load for each data point in the predicted data points.
[0051] The predicted data points, along with the load predicted for each data point, are next sent to the equipment efficiency predictor. This predictor additionally uses the historical data points. In one embodiment this efficiency predictor uses a linear regression model. Since the historical data points contain dimensions with diverse data types the historical and prediction data points are first scalarized. This process changes each dimension in to a number for use in the linear regression. Next, the scalarized historical data points are modeled using a linear regression model that returns the equipment's efficiency as a linear function of the time, the date, the outside air temperature, the outside air wet bulb temperature, and the load. Next, for each data point in the predicted data points, the energy efficiency for each piece of HVAC equipment is predicted using the predicted data points as input to the model. Further modeling can be done based on best combinations and covariance operation, and efficient load balancing of the HVAC equipment. Finally, the extended prediction data points are output, each containing the information in along with the predicted load and predicted energy efficiency for the equipment.
[0052] In another embodiment the efficiency predictor uses a KNN model to predict energy efficiency for the HVAC equipment rather than a linear model. In this process, first the historical data and the prediction data are scalarized so that each dimension of the data points represent a number. Next, the both historical data and prediction data sets are cleaned, with invalid data points removed from both sets. The next step normalizes the historical prediction data points. This is done by first finding the average and standard deviation of each dimension in the historical data set. Next, each dimension in both the historical data set and prediction data set is normalized by subtracting their respective average from the historical data set and then dividing each of them by the standard deviation. After normalization each dimension of the historical and prediction data sets is re-weighted. This is done by multiplying each value in each of the dimensions by a constant. Next, the historical data is put into a KNN space which builds a model capable of accepting prediction data points, finding historical data points that are close to those prediction data points in terms of the independent variables (time, data, outside air temperature, outside wet bulb air temperature and load) and returning a value for each of the dependent variables (efficiency for each piece of equipment). Finally the extended prediction data points are output after de-weighting by dividing each dimension by its re-weighting constant and de-normalization, reversing the normalization process.
[0053] The extended prediction data points are then fed into the order equipment module. In one embodiment, the equipment's predicted energy efficiency is calculated by averaging the predicted energy efficiency determined for the equipment over all time steps. The equipment is then placed in a list in order of its energy efficiency, with highest efficiency first and lowest efficiency last. In another embodiment, the total energy used by the system is predicted for each possible ordering of the HVAC equipment, using the extended prediction data to calculate the amount of energy the HVAC system would use if it were run with that ordering of the HVAC equipment. In another embodiment, the combined efficiency and covariance of the HVAC equipment operating together is modeled and used to extend the prediction data to calculate the least amount of energy the HVAC system would use if it were run with that ordering and sequence of the HVAC equipment. Finally, the ordering that uses the lowest amount of energy is returned as the equipment order.
[0054] Next, the equipment orderings are filtered. This process uses knowledge of the current physical state of the HVAC system to remove the pieces of HVAC equipment that are not available for use. Finally, after equipment filtering, a valid equipment sequencing is provided to the BAS for controlling the HVAC system.
[0055] FIG. 4 shows a system 200 in which data or information is exchanged remotely and/or wirelessly 240 . For purpose of brevity and clarity, all components of the system 200 are the same as those illustrated in FIG. 3 except the components having 200 level numbers. In other words, any components of system 200 taken from FIG. 3 retain the same number. In the system 200 , the equipment sequencing program 110 communicates remotely with an external optimization application module 242 , which functions as a communications interface between the equipment sequencing program 110 and the BAS 108 . The external optimization application module 242 may include operating data 244 and operating parameters 246 related to the HVAC equipment 106 . In the illustrated embodiment, the weather prediction 124 may be acquired from a third party weather service provider 248 via an application programming interface (API) over the Internet.
[0056] While the preferred embodiment of the invention has been illustrated and described, as noted above, any changes can be made without departing from the spirit and scope of the invention. In addition, other advantages will also be apparent to those of skill in the art with respect to any of the above-described embodiments whether viewed individually or in some combination thereof. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow. | Systems and methods for sequencing HVAC equipment of an HVAC system using data recorded in situ to build a model capable of making predictions about equipment efficiency and using that information, in combination with predictions about building load, to produce an operational sequence for the HVAC equipment that promotes an improved or optimized overall energy efficiency for the HVAC system. In one embodiment, the process is automated and utilizes Bayesian computational models or algorithms to generate are initial sequence. The process reduces engineering hours and may advantageously provide a means to predict potential sequencing problems for similar types of HVAC equipment. | 5 |
CLAIM FOR DOMESTIC PRIORITY
This application claims priority under 35 U.S.C. §119 to the, U.S. Provisional Patent Application No. 61/896,635, filed Oct. 28, 2013, U.S. Provisional Patent Application No. 61/896,639, filed Oct. 28, 2013, U.S. Provisional Patent Application No. 61/908,763, filed Nov. 26, 2013, U.S. Provisional Patent Application No. 61/913,932, filed Dec. 10, 2013, U.S. Provisional Patent Application No. 61/913,934, filed Dec. 10, 2013, U.S. Provisional Patent Application No. 61/913,935, filed Dec. 10, 2013, U.S. Provisional Patent Application No. 62/006,900, filed Jun. 3, 2014, U.S. Provisional Patent Application No. 62/006,901, filed Jun. 3, 2014, and U.S. Provisional Patent Application No. 62/006,906, filed Jun. 3, 2014, the disclosures of which are incorporated herein by reference in their entirety.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document 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 the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention generally relates to power electronics. Particularly, the present invention relates to methods and power electronics for regulating alternative current (AC) voltage, and more particularly regulating an output AC voltage to a desired level regardless of the variation in an input AC voltage.
BACKGROUND
AC voltage regulators are used to closely control and regulate the AC voltage level being delivered to a load connected to the output of the AC voltage regulator, regardless of the AC voltage variation at the input of the AC voltage regulator.
This has been traditionally done by various low frequency (LF), typically at 50 or 60 Hz, electrical mains magnetic structures. These structures are typically tapped at specific discrete transformer voltage taps in various transformers or transformer configurations. Nonetheless, all these structures rely on traditional AC switching devices such as relays or semiconductor devices such as silicon-controlled rectifiers (SCR)'s or gate turn off thyristor (GTO)'s connected as anti-parallel AC switches, TRIAC's, AC switches such as insulated-gate bipolar transistors (IGBT)'s, MOSFET transistors, and SCR's configured as AC switches, e.g. connected between rectifiers. These AC switches are selected and activated by the electronic control circuit to automatically switch the selected magnetic transformer structure tap, in turn adjusting the transformer or transformer configuration turns ratio to control the AC output voltage as close as possible to the desired level.
Another traditional method to regulate an output AC voltage is to use an electro-mechanically-adjusted auto-transformer that is driven by electrical mechanical means, such as a controlled electrical motor. The electronic control in this case senses the input voltage and then drives the electro-mechanical means to move the output contact to adjust the turns of the auto-transformer, in turn sets the correct turns ratio to fix the output AC voltage to the desired level. These electro-mechanically-adjusted auto-transformer devices are also LF magnetic structures, typically at 50 Hz or 60 Hz, and generally use carbon brushes to make the moving electrical contact to the auto-transformer windings. These brushes, however, undergo mechanical wear as such they need frequent maintenance and replacement.
A more sophisticated fully electronic version utilizes again LF mains transformers, typically at 50 Hz or 60 Hz, connected in series between the AC input and the AC output of the voltage regulator. As the input AC voltage level varies, the AC voltage regulator electronic control senses the input voltage level, and then sets up an in-phase positive or an in-phase negative differential AC voltage that adds or subtracts, to or from, the varying input AC voltage to maintain the output AC voltage to the desired set level. This traditional approach, in its various forms, still uses LF mains frequency transformers or LF magnetic structures, typically at 50 Hz or 60 Hz. In one configuration, the power electronics generates a LF mains frequency to correct the input AC voltage by a high frequency pulse width modulation (HF PWM) means, and this in-phase correction voltage to adjust the input AC mains voltage, is applied to the primary of the LF transformer, with the secondary of the LF transformer connected in series between the input and output of the AC power line. But still the magnetic structures used in these configurations, even though the power electronics operate at higher PWM frequencies, the final differential AC waveform is still applied to the LF series transformer, typically at 50 Hz or 60 Hz, hence the LF transformer or magnetic structures still have the disadvantage of size and weight.
A series AC voltage regulation method is disclosed in U.S. Pat. No. 5,747,972. This patent discloses a particular method of using only a simple voltage polarity control, which is a limited and simple method of control. It further describes the limit of the control switching states of power semiconductor devices that is created by only using the simple voltage polarity control method at the low AC input voltage positive and negative levels around the zero voltage crossover points. To solve this problem using only simple voltage polarity control method in this indeterminate low positive or negative input voltage level range around the zero voltage crossover points leads to an ambiguous determination of the actual input voltage polarity because of the low zero crossing AC input voltages, and hence the status of the PWM switching sequence of the power semiconductors at these low positive or negative voltage levels of the AC input voltage zero crossover points. The '972 patent discloses this input AC voltage polarity indeterminate low voltage level state at below 4 volts, positive and negative—13.65, 14.5 and again 17.65, 18.5, 18.10. Accordingly, an abnormal switching sequence is generated by turning on, for a short period (e.g. 13.65 microseconds as disclosed), all of the power semiconductor switching devices. This creates a power semiconductor “shoot-through” that short circuits the input AC power source, which can cause degrading or destructive damage of the semiconductor power devices. “Shoot-through” is a term very clearly understood in the electronics industry as a very serious condition that must be avoided for power semiconductors, and engineers are always critically concerned about “shoot-through” because of its degrading and destructive impact on the power semiconductors.
It is clearly taught in the '972 patent about the aforesaid problem but seemingly rely on the actual low AC input voltage at the points of positive and negative AC input voltage near zero crossover, and also the high voltage characteristics of power semiconductor conducting voltages. The '972 patent teaches to create a deliberate shoot-through PWM switching sequence status (13.65, 14.5, and 17.65, 18.5, 18.10). Thus, because of the limitation of using AC input voltage polarity control, the '972 patent attempts to solve this problem by actually generating a deliberate “shoot-through” state of the power semiconductor switching devices that actually short circuits the AC input voltage source. This is a critical compromise, and especially in the case with modern power semiconductor devices which have much lower on-resistance and depend on the low source resistance of the AC input power supply or circuit capacitance near the semiconductor power switches. Furthermore, a “shoot-through” can also create an undefined uncontrolled current steering in the power inductor that negatively impacts operating performance. Therefore, the series AC voltage regulation method as disclosed in U.S. Pat. No. 5,747,972 has serious shortcomings.
SUMMARY
It is an objective of the present invention is to provide an improved method of control that overcomes potential operating problems using only the simple voltage polarity control disclosed the U.S. Pat. No. 5,747,972 and other like prior arts. The present invention addresses the disadvantages of the previous traditional approaches in using series low mains frequency (typically at 50 Hz or 60 Hz), large and heavy magnetic structures. Since the size of any magnetics is largely inversely proportional to its operating frequency, the present invention approaches with this as a central design parameter. So another objective of the present invention is to achieve a unique efficient robust direct AC to AC bidirectional power flow high frequency (HF) AC series voltage regulator topology that utilizes HF (e.g. from 1 KHz to 1000 KHz) series magnetic structures that reduce significantly the size, weight and cost of these magnetic structures.
Since the HF AC series voltage regulator is normally connected to high AC voltage electrical distribution and grid networks and utilizes power semiconductors for switching these high voltages, extreme care has to be taken in specifying and even more significantly derating the voltage breakdown of these power semiconductors. So extreme care must be taken in the deployment of HF AC series voltage regulator especially in the pulse width modulation (PWM) control of these power semiconductors and the operating conditions of the power inductors that are connected to the power semiconductors. For example, referring to FIG. 1 a , FIG. 1( b ) and FIG. 2 (Power Inductor L 3 , Power Inductor L 8 , Power Inductors L 3 and L 4 ).
The power semiconductors must not experience destructive “shoot-through” and high voltages, especially under certain operating conditions that the PWM control method cannot define and lose control of the power semiconductor switch commutation states, or the condition as disclosed in the U.S. Pat. No. 5,747,972 in which potentially dangerous “shoot-through” is generated deliberately in the control switching sequence to solve the problem of using only AC input voltage polarity for the PWM switching sequence control.
Also there is a critical compromise of the HF AC series voltage regulator efficiency and robustness that cannot be solved by simply selecting safe high power semiconductor breakdown voltages or high conduction voltages as required in the U.S. Pat. No. 5,747,972.
In general for any power semiconductor device, the higher the breakdown voltage the higher the conduction and switching losses, hence higher losses and power dissipation in the power semiconductor devices with lower efficiency and higher heat generated in the power semiconductor devices and in the overall HF AC series regulator product. With the present invention, no “shoot-through” PWM status is ever generated in the PWM switching sequence of the semiconductor power devices.
The present invention critically removes significant compromises and allows normal breakdown voltages and the use of low conduction voltages of the modern low on-resistance power semiconductor devices to be safely specified for the power semiconductor devices, hence the power semiconductor devices operate safely, with lower losses with less heat generated, and increases the HF series voltage regulator efficiency. Further driving the need of the present invention is the significant increase in sophistication in the PWM control method that operates differently to the aforementioned only simple voltage polarity method.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described in more detail hereinafter with reference to the drawings, in which
FIG. 1 a depicts a circuit diagram of an embodiment of a HF AC series buck convertor with bidirectional AC semiconductor;
FIG. 1 b depicts a circuit diagram of another embodiment of a HF AC series boost convertor with bidirectional AC semiconductor;
FIG. 2 depicts a circuit diagram of an embodiment of a HF AC series buck-boost voltage regulator;
FIG. 3 a depicts a schematic diagram of an embodiment of a buck switch control circuit; and
FIG. 3 b shows a table of logic switching for buck allowed states of the buck switch commutation sequence as shown in FIG. 3 a.
DETAILED DESCRIPTION
In the following description, methods, systems, and apparatuses for regulating an output AC voltage to a desired level regardless of the variation in an input AC voltage and the like are set forth as preferred examples. It will be apparent to those skilled in the art that modifications, including additions and/or substitutions may be made without departing from the scope and spirit of the invention. Specific details may be omitted so as not to obscure the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.
Referring to FIG. 1 a . Shown in FIG. 1 a is an AC series buck convertor with bidirectional AC semiconductor switches S 1 and S 2 . Also shown in FIG. 1 a are the HF filter components added to suppress and filter the HF (e.g. 1 Khz-1,000 Khz) switching frequency at the input and output. Filter inductors L 1 and L 2 with filter bypass capacitors C 1 and C 2 on the input; and filter inductors L 4 and L 5 with filter bypass capacitors C 3 and C 4 on the output. Filter inductors L 4 and L 5 with filter bypass capacitor C 4 average the HF voltage PWM ripple to an average DC level to create a smooth regulated AC output voltage. Inductor L 3 is a power inductor that is designed to operate at HF (e.g. 1 Khz to 1,000 Khz).
Since the bidirectional AC semiconductor switching devices S 1 and S 2 are switching at HF (e.g. 1 KHz to 1000 KHz) under electronic PWM control either through analogue or mix of digital and analogue circuitry, but typically digital control circuitry with DSP or microprocessor signal processing, and the PWM outputs from the control electronics drive the bidirectional AC Semiconductor switches S 1 and S 2 with HF (e.g. 1 KHz to 1000 KHz) PWM modulation, and at each HF point along the LF mains AC voltage input, typically at 50 Hz or 60 Hz, the PWM control electronics generates a specific PWM pulse of width wide enough to drive the bidirectional AC semiconductor switches S 1 and S 2 in combination with power inductor L 3 ; hence bucking and regulating the output voltage at each point along the input AC voltage to the desired value set by the control set voltage reference.
For example, if the control is switching at a design frequency of 25,000 Hz, then for every 40 microseconds the amplitude of the input mains LF voltage, typically at 50 Hz or 60 Hz, is bucked and decreased at that point, against the set voltage reference. Thus, for every 40 μs the circuit bucks the input AC voltage to adjust and regulate the desired set output AC voltage. The input filter comprises capacitors C 1 and C 2 , and filter inductors L 1 and L 2 . The output filter comprises capacitors C 3 and C 4 , and filter inductors L 4 and L 5 . Alternatively, various combinations of HF filter elements can be used to filter and bypass the HF switching frequencies of the bidirectional AC semiconductor switches switching at HF, such as in this example at 25,000 Hz, and average the HF voltage PWM ripple to an average DC level to create a smooth regulated AC output voltage.
Referring to FIG. 1 b . Shown in FIG. 1 b is an AC series boost convertor with bidirectional AC semiconductor switches S 3 and S 4 . Also shown in FIG. 1 b are the HF filter components added to suppress and filter the HF (e.g. 1 Khz-1,000 Khz) switching frequency at the input and output. Filter inductors L 6 and L 7 with filter bypass capacitors C 5 and C 6 on the input. Filter inductors L 9 and L 10 with filter bypass capacitors C 7 and C 8 on the output. Filter inductors L 9 and L 10 with filter bypass capacitor C 8 average the HF voltage PWM ripple to an average DC level to create a smooth regulated AC output voltage. Inductor L 8 is a power inductor designed to operate at HF (e.g. 1 Khz to 1,000 Khz).
Since the bidirectional AC semiconductor switches S 3 and S 4 are switching at HF (e.g. 1 KHz to 1000 KHz) under electronic PWM control either through analogue or mix of digital and analogue circuitry, but typically digital control circuitry with DSP or microprocessor signal processing, and the PWM outputs from the control electronics drive the bidirectional AC semiconductor switches S 3 and S 4 with HF (e.g. 1 KHz to 1000 KHz) PWM modulation, and at each HF point along the LF mains AC voltage Input, typically 50 Hz or 60 Hz, the control electronics generates a specific PWM pulse of width wide enough to drive the bidirectional AC semiconductor switches S 3 and S 4 in combination with power inductor L 8 ; hence boosting and regulating the output voltage at each point along the input AC voltage to the desired value set by the control voltage reference.
For example, if the control is switching at a design frequency of 25,000 Hz, then for every 40 microseconds the amplitude of the Input mains LF Voltage, typically at 50 Hz or 60 Hz is boosted and increased at that point, against the set voltage reference. Thus, for every 40 microseconds the PWM control circuit driving the bidirectional AC semiconductor switches S 3 and S 4 in combination with the power inductor L 8 , boosts the input AC voltage to adjust and regulate the desired set Output AC voltage. The input filter comprises capacitors C 5 and C 6 , and filter inductors L 6 and L 7 . The output filter comprises capacitors C 7 and C 8 , and filter inductors L 9 and L 10 . Alternatively, various combinations of HF filter elements can be used to filter and bypass the HF switching frequencies of the AC bidirectional semiconductor switches, switching at HF, such as in this example at 25,000 Hz, and average the HF voltage PWM ripple to an average DC level to create a smooth regulated AC output voltage.
A person who is ordinarily skilled in the art may choose to use the individual buck AC series voltage regulator section as shown in FIG. 1 a as a AC series buck voltage regulator, or the individual boost AC series voltage regulator as shown in FIG. 1 b as a AC series boost voltage regulator, a combination of the buck AC voltage regulator as shown in FIG. 1 a with the boost AC voltage regulator as shown in FIG. 1 b as a complete full HF AC series voltage regulator, or the automatic voltage regulator (AVR) is shown in FIG. 2 as a full HF AC-AC series AVR automatic voltage control topology.
FIG. 2 shows the basic operating principles of the present invention as a complete full AVR HF AC series voltage regulator that can buck or boost the AC input voltage at each HF point. For example, if the operating frequency of the AVR HF AC voltage regulator is configured to be 25 kHz, then the input voltage is sensed by the electronic analogue or mix of digital and analogue circuitry and compared to a voltage reference, and then the AC bidirectional semiconductor switches S 1 , S 2 , S 3 , and S 4 in combination with the power inductors L 3 and L 4 are driven under PWM control to buck (reduce) or boost (increase) the AC input voltage at the AVR HF AC series voltage regulator output. The voltage is adjusted at each 40 microsecond interval point through each LF mains voltage cycle, typically, but not limited to, 50 Hz or 60 Hz. Therefore, under an analogue or digital electronic PWM control with reference to a fixed reference voltage level, the full AVR HF AC series voltage regulator is able to fully regulate the AC output voltage to the desired set level.
FIG. 2 also shows the waveforms of the HF PWM bucking or boosting the input AC voltage at the AVR HF AC series voltage regulator output, and the input filter components C 1 , C 2 , L 1 , and L 2 in combination are used to eliminate the HF switching energy from passing back into the input AC source; and the output filter components C 3 , C 4 , L 5 , and L 6 in combination are used to eliminate the output HF PWM switching pulses and to average the HF voltage PWM ripple to an average DC level, creating a smooth regulated AC output voltage.
The circuitries and description thereof disclosed herein are simplified for clarity and various other circuit configurations and devices can be used in applying the principles of the present invention. For instance, the bidirectional AC switches are semiconductor devices and can comprise of various circuit configurations, but these switches are still acting as AC bidirectional semiconductor switches as used commonly in the industry. Such Bidirectional AC semiconductor switches, for example, but not limited to, can be a rectifier bridge comprising of four rectifiers with a unipolar semiconductor device configuration inserted in the bridge such as SCR, GTO, IGBT, MOSFET, or any other semiconductor device used for the same effect with PWM drive control that can create a controlled bidirectional AC semiconductor switch device. Also, other semiconductor AC switch configurations and devices used in the industry with or without rectifiers such as back-to-back or anti-parallel-SCR's, GTO, IGBT, RB-IGBT, MOSFET, any other back-to-back or anti-parallel bidirectional AC semiconductor devices or configurations, or any other similar new semiconductor devices in the future, such as, but not limited to, GaN, SiC are some of the alternative embodiments of the present invention.
Although only single phase electrical systems are described herein, the principles of the present invention can be applied to other AC frequency and poly-phase AC systems, for example, common 3-phase electrical systems, by utilizing and interconnecting a number of the HF AC series buck topology, HF series boost topology, or combined AVR HF series buck-boost topology for full HF AC AVR automatic voltage control sections or units to create poly-phase voltage regulators. Since these HF series voltage sections can be independently controlled, they can also be designed for voltage balancing configurations to rebalance out of balance poly-phase voltages.
The AVR HF buck-boost AC series voltage regulator shown in FIG. 2 utilizes the HF (e.g. 1 KHz-1,000 KHz) power inductor L 3 in combination with the AC bidirectional semiconductor switches S 1 and S 2 to bucks the AC input voltage, and HF power inductor L 4 in combination with the AC bidirectional semiconductor switches S 3 and S 4 to boosts the AC input voltage. The AC bidirectional semiconductor switches, S 1 , S 2 , S 3 , and S 4 , are driven individually by PWM outputs from the electronic control circuit to create an AVR automatic voltage control topology that can decrease (buck) or increase (boost) the input AC voltage to regulate the AC output voltage to a set desired level. This design is power-flow bidirectional, direct single stage, and has no internal DC link capacitor, which is typically an unreliable electrolytic capacitor.
In other embodiments, the buck topology and the boost topology can operate separately. Along with the combined AVR HF buck-boost AC series voltage regulator topology shown in FIG. 2 , anyone of these topologies needs only to process a portion of the total output power depending on the level of AC input voltage range and variation.
At each HF PWM interval, for example 40 microsecond PWM intervals at 25 kHz, the input voltage in bucked (reduced) or boosted (increased) under HF switch PWM control that generates the correct PWM drive signal to the bidirectional AC semiconductor switches at each HF point on the mains low frequency, typically 50 or 60 Hz, to buck or boost and correct the output AC voltage level to a desired set output AC voltage reference fed to the control electronics.
Other embodiments include various filter configurations that can create the desired effect as described above, with an input filter configuration to eliminate the high frequency switching pulses from entering the input AC mains source, and an output filter configuration eliminating the high frequency switching pulses from the output AC voltage. Still other embodiments include an AC output voltage feedback loop and control electronics to regulate the output voltage to meet the AC output voltage specification of a root-mean-square (RMS), the preferred embodiment, an average voltage, or peak voltage levels of the AC output voltage.
Also, the AVR HF AC series buck-boost AC voltage regulator, and the independent buck or boost sections if used separately, only have to process the differential power across the buck and boost inductors, L 3 and L 4 respectively, to regulate the varying input AC voltage to a fixed and regulated output AC voltage; thus, this is much less power than the total output power because of the configuration. The buck and boost inductors, L 3 and L 4 respectively only have to handle the proportion of the total output power required to adjust the differential input AC voltages to regulate the output AC voltage to the desired set level.
The control of an independent HF AC series Buck topology, an independent HF AC series boost topology, or a combined AVR HF series buck-boost topology for full HF AC AVR automatic voltage control can be configured to be a simple voltage Polarity PWM control as disclosed in the aforementioned U.S. Pat. No. 5,747,972. However, as previously discussed, such simple voltage polarity PWM control method cannot ensure the safe commutation of the power semiconductor devices due to the deliberate power semiconductor “shoot-through” during the voltage polarity sensing ambiguity at the very low voltages near the positive and negative zero crossing of the input AC voltage.
The present invention teaches away from U.S. Pat. No. 5,747,972 and other known prior arts in that for example, the HF AC series buck convertor section comprises bidirectional AC semiconductor switches S 1 and S 2 , in combination with power inductors L 3 and current transformer CT 1 . The current transformer CT 3 in FIG. 2 is typical and commonly used in most power supplies, as it is used here, to simply measure the output current as output current over-current protection, or over-current protection can be accomplished by current transformers added in series with each of the power semiconductor devices to accomplish the same function as the output currents are detected by the current overprotection transformers and the output current information is fed back to the control circuit to shut down or limit the output current to control output current for output over-current protection. Output over-current protection is also referred to in U.S. Pat. No. 5,747,972. However, as detailed in FIGS. 1, 4, 5, 6, 7, and 9, except for FIG. 4 in the '972 patent disclosure, no current transformer is shown in any of these figures. And the current transformers T1 and T2 that appear only in FIG. 4 in the '972 patent disclosure are used as typical output over-current protection current sensing transformers. This is also confirmed in Par. 14.50 of in the '972 patent's specification and clearly indicated and explained as typical and common “Output Over Current protection”, and the current sensing information from T1 and T2, the only Current Transformers referred to in FIG. 4 in the '972 patent disclosure, are not used or anywhere disclosed as relevant to the PWM switching AC voltage control method. So clearly U.S. Pat. No. 5,747,972 teaches only the use of only simple voltage polarity PWM control without using any current information in the power inductors, which is the unique and critical basis of the present invention. So clearly in the case of U.S. Pat. No. 5,747,972, and also in all of the disclosed prior arts included thereof, it discloses many topology figures that do not even include a current transformer included. The only figure that it did include, the current transformers T1 and T2 were only used for standard common typical over-current protection. Therefore, it is clear that U.S. Pat. No. 5,747,972 discloses that only simple voltage polarity PWM control was used to generate the PWM power semiconductor switching sequence for the actual buck AC voltage regulation. The critical current direction sensing in the actual power inductors as used in the present invention is a PWM control method improvement over the prior arts that was clearly never considered in U.S. Pat. No. 5,747,972. The advantages of this new improved invention will be further made clear in the following disclosure, and has significant critical advantages and improvements with respect to the PWM control method in safe commutation of the power semiconductors to generate a PWM control power semiconductor switching sequence method that never generates a “shoot-through” status, hence specifically prevents degradation or destructive “shoot-through” as disclosed in the present invention.
For the purpose of demonstrating the critical advantages of the present invention over the just simple voltage polarity control in U.S. Pat. No. 5,747,972, referring to FIG. 2 for example, in the HF AC series buck convertor section, the current transformer CT 3 is used for typical output over-current protection, whereas the current transformer CT 1 is the critical specific improvement in the present invention as current transformer CT 1 generates the critical L 3 power inductor current direction data for the AC power semiconductor switches S 1 and S 2 . The PWM control method in the present invention specifically uses the current direction in the power inductor L 3 for the HF AC series buck convertor section. The use of current transformers CT 1 and CT 2 as shown in FIG. 2 is one method of sensing current direction in a conductor, other means can be utilized, such as utilizing Rogowski coil or coils, resistor or resistors in series with the power inductor, Hall Effect devices associated with the magnetic field from the power inductor, or other known various methods of deriving the actual current information from the voltage waveform across the power inductor winding or partial inductor winding or additional windings on the power inductor specifically for this industry known inductor voltage method, or combination of these current sensing devices, but the use of any alternative current sensing devices, does not in any way address or avoid the core innovative new PWM control method principle of the present invention in using the power inductor current direction as the critical parameter to derive, in this for example, the buck convertor PWM switching sequence method, regardless of the method of how the power inductor current direction is actually sensed.
For the purpose of further demonstrating that the present invention is a clear and significant improvement and departure from the prior arts, referring to the HF AC series boost convertor section as shown in FIG. 2 and to just the boost convertor section of the full buck-boost AVR for example. The boost convertor section comprises major boost convertor components, namely the AC semiconductor switches S 3 and S 4 , power inductor L 4 , and power inductor L 4 current transformer CT 2 . The current transformer CT 3 is used for common and typical output over-current protection, whereas the current transformer CT 2 is the critical specific improvement in the present invention as it generates the critical L 4 power inductor current direction data for the power semiconductor PWM control that specifically uses the current direction in the power inductor L 4 for the boost section. And as detailed above for the buck convertor section as an example, the use of any alternative current sensing devices or methods, does not in any way address or avoid the core innovative new PWM control method principle of the present invention in using the power inductor current direction as the critical parameter to derive, in this for example, the boost convertor PWM switching sequence method, regardless of the method of how the power inductor current direction is actually sensed.
To summarize the critical advantages of the improvement of the present invention over the simple only voltage polarity PWM control method as disclosed in U.S. Pat. No. 5,747,972, a new innovative PWM Control method in accordance to the present invention not only uses voltage polarity but uniquely and specifically uses in addition the critical data for the current direction in the power inductors. This allows the PWM switching sequence of the power semiconductors to be driven by the PWM control to be based on an absolute controlled switching sequence without ambiguity that allows the PWM control to steer the power inductor current into the appropriate power semiconductor device without resorting to any degrading or destructive “shoot-through” condition, such that the deliberate “shoot-through” of the power semiconductors as taught in U.S. Pat. No. 5,747,972 is completely and safely avoided.
FIG. 3 a shows the following functioning electronic circuit sections:
(1) Digital circuitry that can also be, but not limited to, a DSP or a microprocessor that generates digital outputs such as PWM and clock signals, as inputs to the power semiconductor switching sequence digital circuit (4). (2) Analogue circuitry that comprises, but not be limited to, discrete circuitry, or generally single or multiple combination of analogue integrated circuits that accepts the Input AC voltage (V input) and the major and critical parameter of the present invention—L 3 inductor current, which is shown here as the analogue current signal from the current transformer CT 1 in this example, that indicates the current level and direction in power inductor L 3 (L 3 inductor current). This analogue circuitry then processes these analogue inputs to generate analogue outputs as analogue inputs to the analogue to digital convertors (3). The analogue circuitry functional section (2) generates the following analogue and digital outputs:
Vi—Input AC voltage. Vp—Input AC voltage polarity as positive (+VE), negative (−VE), or zero (0). Ii—Inductor current in power inductor L 3 from current transformer CT 1 . Ip—Inductor current polarity in power inductor L 3 from Ii as +VE, −VE, or 0.
(3) Analogue-to-digital convertors, and these analogue-to-digital convertors are generally integrated into and as part of the power semiconductor switching sequence digital circuit (4), or can be separated. The digital convertors (3) accept the analogue outputs from the analogue circuit function section (2) and convert the analogue inputs Vi, Ii, into digital format Vp, Ip that is then used and processed by the digital circuit (4) with the digital PWM and clock inputs from the digital circuit (1) to generate the necessary power semiconductor PWM switching sequence q1, q2, q3, and q4. (4) AC power semiconductor switches (5) and (6) as back-to-back unipolar MOSFET power semiconductor devices. The buck section AC power semiconductor top switch S 1 comprises the combined back-to-back unipolar MOSFET power semiconductor devices Q 1 and Q 2 . The AC power semiconductor bottom switch S 2 comprises the combined back-to-back unipolar MOSFET power semiconductor devices Q 3 and Q 4 . These power semiconductor devices: Q 1 , Q 2 , Q 3 , and Q 4 are switched and control independently driven by the PWM switching sequence outputs q1, q2, q3, and q4 generated from the PWM switching sequence digital circuitry (4).
An ordinarily skilled person in the art can generate a number of different configurations of analogue and digital circuitry to reproduce the same functions as detailed above; but these potentially different analogue or digital configurations in no way can avoid the basis of this new and innovative principle of the present invention in that the specific use of the current information in the power inductor to remove the problem of only using voltage polarity PWM control method when the AC input voltage approaches low positive and negative levels at the AC Input voltage zero crossover points.
Since the present invention removes the compromise in using the voltage polarity alone as taught in U.S. Pat. No. 5,747,972 without the current direction in the power inductor that allows all of the PWM switching sequence for the power semiconductors to be determined unambiguously and safely as disclosed in the present invention, so the present invention allows this new HF AC series buck topology, a HF series boost topology, or a combined AVR HF series buck-boost topology for full HF AC AVR automatic voltage control to be scaled up and down in power levels and voltage levels with the relevant and appropriate selection of components such as the semiconductor power devices with respect to current, voltage and thermal design considerations, the sizing and performance of the power inductor, and the other components as determined by anyone skilled in the art of scaling this new innovative topology as disclosed in the present invention.
In summary, referring to the full buck section in FIG. 2 in combination with the input and output filters and components, the PWM switching sequence for the independently controlled power semiconductor devices (5): Q 1 and Q 2 for S 1 in FIGS. 2 , and (6): Q 3 and Q 4 for S 2 in FIG. 2 , with the utilization of the current information in power inductor L 3 through the current transformer CT 1 generating the current level and direction in power inductor L 3 , combined with the control functional Sections for the AC voltage regulator buck section, as in this example (1), (2), (3), and (4) creates an innovative invention that, in this example, an AC HF voltage regulator that overcomes the limit, compromise, and risk of using only voltage polarity information for the PWM switching Sequence, as with the critical improvement of the present invention, of using the critical power inductor current direction as detailed above. Thus, this new innovative PWM control method never generates an undefined PWM switching sequence for the power semiconductors, and certainly not a deliberate “shoot-through” PWM sequence. So
Referring to FIG. 3 a and FIG. 3 b . The steps for the PWM control method, for example, of the buck section of the present invention is as follows:
1) Establish an input voltage polarity signal (Vp) from the input voltage information (Vi). The input voltage polarity signal (Vp) includes three logic states: positive (+VE), negative (−VE), and zero (0); where zero (0) refers to an input voltage lower than a predefined absolute value, e.g. 1 Volt or below. In referencing, for example FIG. 3 a , the input voltage polarity signal (Vp) is derived from the input voltage (Vi) with the analogue circuitry, section (2).
2) Establish an inductor current polarity signal (Ip) from the power inductor L 3 current signal (Ii) from the power inductor L 3 current transformer CT 1 , to derive the power inductor L 3 current direction polarity information (Ip). The power inductor current polarity signal (Ip) includes three logic states: positive (+VE), negative (−VE), and zero (0); where zero (0) refers to an inductor current lower than a predefined absolute value, e.g. 2% of full load inductor current or below. In referencing, for example FIG. 3 a , the inductor current polarity signal (Ip) in the power inductor L 3 is derived from the power inductor current (Ii) signal from the power inductor L 3 current transformer CT 1 , and the inductor current polarity signal (Ip) is generated with the analogue circuitry (2).
3) The switching states of the four independent power semiconductor devices under PWM control and driven by switching signals q1, q2, q3, and q4 derived from the digital circuitry (4), which can be, for example, but not limited to, a logic array, as shown in this example section (4) referencing FIG. 3 a . In this preferred embodiment, the bidirectional AC semiconductor switches in the buck section of the AVR HF AC series buck-boost AC voltage regulator referencing S 1 and S 2 in FIG. 2 are shown as using back-to-back unipolar MOSFET power semiconductor devices Q 1 , Q 2 , Q 3 , and Q 4 , as for example the form and configuration, but not limited to, as shown here for example in FIG. 3 a , (5) and (6) are now sequenced correctly and unambiguously based upon the voltage and current polarity information referencing Step 1) and Step 2) above. For example, and referring to FIG. 3 a and the preferred embodiment is the use of four back-to-back independently controlled unipolar semiconductor power switches Q 1 , Q 2 , Q 3 , and Q 4 , such as unipolar MOSFETS as in this example, again referring to FIG. 3 a , that are configured to operate as bidirectional AC semiconductor switches, again shown as S 1 and S 2 in FIG. 2 , reference the buck section only of the AVR HF AC series buck-boost AC voltage regulator referencing FIG. 2 . The four independently controlled unipolar power semiconductor devices Q 1 , Q 2 , Q 3 , and Q 4 as shown in this example referencing FIG. 3 a have very specific PWM switching sequences derived from Step 1) above, and very critical, and the basic principle of the present invention—the power inductor L 3 , in this example, current polarity—Step 2). Therefore, each PWM switching sequence is absolutely and unambiguously specifically controlled and generated for each of the forward to freewheel transition as well as freewheel to forward transition, that guarantees all switching states are clearly defined for all operating conditions, including heavy reactive leading or lagging loads, and never a dangerous and deliberate “shoot-through” condition in that switching sequence, as taught U.S. Pat. No. 5,747,972.
A similar PWM control and switching sequence can be constructed for both the buck topology, as in this example, and the boost topology, for the two transitions for any complementary AC power semiconductor switches.
The embodiments disclosed herein may be implemented using general purpose or specialized computing devices, computer processors, microcontrollers, or electronic circuitries including but not limited to digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA), and other programmable logic devices configured or programmed according to the teachings of the present disclosure. Computer instructions or software codes running in the general purpose or specialized computing devices, computer processors, or programmable logic devices can readily be prepared by practitioners skilled in the software or electronic art based on the teachings of the present disclosure.
The foregoing description of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to the practitioner skilled in the art.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications that are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalence. | A bidirectional AC series voltage regulator that regulates an output AC voltage level regardless of the varying AC input voltage utilizing high frequency series inductors that only process a proportion of the total output power. The AC series voltage regulator detects the power inductor current direction data signal and can generate power inductor current direction data signals for its control to determine the AC input voltage polarity at all time; wherein the determination of the AC input voltage polarity is unambiguous during the AC input voltage zero crossover and near zero points; and wherein the determination of the AC input voltage polarity allows normal switching sequence of the AC bidirectional switches during the AC input voltage zero crossover and near zero points to prevent power “shoot-through.” | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/683,643, filed May 23, 2005.
TECHNICAL FIELD
[0002] The present invention is related to meltblowing processes that produce non-woven polymeric materials. More particularly, the present invention is related to meltblowing while utilizing fluid flow from an auxiliary manifold in conjunction with ducts dispensing a secondary flow into the fiber emerging for the meltblowing die.
BACKGROUND
[0003] Nonwoven webs with useful properties can be formed using the meltblowing process in which filaments are extruded from a series of small orifices while being attenuated into fibers using hot air or other attenuating fluid. The attenuated fibers are formed into a web on a remotely-located collector or other suitable surface.
[0004] More recently, the literature in this field has described how secondary flows of fluid can be directed onto the fibers after they have been extruded from the orifices and attenuated, but before they have impacted on the collector. By manipulating the velocity and temperature of the secondary flows, the properties of the fibers, and thus the nonwoven web they form on the collector, can be modified in useful ways.
[0005] However, there are limitations to the use of secondary flows in this way. As the rate of fabric formation is increased, at a certain point the known techniques break down. The streams of attenuating fluid and the streams of secondary fluid begin to interact in unwanted ways as production rates increase. One particular failure mode that begins to manifest is the appearance of swirling recirculation zones downstream of the orifices. Some of the emerging fibers are swept into the recirculation zones and are swept off in unwanted directions, causing waste, reducing production, and fouling equipment. There has been an ongoing effort to improve the uniformity of nonwoven webs. The art desires a mechanism by which the advantages of a secondary flow for the fiber properties can be extended to the high production rates that reduce the costs of production.
SUMMARY
[0006] Embodiments of the present invention address these issues and others by providing methods and apparatus that reduce the recirculation zones to thereby decrease the amount of errant fibers fouling the die face. An auxiliary manifold dispenses fluid between the flow of quench gas and the orifice of the die. The fluid from the manifold reduces the area of low pressure, which thereby reduced the recirculation of quenching gas. As a result, the amount of errant fibers at the die face is also reduced.
[0007] One embodiment is a meltblowing apparatus having a die having a plurality of filament orifices for expelling polymeric material. At least one duct is positioned to direct a stream of gas towards the expelled polymeric material. The embodiment has at least one auxiliary manifold positioned relative to the die and the at least one duct such that a fluid is dispensed from the auxiliary manifold between the stream and the filament orifices to thereby substantially isolate the polymeric material from recirculation zones. Often enough in actual practice, two ducts will be provided, one on either side of the curtain of expelled polymer. In such cases, it is preferred to have two auxiliary manifolds, each positioned to isolate the polymeric material from its corresponding recirculation zone.
[0008] In preferred embodiments, the auxiliary manifold dispenses the fluid with a substantially uniform mass flow per unit length along the length of the positions of the filament orifices. In the detailed description below, guidance will be provided as to how to conveniently prepare a manifold dispensing substantially uniform mass flow, even when the fluid is compressible.
[0009] Another embodiment of the invention is a meltblowing apparatus having a die having a plurality of filament orifices for expelling polymeric material, the die expelling streams of polymeric material entrained in streams of air from a plurality of air knives within the die. At least one duct is positioned to direct a secondary flow of gas towards the expelled polymeric material and in a direction away from the die. Also at least one auxiliary manifold is positioned relative to the die and the at least one duct such that a fluid is dispensed from the auxiliary manifold into a location between the secondary flow and the streams of polymeric material and toward an area of recirculation zones of gas that is adjacent the die and with a mass flow rate less than the mass flow rate of the secondary flow to thereby substantially isolate the recirculation zones between the duct and the plurality of orifices.
[0010] Another aspect of the invention is a method of meltblowing, comprising:
[0011] expelling polymeric material from a plurality of filament orifices of a die;
[0012] directing a stream of gas towards the expelled polymeric material; and
[0013] dispensing fluid from an auxiliary manifold, wherein the fluid is dispensed between the stream and the filament orifices to substantially isolate the polymeric material from areas of recirculation.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a cross-sectional view of a conventional meltblowing apparatus of the prior art that can develop large recirculation zones.
[0015] FIG. 2 shows the two-dimensional geometrical representation of a cross-section of a meltblowing apparatus utilized in designing an auxiliary manifold.
[0016] FIG. 3 shows the geometrical representation of FIG. 2 after having been meshed into finite elements allowing for modeling of streamlines to be utilized in designing the auxiliary manifold.
[0017] FIG. 4 shows the geometrical representation of FIG. 2 after having an auxiliary manifold added.
[0018] FIG. 5 shows the geometrical representation of FIG. 4 after having been meshed into finite elements allowing for modeling of streamlines that result from the introduction of the auxiliary manifold.
[0019] FIG. 6 shows a three-dimensional geometrical representation of the auxiliary manifold having the conditions defined by the two-dimensional geometrical representation of meshed elements shown in FIG. 5 .
[0020] FIG. 7 shows the distribution of mass flow and direction over the third dimension of the auxiliary manifold after an initial attempt of design within the geometrical representation of FIG. 6 that has resulted in a non-uniform distribution and non-perpendicular direction of flow.
[0021] FIG. 8 shows the distribution of mass flow and direction over the third dimension of the auxiliary manifold after a subsequent attempt of design within the geometrical representation of FIG. 6 that has resulted in a substantially uniform distribution and a substantially perpendicular direction of flow.
[0022] FIGS. 9A-9D shows a flowchart illustrating an example embodiment of a method of designing a manifold.
DETAILED DESCRIPTION
[0023] Embodiments of the present invention provide for a meltblowing apparatus which can treat the polymeric fibers emerging from the die with a controlled secondary flow so as to optimize the properties of the resulting nonwoven fabric, and it can do this even at high production rates. Techniques for planning the fabrication of suitable auxiliary manifolds will also be discussed.
[0024] Referring now to FIG. 1 , a cross-sectional view of a conventional meltblowing apparatus of the prior art that can develop large recirculation zones is illustrated. A meltblowing apparatus 20 including a meltblowing die 22 is illustrated in a representative cross-section. The meltblowing die 22 is used to expel a stream 24 of extended polymeric filaments towards a collection belt 26 moving in direction “D,” is illustrated. According to conventional practice, the meltblowing die 22 is provided with cavities 28 and 30 for directing two streams of heated gas against the stream 24 just after the stream 24 has been extruded from a line of extrusion orifices 32 . The heated gas jets emerging from cavities 28 and 30 to extend and thin the filaments emerging from the extrusion orifices 32 so that they have the proper size and dispersion to form the desired fabric 34 upon the collection belt 26 . Although a belt is depicted in connection with this example, those acquainted with the meltblowing art will understand that a rotating drum can be used for the purposed of taking off the filaments as fabric.
[0025] The meltblowing apparatus 20 further includes a pair of ducts 40 and 42 , one upstream and one downstream of the stream 24 compared to the direction “D”. Secondary flow is expelled from ducts 40 and 42 against the filament stream 24 so the filaments, when they impinge upon the collection belt 26 , have the properties desired in the fabric 34 .
[0026] The foregoing description generally follows the disclosure of U.S. Pat. No. 6,861,025 to Breister et al, and is adequate for the production of meltblown fabrics at low and moderate speeds of collection belt 26 . However, as the process is run harder and faster, e.g. after the production of fabric exceeds approximately 35 g/hour/hole, difficulties arise in the form of erratic motion imparted to some of the emerging filaments. At higher extrusion rates, the orderly accumulation of filaments upon collection belt 26 becomes disrupted, and some filaments begin to collect upon the surface of die 22 and on the ducts 40 and 42 . This observation suggests that paired areas of recirculation, taking the form of standing vortices had formed roughly at the positions marked A and B.
[0027] In that it is desirable to be able to increase line speed while maintaining the desirable properties of the fabric 34 , and in that disrupting the posited recirculation zones A and B seem likely to be amenable to solution by a gas-dispensing manifold that is elongated in the direction perpendicular to the two-dimensional representation of FIG. 1 .
[0028] An initial geometrical representation was set up according to FIG. 2 . A simplifying assumption was made that the problem was symmetrical in spite of the recognized complication that the collection belt ( 26 in FIG. 1 ) is in motion and does generate some fluid motion by the no-slip condition. The existing geometry of the cavity ( 28 in FIG. 1 ), the duct ( 42 in FIG. 1 ) and collection belt ( 26 in FIG. 1 ), are represented virtually as geometric representations 28 v, 42 v, and 26 v, respectively. Boundary conditions are set as being the known gas pressures that provide the best, albeit inadequate, operating conditions when collection belt 26 is operated at high line speed. In the geometrical representation, those pressures are assumed to exist uniformly along lines 50 , 52 , and 54 .
[0029] This two-dimensional geometry and these boundary conditions are provided to a commercially available flow analysis package to determine the presence of the recirculation zones in preparation for adding an auxiliary manifold and determining what the desired mass profile should be to adequately isolate the recirculation zones. Although a number of commercial offerings are considered suitable, the FLUENT solver, commercially available from Fluent, Inc. of Lebanon, N.H., may be used. The k-epsilon two-equation model is selected for this problem, and the use of renormalized groups is enabled. The function taking viscous heating of the gas is also enabled. Once the described geometry and boundary conditions are in place, and the space defined in FIG. 2 has been meshed into finite elements, the solver is run in a manner so as to visualize the streamlines representing gas flow after an equilibrium condition has established itself. These streamlines are illustrated in FIG. 3 . In this figure, the hypothesis that recirculation zones at A and B are formed is strengthened by the appearance of the closed streamlines around those locations.
[0030] In this example, it is believed that the recirculation zones may be disrupted by an additional flow of gas emerging from an aperture 60 in a new manifold 62 as shown in FIG. 4 . As is true for the rest of the geometry, the gas-dispensing manifold 62 is posited to be elongated in the direction perpendicular to the two-dimensional representation of FIG. 1 , and that any given cross-section is representative of the flow at any other cross-section taken along that perpendicular. For simplicity, a boundary condition line 64 is established within the manifold 62 , at this stage it is presumed that a uniform pressure can be maintained uniformly along line 64 at every possible cross-section. Later in the design process, this simplifying assumption may be verified and addressed as necessary.
[0031] As a starting point for this particular example, it is assumed that the mass flow emerging from manifold 62 to disrupt the recirculation zones should be 50% of the mass flow known to be needed from the duct 42 in order to achieve the needed treatment of the filaments at the desired production rate (over 35 g/hour/hole being sought). As another starting point, the pressure along boundary condition line 64 is arbitrarily set at some reasonable value, such as 20 psig total, merely from being a reasonable fraction of the static pressure capacity of a readily available compressor. A starting size for aperture 60 is derived by simple orifice equations from the assumed mass flow needed from manifold 62 at the assumed pressure within manifold 62 .
[0032] With these assumptions in place, the solver is again employed to analyze the new geometry and boundary conditions. For this example, a number of trials may be run varying the position of aperture 60 around the circumference of manifold 62 . Analysis of the streamlines produced by the trials suggested that best results would be achieved not by aiming the outflow from manifold 62 at the center of recirculation zone B, but in front of it so as to create a curtainwall of moving gas to isolate the emerging filaments from the recirculation zone. This condition is illustrated in FIG. 5 , and at this point it can be said that a dispensing direction has been determined for the manifold 62 to go along with the mass flow rate previously assumed for the given input pressure. It is further assumed for this example that the distribution of flow over the elongated length of the manifold in the third dimension should be uniform to properly isolate the recirculation zones.
[0033] Once the best direction for aiming the outflow of manifold 62 are determined for this particular example, an additional group of trials with the solver are performed in order to determine whether the assumed mass flow from manifold 62 can be reduced while still maintaining isolation of the recirculation zones in order to save energy costs in providing that flow. In these experiments for this particular example, it has been found that the mass flow may be reduced to 30% of the mass flow emerging from the duct before the flow from the manifold can no longer isolate the stream of filaments 24 from the recirculation zone.
[0034] By this point, a viable solution to the practical problem needing resolution has been achieved, i.e., the desired mass flow profile, provided it turns out to be possible to provide the identified mass flow appropriately along the elongated length of the manifold 62 in the direction perpendicular to the two-dimensional representation. The previously made simplifying assumption that this would turn out to be possible still must be verified. In order to carry out this challenge, a 3-D mathematical representation of the gas inside the manifold 62 and in its immediate environs is created. In this representation, the geometry of the manifold 62 p is essentially inverse, defining a boundary across which the gas cannot flow. This geometrical representation is illustrated in FIG. 6 . In this Figure, one-half of manifold 62 has been converted to this virtual representation 62 p, because the simplifying assumption has been made that the situation is symmetrical. Also included in the representation is the solution domain of the exhausted gas emanating from the virtual representation of the manifold 62 p. Although it may not be intuitively obvious that the volume of gas adjacent to the outside surface of manifold 62 p so far around the circumference from the slots 80 p need to be included in the 3-D mathematical representation, intuition is incorrect. Not including this seemingly extra volume in the 3-D mathematical representation often causes invalid results.
[0035] The representation of the manifold 62 p may be designed while recognizing that it may be necessary to increase structural strength by providing the aperture 60 p as a series of slots 80 p separated by bridges 82 p. Other geometries for the apertures 60 p are possible, of course, and are considered within the scope of the invention. In the instant description, a cylindrical tube of 51 mm in outside diameter, 45 mm inside diameter, and 188 cm long (a relatively lengthy manifold compared to the trial and error manifolds of the prior art that are typically much shorter than 60 cm) was selected as a starting point for manifold 62 by reason of such a size being conveniently positionable in the meltblowing apparatus 20 . As a starting point for the analysis for this particular example, it was assumed that the tube would be provided with slots 38 mm long and 3.2 mm wide, separated one from the next by 3.2 mm by bridges in accordance with the orifices of the meltblowing apparatus of interest. A rule of thumb is to maintain the total surface area of the exits to an amount that is no more than the total area of the inlet of the manifold.
[0036] The gas volume within and adjacent to the exterior of the inverse representation of the manifold 62 p is then meshed into finite hexahedral elements such that at least some of the hexahedral elements are oriented relative to the dispensing direction, depicted as “F” in this Figure. As a boundary condition, the manifold 62 p is assumed to be filled from one end 84 , or both ends 84 and 86 . More specifically, the mass flow in, e.g. kg/sec/m that provided isolation of the recirculation zones in the 2D representation is multiplied by the length of the manifold 62 p. Then the entry of one half of that total mass flow (because the assumption is being made that the other half to the total mass flow is being handled by the symmetrical other half of the manifold) into the representation through the surface of end 84 , or end 84 and end 86 , is set as a boundary condition.
[0037] This three-dimensional geometry and these boundary conditions are provided again to the FLUENT solver, and once again the k-epsilon two-equation model is employed. Also, the use of renormalized groups, and (because the fluid in the instant example is compressible air) the function taking viscous heating of the gas into account are also enabled. The solver is then run so as to provide the vector and the magnitude of the velocity of the fluid at various points. This vector field was used to prepare a false color visualization of the velocity of the fluid passing through each slot in the dispensing direction, so as to by derivation provide an indication of the actual distribution of mass flow over the elongated length of the manifold. This is illustrated as FIG. 7 , where the gas is entering the manifold from one end in flow direction “F”. It can be observed from the Figure that the flow is not uniform along the elongated length of the manifold such that the trial geometrical parameters have failed to yield the desired mass flow profile.
[0038] According to embodiments of the present invention, if an analysis of these trial geometrical parameters of slot length, slot width, slot spacing, manifold diameter, etc., fails to describe the delivery of the needed mass flow from the manifold in a fashion sufficiently the same as is desired, it is needful to refine these geometrical parameters, and rerun the analysis. It has been found that reducing the ratio of the combined outlet area to the combined inlet area tends to make the flow more uniformly distributed, should uniform flow over the elongated length of the manifold be desired for a particular application. In the present example, when the visualization of FIG. 7 demonstrates that the flow from the 6.4 mm wide slots was insufficiently uniform, the geometrical parameters of the 3-D model are adjusted to 1.59 mm wide and the model is once again put to the solver. The solver is again run so as to provide a visualization of the velocity of the fluid passing through each of these narrower slots in the dispensing direction. This is illustrated as FIG. 8 , and it can be observed from the Figure that the velocity, and by derivation the mass flow profile, has a much more uniform distribution of flow along the elongated length of the manifold than was the case in FIG. 7 . For this particular example, the uniformity of the flow profile is considered to be sufficiently good to generate an even curtainwall of gas flow to isolate the filaments from the recirculation zones across an entire production web.
[0039] To test this estimate for this particular meltblowing situation, a real manifold was fabricated from metal according to the parameters that generated FIG. 8 , and this manifold was installed in a meltblowing line according to the direction and positions identified in the 2-D analysis as illustrated in FIG. 4 . The manifold was pressurized to 20 psig total at both ends, and fabric was made. It was observed that the unwanted accumulation of filaments on the surface of the die and the ducts is arrested, and the properties of the fabric were not adversely affected.
[0040] A caveat is appropriate to note concerning the step of reducing the ratio of the combined outlet area to the combined inlet area of the manifold when needful to achieve the necessary degree of uniformity of output along the length of the manifold. Heedlessly reducing the ratio more than necessary tends to give rise to other difficulties, particularly difficulties related to the amount of pressure needed to drive the mass flow. Higher pressures are more costly to achieve with respect to providing a suitable compressor to supply the manifold 62 , and higher pressures may require that the manifold 62 be constructed out of more expensive materials in order to withstand the stresses of pressurization.
[0041] In fact, in some circumstances it may prove difficult in iterating the geometrical parameters in the three-dimensional model so as to achieve the target mass flow rate, and the target distribution of flow along the length of the manifold, within the limitations of the equipment one hoped to use. When this has occurred, an optional step may be performed. The maximum mass flow rate the desirable equipment can provide with the needed level of uniformity along the length of the manifold is noted, and the 2-dimensional representation is reconstructed with that level of mass flow rate. Then the parameters of the exact position and dispensing direction of the manifold can be iterated and reanalyzed, seeking a combination where the manifold's maximum output of mass flow while retaining the target distribution of flow is sufficient to achieve the goal previously set for the desired mass flow profile, e.g. in the present example the isolation of the recirculation zone. It will be understood that it will sometimes be impossible to achieve some mass flow profiles involving combinations of mass flow and distribution of flow for some combinations of manifold geometry and gas supply equipment. It will further be understood that some configurations that the method allows as being suitable for the desired dispensing will be unsuitable for having sufficient structural strength for containing the internal pressure or for spanning the distance between supports when emplaced. It is contemplated that requirements for suction manifolds that evacuate, rather than dispense fluid, are suitable for treatment by the method of the present invention.
[0042] While the invention has been particularly shown and described with reference to various embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made therein without departing from the spirit and scope of the invention. | Methods and apparatus for meltblowing utilize an auxiliary manifold to dispense a fluid between an orifice of a die that is expelling polymeric fibers and an exit of a duct that is dispensing a secondary flow of gas onto the fibers. The fluid dispensed from the auxiliary manifold reduces a recirculation zone of the secondary flow between the exit and the orifice that, absent the fluid from the manifold, results in errant fibers that are blown back into the face of the die by the recirculating secondary flow. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/570,650 filed Dec. 14, 2011, the contents of which are incorporated herein by reference in its entirety.
FIELD
[0002] This patent specification generally relates to the field of wave stimulation in subterranean rock formations. This patent specification relates more specifically to the generation of vibrations in the formation using tools positioned within a borehole.
BACKGROUND
[0003] Wave stimulation is a known technique for enhancing oil recovery from oil-bearing formations. For example, known techniques include generating shock waves by releasing a compressed liquid or by fluidic oscillation within the borehole. Strong vibrations are known to cause oil droplets to coalesce and form larger bulbs of oil that can move and be produced. These vibrations may also change the wettability of the rock. These effects can help increase fluid production from oil wells.
SUMMARY
[0004] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor intended to be used as an aid in limiting the scope of the claimed subject matter.
[0005] According to some embodiments, a system is described for generating vibrations in a subterranean rock formation. The system includes: a tool body adapted to be deployable in a
[0006] wellbore; a translatable mass member mounted to the tool body such that the mass member is able to translate along a first direction towards an interior surface of the wellbore when the tool body is deployed in the wellbore; a contacting surface oriented to contact the interior surface of a wellbore (e.g., either the borehole wall or a casing); and an actuator subsystem mounted within the tool body and fixed to the mass member and configured to translationally accelerate in said first direction towards the interior surface of the wellbore such that the contacting surface imparts energy into the interior surface of the wellbore when the tool body is deployed in the wellbore thereby generating vibrations within a subterranean rock formation surrounding the wellbore so as to stimulate production from the formation.
[0007] According to some embodiments, the subterranean rock formation is hydrocarbon bearing, and the flow of a hydrocarbon bearing fluid is improved by the generated vibrations in the formation, for example by facilitating coalescence of oil droplets into larger bulbs and/or altering wettability of surfaces within the rock formation. According to some embodiments the actuator subsystem uses one or more pistons to convert gas or hydraulic pressure into motion of the mass member. According to some other embodiments an electric motor can be used in the actuator subsystem.
[0008] According to some embodiments, the contacting surface is configured to strike the interior surface of the wellbore and the contacting surface forms part of the translatable mass member. According to some other embodiments, the contacting surface is on a contacting mass member that is separate from the translatable mass member; and the translatable mass member strikes the contacting mass member.
[0009] According to some embodiments, one or more anchoring members are moveably mounted on the tool body so as to facilitate stable positioning of the tool body within the wellbore when the mass member strikes the interior surface of the wellbore. The contacting surface of the mass member can have a curvature that is substantially the same to an expected curvature of the interior surface of a wellbore. According to some embodiments more than one translatable mass member can be used which can be actuated simultaneously or in sequence. According to some embodiments, the tool body can be configured for short-term application and can be deployed in the wellbore via a wireline cable, coiled tubing, or on a drilling bottom hole assembly during a drilling process.
[0010] According to some embodiments a method for generating vibrations in a subterranean rock formation is described. The method includes: deploying a tool body into a wellbore at a depth within the subterranean rock formation; and linearly accelerating a mass member from the tool body such that the mass member translates towards an interior surface of the wellbore so as to cause a contacting surface to impart energy into the interior surface of the wellbore, thereby generating vibrations within the subterranean rock formation
[0011] According to some embodiments where the tool body is configured for short-term deployment the tool body can be re-positioned at second depth within the wellbore and the accelerating of the mass member can be repeated so as to cause to strike the interior surface of the wellbore at a second location, prior to retrieving the tool body from the wellbore to an above-ground location.
[0012] According to some embodiments, the tool body is configured for long-term deployment in the wellbore. In some cases the tool body is configured to be deployed prior to insertion of production tubing within the wellbore, and in other cases the production tubing is removed from the wellbore prior to deploying of the tool body, and the production tubing is reinstalled following deployment of the tool body. According to some embodiments, the tool body is configured for long-term downhole deployment via a slim tool deployment technique.
[0013] According to some embodiments, an apparatus is described that can be used to generate strong vibrations in the formation. In some embodiments, the apparatus translationally accelerates a mass using mechanisms built into the tool and causes the mass to strike the borehole wall. The mechanisms can control the mass acceleration, and the frequency of strikes. In some embodiments, the apparatus is designed for use in the field of petroleum recovery where the vibrations are used to create or re-establish a flow pass for the fluids in the formation.
[0014] Further features and advantages of the subject disclosure will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The subject disclosure is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the subject disclosure, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
[0016] FIG. 1 is a diagram illustrating an apparatus that uses an accelerating mass to strike the borehole wall, thereby generating vibrations in the formation and achieving wave stimulation, according to some embodiments;
[0017] FIGS. 2-1 , 2 - 2 and 2 - 3 show cross sections of an apparatus for generating vibrations for stimulation purposes, according to some embodiments;
[0018] FIG. 3-1 shows an apparatus for generating vibrations in which air pressure is converted in to mass motion, according to some embodiments;
[0019] FIG. 3-2 shows an apparatus for generating vibrations for stimulation purposes, according to some other embodiments;
[0020] FIG. 4 is a cross-section of an apparatus for generating vibrations for stimulation purposes, according to some embodiments;
[0021] FIG. 5 shows an apparatus for generating vibrations in which an electric motor is used to move a mass for striking a borehole wall, according to some embodiments; and
[0022] FIG. 6 shows a wellsite in which a borehole tool is being deployed for generating vibrations in a subterranean formation for stimulation purposes, according to some embodiments.
DETAILED DESCRIPTION
[0023] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the subject disclosure only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the subject disclosure. In this regard, no attempt is made to show structural details in more detail than is necessary for the fundamental understanding of the subject disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the subject disclosure may be embodied in practice. Furthermore, like reference numbers and designations in the various drawings indicate like elements.
[0024] As used herein, the terms acoustic wave or vibrations refer to the vibrations induced into the subject formation and may be of frequencies generally referred to as seismic, sonic, or ultrasonic. FIG. 1 is a diagram illustrating an apparatus that uses an accelerating mass to strike the borehole wall, thereby generating acoustic waves in the formation and achieving wave stimulation, according to some embodiments. Tool 124 is shown deployed in a borehole 110 formed within formation 100 . A section of borehole wall 122 is shown where tool 124 is disposed at a particular depth. The tool 124 is equipped with a mass 126 that can be projected out of the tool body and strike the borehole wall 122 . The tool 124 is also equipped with one or more anchors 128 and 130 to position the tool 124 . According to some embodiments, the accelerated mass 126 is a piece of metal projected from the downhole tool 124 . The tool 124 has a cylindrical structure, and in some cases more than one mass may be projected from its surface to strike the borehole wall 122 .
[0025] FIGS. 2-1 , 2 - 2 and 2 - 3 show cross sections of an apparatus for generating acoustic waves for stimulation purposes, according to some embodiments. Tool 124 is shown suspended in borehole 110 having borehole wall 100 . In the case of FIG. 2-1 , when the mass 126 strikes the borehole wall 122 , the force associated with the mass 126 and its acceleration is partially transferred to the formation 100 creating an acoustic wave traveling in the formation 100 . The area of the strike zone depends on the surface area of the mass 126 and the curvature of the mass 126 relative to that of the borehole wall 122 . The shape of mass surface 126 may be chosen to have substantially the same curvature as the borehole wall 122 if maximum area of acoustic excitation is desired.
[0026] When the area is reduced the exerting force is concentrated in a small area and can generate higher-pressure waves in the formation 100 . In an extreme case, when the mass surface is reduced to a point, such as shown by mass 127 in the example of FIG. 2-2 , the borehole wall 122 can be indented or permanently damaged. The damage can lead to perforation or microcracks in the rock structure for formation 100 . According to some embodiments, both of the cases (shown in FIG. 2-1 and FIG. 2-2 ) have useful applications in the field of oil well production. FIG. 2-3 shows a case where the stimulation tool 124 is being deployed in a region of borehole 110 that is cased with a casing 210 . In such embodiments, the mass 126 can strike the casing 210 transmitting some of the vibrations to the formation 100 immediately behind the casing 210 . Some of the energy will also be transmitted through the casing 210 and excite areas of formation 100 above and below the strike point depth shown in FIG. 2-3 .
[0027] According to some embodiments, the mechanism of projecting the mass towards the borehole wall can use air (or other gas), liquid (hydraulic), or an electric motor. In the case where air is used, it is provided from the earth surface according to some embodiments. FIG. 3-1 shows an apparatus for generating acoustic waves in which air pressure is converted in to mass motion, according to some embodiments. In the embodiments of FIG. 3-1 , a cylinder 312 having an inner cross sectional area=A 1 is equipped with a piston 310 , and is located inside the tool 124 . An O-ring 332 is positioned within a groove of piston 310 as shown to form a seal with the inner wall of cylinder 310 . The cylinder 310 is filled with air to a pressure P 1 . The piston 310 is compressed to increase the pressure inside the piston to a pressure P 2 >=P 1 . Those skilled in the art will recognize that this structure is a so-called accumulator. Depending on the available air pressure there may or may not be a need for the accumulator. Once the desired pressure P 2 is reached a three way valve 320 is opened to deliver the pressurized air to a second cylinder 314 having a second piston 316 with cross sectional area A 2 <A 1 . As in the case of piston 310 , piston 316 has an O-ring 334 for sealing. The rush of air into the second cylinder accelerates the second piston to a linear motion. The second piston is directly or indirectly connected to the mass 126 , which is then projected out of the tool body and strikes the borehole wall (not shown). If the second piston 316 is not directly connected to the mass 126 , the piston 316 can be arranged to strike the back of the mass 126 , which is of interest in some applications.
[0028] Note that valve 320 can be used to reciprocate the mass for the next cycle. As a result, in this embodiment, valve 320 is an important component that controls the frequencies achievable by the described apparatus.
[0029] According to some embodiments, the gas source is on the surface, and the gas is supplied via a gas supply tube 308 . When the source of compressed air (or other gas) is at the surface, the tool can be made simpler than the case where the source is downhole. The drawback, however, is that one has to have high pressure tube 308 running along the length of the well. According to some embodiments, an alternative approach provides an air tank and a pump within the tool. In this case, the gas supply tube 308 runs to another section of the tool string where the tank and pump are positioned (not shown).
[0030] According to some embodiments, other fluids, such as hydraulic fluid for example, can also be used for driving the piston and the mass, instead of air. In this case, a small reservoir of hydraulic fluid 330 is provided in the tool and there is no need for high pressure tubing to run along the length of the well, unless that is desired.
[0031] FIG. 3-2 shows an apparatus for generating vibrations for stimulation purposes, according to some other embodiments. In this case the mass 328 is applied to the borehole wall 122 using springs 340 and 342 , which are independent of the second piston 316 . The second piston 316 in this case is fixed to an intermediate mass 326 . The piston 316 accelerates mass 326 to strike mass 328 , thereby imparting energy into mass 328 to generate waves in formation 100 . The arrangement as shown in FIG. 3-2 has been found to help to stabilize the tool 124 within the borehole.
[0032] It has been found that by linearly accelerating the moving mass (e.g., mass 126 or mass 326 ) such that it translates towards the borehole wall, such as shown and described herein can generate relatively large amplitude vibrations within the surrounding formation. The amplitudes are significantly greater than can be generated by other techniques such as by rotating or whirling a mass in a circular motion or by bending or distorting a mass such as by piezoelectric bending actuators.
[0033] FIG. 4 is a cross-section of an apparatus for generating vibrations for stimulation purposes, according to some embodiments. In the case shown in FIG. 4 , symmetrically placed pistons are used to drive masses in different directions. The driving can be done simultaneously or in sequence. In the example of FIG. 4 , four pistons are used, although other numbers of pistons can be used according to other embodiments.
[0034] FIG. 4 is a cross sectional view of the tool 404 at the level of cylinders 414 , 424 , 434 and 444 . Cylinder 414 houses piston 416 that applies force to mass 418 . An O-ring 412 sits within a groove of piston 416 to form a seal with the cylinder 414 . Similarly, cylinders 424 , 434 and 444 house pistons 426 , 436 and 446 respectively, which apply force to masses 428 , 438 and 448 respectively. For clarity, the mechanism and the plumbing by which the pressurizing fluid is connected to the pistons are not shown, but it is similar or identical to that shown in FIG. 3-1 , according to some embodiments. As the pressurizing fluid enters the four cylinders 414 , 424 , 434 and 444 , it pushes the pistons 416 , 426 , 436 and 446 outward which in turn causes masses 418 , 428 , 438 and 448 to accelerate and strike the borehole wall (in cases where the borehole is uncased at the location of the tool) or strike the casing 210 (in cases where the borehole is cased at the location of the tool).
[0035] FIG. 5 shows an apparatus for generating vibrations in which an electric motor is used to move a mass for striking a borehole wall, according to some embodiments. According to some embodiments, a gearbox is used between the motor and the mass to control the velocity of the mass and the amount of energy imparted to the formation. In the embodiment shown in FIG. 5 , the tool 124 includes electric motor 542 that rotates the vertical shaft 544 , which is connected to the gear box 546 . The gear box 546 in this case transforms the rotational motion of shaft 544 to the translational motion of mass 518 which in turn strikes the borehole wall and generates acoustic vibrations in the formation.
[0036] FIG. 6 shows a wellsite in which a borehole tool is being deployed for generating vibrations in a subterranean formation for stimulation purposes, according to some embodiments. Shown is a stimulation tool 124 being deployed in a borehole 110 formed within subterranean rock formation 100 . In the case shown in FIG. 6 , the tool 124 is being deployed in borehole 110 via a wireline 610 from wireline truck 620 . However, according to some embodiments, the mode of deploying the stimulation tool 124 depends on a number of factors including the life of the well and whether it is horizontal or vertical well. The stimulation tool 124 can be deployed using other technologies such as for example using coiled tubing, or during a drilling operation on a bottom hole assembly. According to some embodiments, as described hereinabove, an air compressor 612 can be used and connected to the tool 124 via gas tube 308 .
[0037] According to some embodiments, the tool 124 can be deployed for either short-term application or long-term application. In an example of short-term application, the tool 124 is deployed in the well 110 which has just been cased. According to some embodiments, the wellbore 110 in the region of interest of formation 100 can have open hole completion, where there is direct access to the formation and the mass can strike the formation directly.
[0038] According to some other embodiments, the wellbore 110 in the region of interest of formation 100 can be cased with perforations. In this case the mass (or masses) of tool 124 can strike the casing, which then transmits some of the vibrations to the formation immediately behind the casing. Some of the energy will be transmitted through the pipe and excite areas above and below the strike point.
[0039] In an example of a long-term application, according to some embodiments, the tool 124 may be deployed before the production pipes are installed. In this case the connections to the tool for power, control, and possibly compressed air can go through a pipe. According to other long-term application embodiments, the well 110 is already completed and is producing, then the production pipes are removed and tool 124 is deployed, followed by a re-installation of the production pipes. According to yet other long-term application embodiments, the well 110 is already completed and is producing, then depending on the inner diameter of the pipe, a slim version of the tool 124 can be deployed.
[0040] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | According to some embodiments, a borehole deployable apparatus is described that can be used to generate strong vibrations in a subterranean rock formation. In some embodiments, the apparatus accelerates a mass using mechanisms built into the tool and causes the mass to strike the borehole wall. The mechanisms can control the mass acceleration, and the frequency of strikes. In some embodiments, the apparatus is designed for use in the field of petroleum recovery where the vibrations are used to create or re-establish a flow rate for the fluids in the formation. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to braking mechanisms for roller type shades, particularly those of considerable width where the shade material may be of substantial weights. More specifically, the invention relates to an externally adjustable braking mechanism which may be adjusted to provide a selected degree of resistance to the winding and unwinding movement of the roller shade.
2. Discussion of the Prior Art
As is well known, most commercially available roller shades are equipped with a spring driven return mechanism and an intermittantly operable ratchet mechanism for holding the shade against the rewinding force in a desired unwound and extended position. As is also well known, these prior art ratchet devices are subject to intermittant failures resulting in the startling, undesired and abrupt uncontrollable rewinding of the shade. In order to avoid this undesirable behavior, various arrangements of roller shade braking mechanisms have been developed and are known in the prior art.
Such arrangements are exemplified, for example, in prior U.S. Pat. Nos. 1,699,555; 1,268,914; 2,678,094; 2,166,745; 1,772,700; 1,275,168; and 3,211,212. Of these patents, U.S. Pat. Nos. 1,268,914 and 1,275,168 include complicated centrifugally actuated braking governors which are not only expensive but which are also bulky and therefore unsightly, requiring a special housing at the end of the roller. U.S. Pat. Nos. 2,166,745 and 1,699,555 are directed to roller shades which lack the spring driven return mechanism and they, as well as 1,772,700, include braking devices which engage the roller from its exterior, thereby also producing an unsightly arrangement. As may be appreciated, all shade brake mechanisms external to the roller are undesirable since they are not suitable for mounting in the window opening itself but must be either mounted within the window frame or on that portion of the window frame facing into the room so that the roller shade projects into the room; an arrangement which may unsatisfactorily interfere with the interior decor of the room such as window curtains.
Of the remaining prior art U.S. Patents previously listed, U.S. Pat. No. 2,678,094 discloses an adjustable stop mechanism and a braking mechanism which is subject to accidental release and stuttering as the brake is engaging. U.S. Pat. No. 3,211,212 discloses a constantly applied brake which, once installed, is not accessible for subsequent adjustment as either the friction surfaces become polished or as the brake actuating springs become fatigued and less powerful.
SUMMARY OF THE INVENTION
These defects and others of the prior art roller shade braking devices are addressed and solved by the present invention which has no ratchet device and which includes an axially elongated roller shade barrel having an internally mounted motor at one end for urging the barrel to rotate in a shade winding direction and a window shade braking mechanism at the other end of the barrel of the type adapted to be internally mounted. The braking mechanism includes a hollow cylindrical brake drum in one end of the barrel with an internally disposed cylindrical braking device having first and second oppositely directed brake shoes. Each of the brake shoes has a cylindrical outside surface for frictional engagement with the interior surface of the brake drum. The brake shoes include opposed inwardly facing surfaces which form an axially inwardly tapering cavity which receives therewithin an axially inwardly tapering wedge. Axial adjustment of the position of the wedge urges the respective brake shoes outwardly into frictional contact with the brake drum. Means are provided for holding the brake shoes rotationally stationary relative to the rotation of the elongated barrel and one of the brake shoes includes a means for adjustably providing the axial positioning of the wedge.
In a preferred form, one of the brake shoes is formed to have an end member or flange which carries an axially, outwardly extending square spindle with a threaded bore therethrough adapted to receive therein a threaded adjustment screw. The position of the biasing wedge is determined by the axial position of the adjustment screw which is adjustable through a bore in the square spindle.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings wherein like reference numerals refer to like elements in the several figures and in which:
FIG. 1 illustrates a roller shade broken away in cross-section at both ends to show the driving motor and the braking mechanism respectively;
FIG. 2 is an end view of the roller shade taken along a line 2--2 of FIG. 1;
FIG. 3 is a cross-section of the roller shade taken along lines 3--3 of FIG. 2 and shows the cross-sectional details of a braking device; and
FIG. 4 is an exploded perspective view of the braking mechanism of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the invention is susceptible of various modifications and alternative constructions, there is shown in the drawings and there will hereinafter be described, in detail, a description of the preferred embodiment of the invention. It is to be understood, however, that the specific description and drawings are not intended to limit the invention to the specific form disclosed. On the contrary, it is intended that the scope of this patent include all modifications and alternative constructions thereof falling within the spirit and scope of the invention as expressed in the appended claims to the full range of their equivalence.
In the present invention, a roller shade braking mechanism has been designed to provide the function of constantly applying a braking force which continuously resists both the winding and unwinding motions of the roller. Such a braking device is advantageous in that, when properly adjusted, the roller shade may be pulled down and returned to any desired position by the mere actions of pulling or lifting the unwound shade portion. Thus, the inconvenient simultaneous actions necessary in many prior art shades requiring the use of two hands to change the position of the shade are eliminated. Additionally, the jerking motion required for the release of the ratchet positioning mechanism of prior art roller shades is also eliminated.
In order to perform most satisfactorily, it is desirable that the roller shade of the present invention be designed so that the linearly increasing weight of the unwound portion of the shade approximately balances and therefore substantially cancels out the linearly increasing winding force provided by the rewinding spring motor. When this balance has been achieved by the proper selection of the torsional spring in the motor, a relatively minor braking force is required to maintain the unwound roller shade in any desired position. With this arrangement, movement of the shade in an up or down direction is easily accomplished by lifting up on or pulling down on the roller shade, thereby upsetting the balance of forces and overcoming the braking force constantly applied by the brake. However, as may readily be appreciated, if the downward force of the unwound portion of the roller shade and the upward force of the spring motor are not closely balanced, the desirable objective of halting the roller shade in any position may still be achieved by increasing the braking force applied by the brake which overcomes the imbalance.
As may be readily appreciated, the above concepts are applicable to any shade or partition device which is windably mounted on a roller which is continuously urged to rotate in its winding direction. Therefore, while the present invention is applicable to relatively light roller shades suitable for a homeowner's window, it is even more applicable to the wider roller shade used in commercial buildings as well as to the heavier roller shades such as bamboo or woven wood shades or room dividers.
Turning now to a description of the apparatus embodying the invention as shown in FIG. 1, the roller shade 10 is illustrated with broken away end sections showing the spring motor 18 at one end and the brake assembly 20 at the other end and is mounted in position by a pair of wall brackets 70 and 78. The roller shade 10 includes a roller 12 and a shade 14 would therearound. As will be well understood by those skilled in the art, spring 18 is fastened to the interior of roller 12 at one end and to a spindle 16 at its other end. Spindle 16 in turn is rotatably mounted in the end of the roller 12 for relative rotational movement and is held rotationally fixed by the appropriate end mounting bracket 78. In a common arrangement, spindle 16 includes two flat surfaces which are slidingly received within a rectangular slot formed by the mounting bracket 78.
At the opposite end of the roller shade 10 of FIG. 1, the structure of the braking mechanism 20 is shown as including a cup-like cylindrical brake drum 24 axially received within the end of roller 12. Brake drum 24 is rotationally fixed to roller 12 and includes an interior cylindrical surface 26 which provides the friction surface for the brake mechanism. In a preferred form, brake drum 24 has a radially extending end flange 28 whose diameter equals the diameter of roller 12.
Mounted within brake drum 24 are first and second brake shoes 30 and 50 which together have the appearance of a spool with a right circular cylindrical shape. Exterior cylindrical surfaces 58 and 56 respectively form the friction surfaces of the brake shoes. An outwardly extending circular flange 44 which has a maximum diameter equal to the diameter of roller 12 is formed at one end of brake shoe 30. As may best be seen in FIGS. 2 and 4, brake shoe 30 also includes an axially outwardly extending square spindle 32 which has a central axial bore 34 formed therewithin. Axial bore 34 communicates with a threaded axial bore 36 adapted to threadedly engage a screw 22. As may be seen, brake shoe 30 is formed to have a laterally extending recessed portion 40 and an interior end flange 38. This recessed portion 40 is formed to receive therewithin the second brake shoe 50 and cooperates to hold shoe 50 and shoe 30 rotationally fixed relative to one another.
Each of the brake shoes 30 and 50 have inwardly and opposite facing surfaces 46 and 54 respectively which are angled to form an axially inwardly tapering cavity 52 between the brake shoes when shoe 50 has been slidingly positioned within depression 40. Tapered cavity 52 is provided to receive therewithin an axially inwardly tapering brake wedge 60 which includes an inclined plane 62 and an end bearing surface 64. Recessed groove 42 within recessed portion 40 of brake shoe 30 functions as a means for receiving, positioning, and guiding the brake wedge 60. The axially exterior end of groove 42 communicates with the threaded bore 36 so that when threaded screw 22 is screwed in through the bore 36 it can be brought to bear against the bearing surface 64 of the wedge 60 in order to influence its axial position.
Since screw 22 is externally accessible through bore hole 34, the position of screws 22 and hence the position of braking wedge 60 may be externally adjusted. Accordingly, when assembled as shown in FIG. 1, the desired degree of braking force may be applied by the adjustment of screw 22. The axial inward movement of screw 22 brings about the axial inward movement of wedge 60 which is inserted deeper into the tapered cavity 52 thereby forcing brake shoes 30 and 50 apart to cause their cylindrical braking surfaces 56 and 58 to bear respectively on the interior friction surface 26 of brake drum 24.
As best seen in FIG. 2, the square end spindle 32 of brake shoe 30 is slidingly received in and supported by a rectangular slot 72 formed in mounting wall bracket 70. In this manner, brake shoe 30 is rotationally fixed relative to the wall and is rotationally moveable relative to the roller 12. As previously discussed, brake shoe 50 is prevented from rotating with the brake drum 24 by the interaction of the surfaces of both shoes 30 and 50. In addition, rotational movement of shoe 50 is prevented by the keying effect brought about by the insertion of wedge 60 in mating grooves 42 and 52.
While a preferred embodiment has been disclosed, it is apparent that many variations and modifications of the invention are possible without deviating from the scope of the invention. For example, one such variation would be the formation of a conical cavity 52 with a conical "wedge" member 60. Another possible and perhaps desirable modification might be the formation of the "wedge" member 60 as an integral part of screw 22 at its innermost end. | A roller shade braking mechanism of the type including a pair of outwardly biased braking shoes for engaging a cylindrical brake drum. The brake shoes are urged into braking engagement by an axially positionable wedge which cams against the interior surfaces of the brake shoes to thereby produce a constantly applied braking force. Externally accessible adjustment means are also provided for adjusting the pressure exerted by said brake shoes. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for treating textile material. More particularly, the present invention relates to apparatus for treating textile material with a fluid.
2. Technical Considerations and Prior Art
In the textile industry, it is a current practice to treat textile material while in yarn form with fluids that are impinged upon the yarn as the yarn is advanced through a chamber. Generally, for the purposes of this application, the term "yarn" includes any continuous length of textile material, regardless of its structure, that is subsequently made into textile fabrics. The yarn can be composed of a single filament, a thread which is made of fibers by processes such as twisting and interlacing, or any other arrangement. There may, of course, be numerous filaments or threads or, perhaps, just a single filament or thread.
Since the present invention is concerned with fluid treatment, the term "fluid" as used in this application is defined as a gaseous or liquid substance which may contain a dye or agents, such as anti-static agents, anti-stain agents, oiling agents, optical blueing agents, or softening agents. In addition, the fluid may contain agents such as ultra-violet absorbers, non-flammability chemicals, dye inhibitors, or fixing agents. In addition, the application of fluid includes the concept of injecting water with the fluid containing any or some of the above-described agents. All of these agents and chemicals are exemplary of the agents and chemicals which are, and may be, used to treat yarns in accordance with the processes and apparatus utilized in practicing the instant invention.
The prior art discloses several patents which are concerned with treating yarn with a fluid while the yarn is advanced through the chamber. For example, U.S. Pat. No. 2,854,728 discloses a process in which the yarn is treated in a curling or crimping chamber with a liquid, such as a dye or an oil, which is introduced into the chamber by an orifice and the flow of which is regulated by a valve provided with a manual regulating button. The treating liquid is injected into the curling or crimping chamber through an adjustable nozzle. However, with this device, uniform treatment of the yarn is not adequately achieved because there is heterogeneity of the dyeing process due to heterogeneity of temperature. In addition, the fixation of the oil or dye is not adequate due to insufficient heat treatment of the yarn. Finally, the apparatus of U.S. Pat. No. 2,854,728 permits the yarn to be dyed only one color.
French Pat. No. 1,499,744 discloses a device wherein the yarn is advanced through a treatment chamber while being dyed with a periodic pattern by impinging the dye on the yarn variably with a jacquard type mechanism of a weaving or knitting frame which is placed directly downstream from the yarn treatment chamber. In this device, the dye is fixed to the yarn while the yarn is in the chamber. This device is rather difficult to control and has the deficiency that there is no means for draining the dye from the chamber which, consequently, results in difficulties in fixing the dye to the yarn. Since there is a great deal of dye on the yarn, it is most difficult to increase the temperature of the yarn to a level allowing fixation of the dye.
In U.S. Pat. Nos. 3,644,969 and 3,751,778, which are assigned to the inventors of the instant invention, it is proposed to fabricate textured yarn at high speed, while simultaneously treating the yarn with a finishing agent or dye solution. In order to provide for this simultaneous treatment, it is necessary to use a fluid distribution device which has great flexibility in handling and operation. A successful fluid treatment device used in conjunction with the teachings of these patents ideally should be relatively compact, have few moving parts, be reliable and resist corrosion by various chemical agents present in fabrication plants. These features are especially important when processing yarn to obtain treated yarn having variable characteristics.
The apparatus proposed in the U.S. Pat. No. 2,854,728 and French Pat. No. 1,499,744 do not meet the afore-described requirements for a fluid distribution device because they disclose mechanical structures which require constant maintenance. In addition, the output adjustments are not satisfactory in that the adjustments disclosed in U.S. Pat. No. 2,854,728 are manual, and those described in French Pat. No. 1,499,744, while programmed, require a relatively large jacquard type mechanism which is not as reliable as desired. In addition, the fluid distribution devices of these prior patents are not responsive enough to be compatible with high speed operation in which fluid distribution must be varied rapidly.
SUMMARY OF THE INVENTION
In view of the afore-described deficiencies in the prior art, it is an object of this invention to provide new and improved apparatus for treating yarn with fluid.
It is another object of this invention to provide new and improved apparatus for treating yarns with fluids, wherein the treatment may be varied rapidly to give a varying pattern of treatment to the yarn.
It is an additional object of the instant invention to provide new and improved apparatus for controlling the impingement of a treatment fluid on yarn while the yarn is advanced through a chamber.
It is a further object of the instant invention to provide new and improved apparatus for controlling impingement of fluid on yarn, wherein the yarn is stuffed in a compacting chamber and wherein numerous fluid treatment products may be selectively applied to the yarn according to selected spacings and patterns.
It is still another object of the instant invention to provide new and improved apparatus for distributing fluid on yarn, wherein the operation of the processes disclosed in U.S. Pat. Nos. 3,644,969 and 3,751,778 is enhanced.
It is still a further object of the instant invention to provide a new and improved fluid distribution apparatus for impinging fluid on a yarn which has great flexibility.
An additional object of the instant invention is to provide new and improved apparatus for impinging fluid on yarn, wherein the apparatus is relatively compact, has few moving parts, and will resist the corrosive chemical agents present in most manufacturing facilities.
In view of these and other objects, an apparatus for practicing the principles of the instant invention may include a fluid circuit in which the treatment fluid in continuously circulated, and a conduit registered with a chamber through which the yarn passes and the fluid circuit. The circulating fluid is selectively diverted by a valve means into the conduit to impinge upon the yarn when circulation of the fluid in the fluid circuit is interrupted. By selectively interrupting circulation of the fluid according to a predetermined pattern, a desired pattern of impingement of the fluid on the yarn may be achieved.
The afore-described apparatus functions to provide a new and improved process which achieves the objects of the instant invention by selectively diverting circulating fluid upon interrupting circulation of that fluid to impinge the fluid upon yarn advancing through a closed member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a system for impinging fluid onto yarn in accordance with the principles of the instant invention;
FIG. 2 is a schematic cross-sectional view of an injector which may be used with the system of FIG. 1, wherein two channels are provided for injection of fluid into a treating chamber;
FIG. 3 is a schematic cross-sectional view of an injector for use with the system of FIG. 1, wherein four channels are provided for the injection of four fluids which may, for example, be dyes;
FIG. 4 is a cross-sectional view of one embodiment of an injector according to the principles of the instant invention, wherein two fluids are injected;
FIG. 5 is a cross-sectional view of a chamber showing three injectors registered therewith;
FIG. 6 is a cross-sectional view of a chamber showing four injectors registered therewith; and
FIGS. 7 through 21 are figures schematically showing the appearance of yarn resulting from various fluid treatments performed in accordance with the principles of the instant invention.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is schematically shown a fluid treating apparatus, designated generally by the numeral 30, which operates in accordance with the principles of the instant invention. Fluid treating apparatus 30 treats yarn 31 which is advancing through a chamber 32 into which fluid 33 is injected by an injector 34. It should be kept in mind that the yarn 31 may be in any form. For example, it may be a single stand or it may be multiple strands which are either separate or interwoven. In other words, the yarn 31 may be in any of the forms in which yarn is configured as it is fluid treated. The chamber 32 may be a chamber in conformance with those chambers disclosed in U.S. Pat. Nos. 3,644,969 and 3,751,778. The chamber 32 receives and compacts the yarn by doubling the yarn up in a crimping configuration, as shown in the afore-described patents which are all incorporated in this present application by reference.
In accordance with the principles of the present invention, the fluid distribution system 30 continuously circulates fluid 33 through lines 34, 35 and 36 by an injector device, designated generally by the numeral 37. The fluid circuit prescribed by the lines 34, 35 and 36 also includes a reservoir or holding tank 38, which is located upstream from the injector device 37.
In operation, the fluid 33 is drawn through the line 34 by an ejector 39 and passes into an orifice schematically shown as 41 which is registered with the ejector 39. The ejector 39 is a conventional, well-known device which functions to eject the fluid 33 from an outlet orifice of the ejector 39 into the aligned orifice 41 which forms an inlet for the line 35. As the fluid 33 circulates, it will naturally flow from line 34 to line 35 due to the alignment of the afore-described orifices. However, registered with the outlet orifice of the ejector 39 and the inlet orifice 41 is another orifice schematically illustrated by the numeral 42. The orifice 42 is preferably what is generally referred to as an aspiration orifice, and it is generally, normally disposed to the alignment of the orifices of the afore-mentioned fluid circuit. Whenever flow of fluid 33 in the circuit 34, 35, 36 is interrupted downstream from the ejector 39, the fluid 33 will exit through the aspirator orifice 42 and flow through line 43 into injector 34 so as to impinge upon yarn 31 in the chamber 32.
In accordance with the principles of the instant invention, the afore-described interruption to divert the fluid 33 into the line 43 is accomplished by a throttling device schematically illustrated by numeral 44 which is disposed between the outlet end of line 35 and the inlet end of line 36. The throttling device 44, according to the instant invention, includes a chamber 45 having an inlet 46 with which the line 35 is registered, and an outlet 47 with which the line 36 is registered. According to one embodiment of the instant invention, a diaphragm 48 forms one wall of the chamber 45 and is disposed opposite the inlet 46. On the other side of the diaphragm 48, there is positioned a second chamber 49 that is completely closed from the chamber 45 by the diaphragm. Into the chamber 49 air is injected to deflect the diaphragm 48 against the inlet 46 to block the inlet 46 and prevent flow of fluid through the line 35. The fluid 33 then has no choice but to flow through line 43 and into the chamber 32.
While, for purposes of illustration, a pneumatic system is shown for closing the inlet 46, it is, of course, possible to use any convenient system, such as a mechanical system in which a valve closes the orifice or an electromechanical system in which a valve operated by a solenoid closes the system. For purposes of illustration, however, the pneumatic system may utilize a closed cylinder 51 having a line 53 registered with the chamber 49. A piston 55 may be reciprocated in the chamber 51 to pressure the chamber 49, and thereby close the inlet 46. Any sort of conveniently operated electrical or mechanical apparatus, generally designated by the numeral 56, may be used to reciprocate the piston 55. The apparatus 56, in turn, may be conveniently controlled or programmed by a controller 57 so as to deflect the diaphragm 48 according to a programmed pattern. The programmed pattern generated by the controller 57 controls the impingement of the fluid 33 on yarn 31 as the yarn 31 advances through the chamber 32.
It should be kept in mind that the amount of the fluid 33 diverted into the line 43 may be controlled by the degree to which the inlet 46 is throttled. In other words, by completely closing off the inlet 46, a great deal of the fluid 33 will be diverted to line 43. However, by just partially closing the inlet 46, a lesser amount of fluid 33 will be diverted because some fluid will still be able to pass from line 35 to line 36.
Referring now to FIGS. 2 and 3, there are shown alternative embodiments 34' and 34" of the injector 34. With the injector 34', two fluids may be injected at a single location by having a pair of channels 60 and 61 with which separate lines 43 and 43', respectively, are registered. The line 43, of course, may come from the system 30 of FIG. 1. However, a redundant system (not shown) similar or identical to the system 30 may be attached to the line 43'. While one system 30 diverts a first fluid through the line 43, a second system 30 can divert a second fluid or even an identical fluid through the line 43'. The fluid flowing through the lines 43 and 43' may be pulsed and varied according to desired patterns so as to impinge the fluids on yarn 30 according to desired patterns. For example, fluid flowing in line 43 may be red, while the fluid flowing through the line 43' may be a sickly green. By, for example, alternating the diversion into line 43 with the diversion into line 43' and alternating pattern of red and green will appear on the yarn 31.
Referring now specifically to FIG. 3 where there is shown an injector 34", four channels 62, 63, 64 and 65 are shown which register with lines 43, 43', 43" and 43'". An injector, such as the injector 34", would have four systems 30 such as that shown in FIG. 1 so that four different fluids might be programmed to pass through the various channels 62 through 65. For example, the fluids flowing through channels 62, 63 and 64 might consist of fluids containing dye solutions of the three basic colors (green, yellow and red), while the channel 65 may be a dye additive. By utilizing the system of FIG. 3, it is possible to dye the yarn 31 according to any desired color through selecting and dosing the various dye solutions.
Referring now to FIG. 4, there is shown an injector 34'" which is another embodiment that the injector 34 of FIG. 1 may assume to impinge fluid onto the yarn 31. The injector 34'" has a pair of inlet lines 43a and 43b through which fluids from separate systems such as the system 30 of FIG. 1, are injected. With the injector 34, the fluid arriving through channel 43a and that arriving through 43b are separated by a plate 68 so that the passage section is constant. Consequently, it is possible to obtain an orifice 70 with a thin slit at the level of the yarn 31 being treated without interrupting the velocity of the treating fluid. With this system, it is possible to obtain a delivery having a constant speed.
Referring now to FIGS. 5 and 6, there are shown arrangements wherein pluralities of injectors 34 are circumferentially arranged around the chamber 32. The arrangement of FIG. 5 can, for example, be used with the processes and apparatus described in the afore-mentioned U.S. Pat. Nos. 3,644,969 and 3,751,778 which are incorporated by reference in this application, and are assigned to the instant inventors. With the injector devices 34 of FIG. 5, it is possible to act on three zones a, b and c simultaneously. When dyeing yarn 31 which is formed in the chamber as a pile, there are many different possibilities which can be pursued in using the arrangement of FIG. 5. For example, one of the zones a, b, c could be dyed while the other two zones are left natural, or the three zones could each be dyed different colors, and so forth. It should be remembered that as the pile 31 is being dyed, it is advancing longitudinally along the axis of the chamber 32 so that the dyes are distributed along the lengths of the pile, as well as through the pile. By pulsing the injectors 34 with the system 30 according to selected patterns, it is possible to generate numerous dyeing patterns in the pile.
Referring now specifically to FIG. 6, there is shown an arrangement similar to FIG. 5. However, this time, four injectors 34 are utilized, resulting in a situation where the individual dyeing zones a, b, c and d are more compact, and wherein additional variations in the dyeing pattern of the pile of yarn 31 may be achieved.
Referring now to FIGS. 7 through 21, there are shown schematic illustrations of yarn treated by the apparatus and according to the process of the instant invention while in the form of a pile. As seen in these figures, the various configurations are a function of the number of injectors, the number of different fluids used, and the frequency of injection. The longer the diaphragm 48 (see FIG. 1) remains closed, the longer will be the length of each treatment zone.
FIGS. 7 through 12 are exemplary of the appearance of piles of yarn 31 treated with a device according to the instant invention where two injectors 34 (not shown) and two different fluids are used.
FIGS. 13 through 15 are exemplary of appearances of piles of yarn 31 after treatment, wherein two injectors are utilized with four fluids. In this case, the two injectors each resemble the injector 34' of FIG. 2, or the injector 34'" of FIG. 4.
FIGS. 16 and 17 are exemplary of the appearances of piles of yarn 31 after treatment where three injectors or groups of injectors, as illustrated in FIG. 5, are used, and four different fluids are used.
FIGS. 18 through 20 are exemplary of appearances of piles of yarn 31 after treatment where four injectors 34 or groups of injectors are used with four fluids, as illustrated in the embodiment of FIG. 6.
Finally, FIG. 21 is illustrative of the situation where a pile of yarn 31 is treated with four injectors 34 or groups of injectors, and three fluids.
The FIGS. 7 through 21 illustrate the flexibility obtainable by utilizing the processes and apparatus of the instant invention. These results can be obtained either simultaneously with or, on the other hand, not simultaneously with texturization of yarns, as exemplified in the inventor's other afore-mentioned patent applications. After the products illustrated in FIGS. 7 through 21 are obtained, they may be used either in the form of a pile or the yarn 31 may be unwound from the pile formed in the chamber 32 and rewound on a spool. In addition, while the pile is unwound, it may be continuously twisted to obtain a multi-filament strand having the appearance of a uniformly colored yarn or, on the other hand, a marbled yarn or perhaps either a cloud yarn or assembled false yarn. Again, it is emphasized that the system has great flexibility for producing yarns 31 of various dye patterns and configurations.
Further, expanding on the flexibility of the inventors' process and apparatus, it should be kept in mind that several strands of yarn 31 may be treated at the same time, as well as treating a single strand. These several strands may undergo a uniform or heterogeneous treatment, and the treated yarns may be further processed either individually or together. As described in French Pat. application No. 73/05089, filed Feb. 8, 1973, the piles resulting may be either totally cut or partially cut to obtain either separate dyed fibers or by additionally using continuous or delayed twisting, a thread or fibers. When treating roves or strips of fibers, it is possible to utilize the apparatus of the instant invention with a spinning device to produce a thread of dyed fibers by what is known as an open end spinning process.
Finally, it is emphasized that the textile materials treated in accordance with the process and apparatus of the instant invention can be utilized in weaving, knitting or for fabrication of unwoven articles. The method and apparatus of the instant invention can be used to produce materials for all possible textile applications, such as those relating to clothing, furniture, floor or wall coverings, other technical applications and so forth.
EXAMPLES
EXAMPLE 1
The method and apparatus of the instant invention was practiced by using an embodiment where two dyes were alternately injected into a crimping chamber with a constant frequency of alteration. The apparatus on which the apparatus of the instant invention was mounted was that described in U.S. Pat. No. 3,752,778 which is utilized to cause simultaneous texturization and dyeing of yarn by piling and compressing the yarn in a chamber with a current generated by an expanding compressed fluid. In this situation, a compressed fluid was steam elevated to a temperature causing fixation of the yarn. The pile in this example is carried through the chamber by the expanding steam, while a portion of the steam escapes laterally from the chamber through lateral ports therein. With this arrangement, the dyes are introduced into the chamber to impinge upon the piling, while the piling is passed continuously into a release zone, a steam injection zone, and then finally into a second release zone. In utilizing the process and apparatus of the instant invention with U.S. Pat. No. 3,752,778, the treatment conditions for continuous yarn made of polyhexamethylene adipamide (polyamide 66) having a count of 2,300 dtex/136 strands were as follows:
Speed of supply of the yarn fortexturization 406m/min.Speed of the leaving pile 4.5m/min.Speed of winding of the yarnafter unravelling the pile 332m/min.Pressure of steam supply atthe input of the texturizationchamber 8 barsPressure of the steam insidethe closed volume or closedchamber and in the injectionzone which follows the releasezone 3 barsTemperature of the steam on theyarn at texturization 136°C.
In this example, a configuration shown in FIG. 6 was used with four injectors 34 spaced at 90° around the crimping chamber 32. Each injector was of the type shown in FIG. 2 and having the reference numeral 34', wherein each injector has two channels similar to channels 60 and 61. With this example, two circuits similar to the circuits of FIG. 1 were utilized, each circuit having separate dye solutions circulating therein. The injection modulation means and program means were combined as shown in FIG. 1 in the form of a programmed pneumo-hydrolic injection system, such as the type developed by the company Bertin et Compagnie.
The dyes used were an aqueous solution of brilliant polar blue RAWL (C.I. No. 61,585) in a concentration of 40g/l and an aqueous solution of Fuller yellow 2R (C.I. No. 25,135), also in a concentration of 40g/l.
The dye solutions are injected alternately at a constant frequency of one cycle per second, and with a quantity of 38cc per injector per 100g of yarn per minute. These parameters are used to obtain alternately dyed zones on the pile having a constant length of 61mm, and having an appearance such as that schematically shown in FIG. 8. The resulting wound and unwound yarn has dyed sections with the length of 1,445mm measured by putting the yarn under a tension of 100g in the texturized state, wherein the yarn has a count of 2,850 dtex.
EXAMPLE 2
In this example, the apparatus and process of FIG. 1 were utilized for alternate injection of two dyes with a variable injection frequency. The differences between this example and Example 1 are as follows:Speed of supplying the yarnfor texturization 1,070m/min.Speed at which the pile leaves 12.5m/min.Speed of winding the yarn afterunravelling the pile 860m/min.Supply pressure of the steamat the input of the texturizationchamber 8.5 barsTemperature of the supplied steam 142°C.
The dyes are the same dyes used in Example 1 and are injected alternately with a variable frequency of 1 to 5 hertz and with a quantity of 90cc of dye per injector per each 265 g of yarn per minute. The lengths of the dyed sections thus produced alternately on the pile are 22mm for the 1 hertz cycle and 4.1mm for the 5 hertz cycle. On the resulting yarn which is unwound and wound, then put under tension, the lengths are 503mm for the 1 hertz cycle and 100mm for the 5 hertz cycle. As in Example 1, the measurements were taken while putting the yarn under a pre-tension of 100g, while the yarn is in the texturized state, and has a count of 2,850 dtex. The pile resulting from the dyeing treatment has the appearance of the schematically shown pile of FIG. 8.
EXAMPLE 3
This example illustrates how the process and apparatus of the present invention may be used for injection of a dye inhibiting agent at a variable frequency on a product intended to be later dyed while in the form of yarn, fabric or knit. As with Example 1, the process and apparatus described in U.S. Pat. No. 3,751,778 was combined with the process and apparatus of the instant invention to treat continuous yarn of polyhexamethylene adipamide (polyamide 66) having a count of 2,280 dtex/136 strands. The treatment was carried out under the following parameters:
Supply speed of the yarn tothe texturization chamber 1,070m/min.Speed of the immerging pile 12.5m/min.Winding speed of the yarnafter unwinding the pile 855m/min.Supply pressure of the steamat the input of the texturizationchamber 8.5 barsTemperature of the steam supplied 142°C.
The injection device utilized is the same as in Example 1, wherein four injectors having two channels each are utilized.
In practicing the invention as illustrated by this example, and aqueous solution of dye inhibitor, designated commercially as "Sandospace R" is injected alternately with water at frequencies of 1, 3 and 5 hertz. The aqueous solution contains the dye inhibitor at a ratio of 15g/l, and is a colorless organic substance containing a sulfonic group and a reactive group which modify the affinity of polyamide textiles for acid and cationic dyes. The solution is injected through four injectors at a delivery rate of 107cc per injector per each 265g of yarn per minute. The texturized yarn thus treated is then wound and knitted, and the knit obtained is degreased and then dyed. The dyeing takes place at 98°C., pH6, in a bath having a ratio of 1/40, with a solution which is 1g/l of soluble Kiton blue 4GL (C.I. Acid Blue 23) and 1g/l of Astrazon Red BBL (C.I. Basic Red 23) and 0.2g/l of a non-ionic wetting agent. The parts of the yarn untreated with the Sandospace R are dyed blue, and the parts of the yarn treated with the Sandospace R are dyed red. Thus, a knit with differentiated dye is obtained.
The afore-described examples, illustrations and embodiments are meant to be merely exemplary of the instant invention, which is to be limited only by the following appended claims. | Methods of and apparatus for treating yarn with a fluid material include a chamber through which the yarn is advanced and an injection nozzle for impinging fluid on the yarn as it advances through the chamber. The injection nozzle is registered with a fluid circulation system in which a dyeing substance or other fluid treating substance or material is circulated. Upon interrupting the circulation of the fluid treating material, a portion of the material is diverted into the chamber through which the yarn is advancing. By interrupting the circulation of the fluid treating material according to a selected pattern, the fluid treating material will impinge on the advancing yarn with a corresponding pattern. If it is desired to impinge treating materials having different characteristics, such as dyes of different colors, then a plurality of circuits may be utilized to direct the fluid materials into the chamber through which the yarn advances. The fluid circuits may be controlled and coordinated according to selected patterns in order to produce a varying effect on the yarn progressing through the chamber. | 3 |
RELATED APPLICATION
This application is a national stage application under 35 USC §371 of PCT Patent Application No. PCT/US2010/054165, filed Oct. 26, 2010, which claims the benefit of U.S. Provisional Application No. 61/255,045, filed Oct. 26, 2009, and U.S. Provisional Application No. 61/382,850, filed Sep. 14, 2010.
TECHNICAL FIELD
This invention relates to a bariatric device for weight loss, and ancillary items such as sizing, and monitoring.
BACKGROUND
Obesity has been steadily increasing worldwide and poses serious health risks, which if untreated, can become life threatening. There are various methods for reducing weight such as diet, exercise, and medications but often the weight loss is not sustained. Significant advances have been made in the surgical treatment of obesity. Surgical procedures such as the gastric bypass and gastric banding have produced substantial and lasting weight loss for obese patients. These procedures and products have been shown to significantly reduce health risks over time, and are currently the gold standard for bariatric treatment.
Although surgical intervention has been shown to be successful at managing weight loss, both procedures are invasive and carry the risks of surgery. Gastric bypass is a highly invasive procedure which creates a small pouch by segmenting and/or removing a large portion of the stomach and rerouting the intestines permanently. Gastric bypass and its variations have known complications. Gastric banding is an invasive procedure which creates a small pouch in the upper stomach by wrapping a band around the stomach to segment it from the lower stomach. Although the procedure is reversible, it also carries known complications.
Less invasive or non-invasive devices that are removable and capable of significant weight loss are desirable. A device that has demonstrated less invasive approach is defined in U.S. patent application Ser. No. 11/463,192 and PCT/US2008/053912, and shows a three element or single element device that is sutured through the esophagus and cardia or the cardia. The inventions included herein demonstrate improvements of this device such as improved means of adjustability, use of sensors for monitoring physical parameters, use of sensors to controls adjustments, remote adjustments with sensor data, data storage for data collected through the sensors, improvements in fixation, shape and form, and improvements in contact area.
This application also includes new inventions for bariatric devices that apply force to the upper stomach which are placed with fixation or devices which could be placed without fixation in the pouch of a gastric band or by pass patient.
SUMMARY
The bariatric device described herein induces weight loss by engaging the upper stomach which could include the cardia, the adjacent fundus, the abdominal portion of the esophagus or the gastroesophogeal junction. One embodiment of the bariatric device disclosed herein is based on applying force or pressure on or around the gastroesophogeal (GE) junction and upper stomach. It may also include pressure in the lower esophagus. The device can be straightened or compressed to allow for introduction down the esophagus and then change into the desired shape inside the stomach. This device is then secured with sutures or other fixation to maintain the pressure against the upper stomach. The device may be constructed of a single main element with fixation and adjustability:
1) A cardiac element that contacts or intermittently contacts the upper stomach a. Fixation to hold the device position and location b. Adjustment means
One of the purposes of the cardiac element which contacts the upper stomach or cardia is to at least intermittently apply direct force or pressure to this region of the stomach. Applying force or pressure to this region of the stomach replicates the forces and pressures that are generated during eating and swallowing. It also engages or stimulates the stretch receptors that are present in this region of the stomach. During eating, as the stomach fills, peristalsis starts and generates higher pressures in the stomach for digestion, which activates the stretch receptors to induce a satiety response, and may also trigger a neurohormonal response to cause satiety or weight loss. The cardiac element replicates this type of pressure on the stretch receptors. The cardiac element could take the form of many different shapes but a preferred shape is the frusto-cone. This element could take the form of many different shapes such as a ring, a disk, a cone, a frusto-cone, a portion of a cone, portion of frusto-cone, a sphere, an oval, an ovoid, a tear drop, a pyramid, a square, a rectangle, a trapezoid, a wireform, a spiral, a protuberance, multiple protuberances, multiple spheres or multiples of any shape or other suitable shapes. It could also be an inflatable balloon or contain an inflatable balloon. For the purpose of the claims of this patent, the “upper stomach” includes the cardiac region (a band of tissue in the stomach that surrounds the gastroesophogeal (GE) junction), and the fundus adjacent to the cardiac region, and may be either of these two areas, or both.
With the single cardiac member, a means of fixation will be required to hold the device in place. This could be accomplished by sutures, barbs, tacks, clips, t-connectors or others. The device could also be placed without fixation where the device may be held in place by restriction caused by a gastric band, gastric bypass, sleeve gastrectomy or other previous bariatric procedure. Where fixation is used, it could be permanently integrated into the cardiac element or it could be a separate piece that is modular to add at the time of placement. To make the device customized for each patient, a means for adjusting the amount of pressure that is placed on the cardia can be incorporated into the device.
In another embodiment of the bariatric device disclosed herein, the device may be constructed of three main elements with fixation and adjustability:
1) A cardiac element that contacts or intermittently contacts the upper stomach 2) An esophageal element located in the abdominal portion of the esophagus. 3) A connecting element to connect the first 2 elements a. Fixation to hold the device position and location b. Adjustment means
One of the purposes of the cardiac element which contacts the upper stomach or cardiac region would be to apply at least intermittent pressure or force to engage a satiety response and/or cause a neurohormonal response to cause a reduction in weight. This element could take the form of many different shapes but the preferred shape is a frusto-cone. This element could take the form of many different shapes such as a ring, a disk, a cone, frusto-cone, a portion of a cone, portion of frusto-cone, a sphere, an oval, an ovoid, a tear drop, a pyramid, a square, a rectangle, a trapezoid, a wireform, a spiral, a protuberance, multiple protuberances, multiple spheres or multiples of any shape or other suitable shapes. It could also be an inflatable balloon or contain an inflatable balloon. This balloon could be spherical, or it could be a torus or a sphere with channels on the side to allow food to pass, or it could be a cone, a portion of a cone or other shapes. The cardiac element may be in constant or intermittent contact with the upper stomach based on the device moving in the stomach during peristalsis.
The purpose of the esophageal element is to also engage stretch receptors located at the lower esophagus to stimulate satiety and could also provide a means for fixation into the esophagus. Alternatively, the purpose of the esophageal element may be only to fix the device in the esophagus and/or serve as a lever for the cardiac element.
The purposes of the connecting element are to connect the cardiac and esophageal elements, to provide structure for the device to maintain its relative placement location, and to provide tension, pressure, or an outwardly biasing force on the cardiac element.
A means of fixation will be required to hold the device in place. This could be accomplished by sutures, barbs, tacks, clips, T-bars or others. The fixation could be permanently integrated into the cardiac element or it could be a separate piece that is modular to add at the time of placement.
The purpose of the adjustability of the device is to ensure that the proper amount of pressure is applied to each patient. The adjustability allows the pressure to be customized for each patient to optimize the response. If the pressure is too great, the patient may experience discomfort, nausea or a total disinterest in food. Conversely, if the pressure is too low, the patient may continue to overeat and the effectiveness of the device may be reduced. By allowing the physician to adjust the device after placement, the treatment can be customized. Similarly, patients may experience satiety in the beginning, but it may wane over time. These patients may require an adjustment to increase the satiety signal overtime, and the adjustability feature provides the device this flexibility. The adjustability could be achieved in a variety of forms. For example, it may be desirable to change the distance between the esophageal and cardiac elements to change the overall length of the device to increase compression of the cardia. For example, it may be desirable to change the distance between the esophageal and cardiac elements to change the overall length of the device to increase compression of the cardia. This could be accomplished by changing the length of the connecting element or the fixation element. It may also be desirable to change the shape of the device, such as to increase the diameter or angle of the device. The change may be to just a small area of the device. It may also be desirable to increase or decrease the stiffness of the device to increase resistance of the device against the tissue. This change may also be to just a small area of the device to gain a specific response.
The cardiac, esophageal and connecting elements could also be self-expanding or incorporate a portion that is self expanding. Self expansion would allow the element or a portion of the element to be compressible, but also allow it to expand back into its original shape to maintain its function and position within the stomach, as well as the function and position of the other element(s). Self expansion would allow the elements to compress for placement down the esophagus, and then expand to its original shape in the stomach. This may also allow the element to accommodate peristalsis once the device is in the stomach.
In any of the embodiments disclosed herein, the device may be straightened or collapsed for insertion down the esophagus, and then reformed to the desired shape in the stomach to apply pressure at the upper and lower stomach regions or other regions as described above. At least a portion of the device could be made of a shape memory alloys such as Nitinol (nickel titanium), low density polyethylene or polymers to allow for it to compress or flex and then rebound into shape in the stomach. For placement of the device into the stomach, a flexible polymer tube, such as a large diameter overtube or orogastric tube, could be placed down the esophagus to protect the esophagus and stomach. The device could then be straightened and placed into the tube for delivery into the stomach, and then regain its proper shape in the stomach once it exits the tube. Another variation for placement would be a custom delivery catheter to compress the device during placement and then allow the device to deploy out of the catheter once in the stomach.
The bariatric device could be made of many different materials. Elements of the device could be made with materials with spring properties that have adequate strength to hold their shape after reforming, and/or impart an outwardly biasing force. The materials would also need to be acid resistant to withstand the acidic environment of the stomach. Elements of the device could be made of Nitinol, shape memory plastics, shape memory gels, stainless steel, superalloys, titanium, silicone, elastomers, teflons, polyurethanes, polynorborenes, styrene butadiene co-polymers, cross-linked polyethylenes, cross-linked polycyclooctenes, polyethers, polyacrylates, polyamides, polysiloxanes, polyether amides, polyether esters, and urethane-butadiene co-polymers, other polymers, or combinations of the above, or other suitable materials. For good distribution of stress to the stomach wall or to reduce contact friction, the device could be coated with another material or could be placed into a sleeve of acid resistant materials such as teflons, PTFE, ePTFE, FEP, silicone, elastomers or other polymers. This would allow for a small wire to be encased in a thicker sleeve of acid resistant materials to allow for a better distribution of force across a larger surface area. The device could take many forms after it reshapes.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a side view of an embodiment of a bariatric device located within a cross-section of a stomach.
FIG. 2A depicts a front view of an adjustment mechanism for an embodiment of the present invention.
FIG. 2B depicts a side view of an adjustment mechanism for an embodiment of the present invention.
FIG. 2C depicts a front view of an adjustment mechanism for an embodiment of the present invention.
FIG. 2D depicts a side view of an adjustment mechanism for an embodiment of the present invention.
FIG. 3A depicts a top view of an embodiment of the bariatric device of the present invention.
FIG. 3B depicts a side view of an embodiment of the bariatric device of the present invention.
FIG. 3C depicts a side view of an embodiment of a bariatric device of the present invention located within a cross-section of a stomach.
FIG. 4A depicts a side view of an embodiment of a bariatric device of the present invention located within a cross-section of a stomach with a modular adjustment mechanism.
FIG. 4B depicts a top view of an embodiment of the bariatric device of the present invention with 2 modular adjustment mechanisms.
FIG. 4C depicts a top view of an embodiment of the bariatric device of the present invention with 1 modular adjustment mechanism.
FIG. 4D depicts a front perspective view of a modular adjustment mechanism from FIG. 4A .
FIG. 4E depicts a front perspective view of a modular adjustment mechanism from FIG. 4A .
FIG. 5A depicts a side view of an embodiment of the bariatric device of the present invention with an adjustment mechanism located within a cross-section of a stomach.
FIG. 5B depicts a top view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 5C depicts a top view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 6A depicts a side of an embodiment of a bariatric device of the present invention with an adjustment mechanism and a retractable leash located within a cross-section of a stomach.
FIG. 6B depicts a top view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 6C depicts a top view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 7A depicts a side view of a T-bar in the undeployed state.
FIG. 7B depicts a side view of a T-bar in the deployed state.
FIG. 7C depicts a side view of a fixation element in the undeployed state.
FIG. 7D depicts a side view of a fixation element in the deployed state.
FIG. 8A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism located within a cross-section of a stomach.
FIG. 8B depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism located within a cross-section of a stomach.
FIG. 8C depict a close up side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the adjusted state.
FIG. 8D depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism located within a cross-section of a stomach.
FIG. 8E depicts a perspective view of an embodiment of the bariatric device of the present invention.
FIG. 9A depicts a side view of the embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 9B depicts a close up of the adjustment mechanism of 9 A.
FIG. 9C depicts a side view of the embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 9D depicts a close up of the adjustment mechanism of 9 A.
FIG. 10A depicts a remote controller of an embodiment of the present invention, worn next to the user's body.
FIG. 10B depicts a remote controller of an embodiment of the present invention, used without wearing or placing adjacent to the body.
FIG. 11A depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 11B depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 12 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 13A depicts a side view of a fixation element.
FIG. 13B depicts a side view of a fixation element in the undeployed state.
FIG. 13C depicts a side view of a fixation element in the deployed state.
FIG. 13D depicts a side view of a fixation element in the deployed state.
FIG. 13E depicts a side view of a fixation element in the undeployed state.
FIG. 13F depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 13G depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 14A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 14B depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 14C depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 15A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 15B depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 15C depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism.
FIG. 16A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism, located within a cross-section of a stomach
FIG. 16B depicts a variation of the adjustment mechanism in FIG. 16A .
FIG. 16C depicts a variation of the adjustment mechanism in FIG. 16A .
FIG. 16D depicts a variation of the adjustment mechanism in FIG. 16A .
FIG. 17A depicts a side view of an embodiment of the bariatric device of the present invention, located within a cross-section of a stomach
FIG. 17B depicts a side view of an embodiment of a bariatric device of the present invention in the undeployed state.
FIG. 17C depicts a side view of an embodiment of a bariatric device of the present invention in the deployed state.
FIG. 17D depicts a side view of an embodiment of a bariatric device of the present invention in the deployed state.
FIG. 18A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism, located within a cross-section of a stomach.
FIG. 18B depicts a top view of an embodiment of a bariatric device of the present invention with an adjustment mechanism, located within a cross-section of a stomach
FIG. 18C depicts a side view of an embodiment a bariatric device of the present invention with an adjustment mechanism in the deflated state.
FIG. 18D depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the inflated state.
FIG. 18E depicts a front view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the deflated state.
FIG. 18F depicts a front view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the inflated state.
FIG. 19 depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism, located within a cross-section of a stomach.
FIG. 20 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 21A depicts a backside perspective view of an embodiment of the bariatric device of FIG. 20 .
FIG. 21B depicts a front view of an embodiment of the bariatric device of FIG. 20 .
FIG. 22 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 23A depicts a backside perspective view of an embodiment of the bariatric device of FIG. 22 .
FIG. 23B depicts a front view of an embodiment of the bariatric device of FIG. 22 .
FIG. 24A depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the unexpanded state.
FIG. 24B depicts a side view of an embodiment of a bariatric device of the present invention with an adjustment mechanism in the expanded state.
FIG. 25 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 26 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
FIG. 27 depicts a side view of an embodiment of a bariatric device of the present invention, located within a cross-section of a stomach.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
The most basic embodiment of the 3 element bariatric device 10 is shown in FIG. 1 , where the device consists of an esophageal element 36 , cardiac element 12 , and a connecting element 25 between the esophageal and cardiac elements. In this embodiment, the esophageal and cardiac elements 36 , 12 are separate structures, and do not form a contiguous surface, but instead are connected by the third separate structure, the connecting element 25 . Such a non-contiguous structure may be referred to in the claims as “dis-contiguous.” This device may require fixation to the stomach and/or esophagus to hold it in place to allow it to induce a satiety response and to prevent it from migrating. The fixation element 31 shown in FIG. 1 comprises a fixation connector 71 (which may be a suture or other suitable connector), coupled with the esophageal element 36 by a first anchor 70 , and coupled with the cardiac element 12 by a second anchor 72 . As will be discussed below, a fixation element 31 may comprise many variations and combinations of anchors and/or fixation connectors. This embodiment delivers direct force to at least one of the following 1) the abdominal portion of the esophagus 2) the esophageal-gastric junction, and 3) the proximal cardiac portion of the stomach; and the force delivered is adjustable through a variety of means to match the individual needs of the patient. To improve the ease of adjustment and the accuracy of the adjustment, the device could be adjusted by manual or automated means.
In another embodiment, the device may have a single structural element for applying force to the upper stomach or cardia. This device may be fixed into the cardia, fundus, body or pyloric region of the stomach. To further improve the satiety response of this device, it may contain an adjustment of this single element to increase or decrease the amount of force applied to the upper stomach.
The bariatric device in either the three -or single-element embodiments may be self expanding. FIG. 1 depicts an embodiment where the cardiac and esophageal elements 12 , 36 are self expanding. These elements could be self expanding or have a portion that is self expanding to allow the device to flex with peristalsis, but maintain tension to spring open to apply pressure or contact and position within the stomach. The self expanding portion could be made of Nitinol, silicone, polyurethane, PTFE, Teflons, stainless steel, super alloys or other suitable materials or combinations of suitable materials. A Nitinol wire mesh pattern 50 can be applied to a frusto-conical shape to create a shell. The Nitinol wire may act as a stiffening member within the cardiac and esophageal elements 12 , 36 . The Nitinol wire could be arranged in many different patterns to allow for the appropriate amount of self expansion while allowing the element to compress during peristalsis. The array pattern could include circular arrays, angular arrays, linear arrays, or other suitable arrays. The pattern could be woven or a continuous spiral.
The self expanding function may also assist in deployment by allowing the device to compress and then regain its shape. A preferred method of deployment is to compress the bariatric device into a long narrow shape, which is then placed in a deployment tube, sheath or catheter. The collapsed and encased device is then guided down the patient's esophagus and into the stomach, where the bariatric device is released from the deployment tube or catheter. Once released, the device would expand to its original operational shape. The stiffening member, such as Nitinol wire, may provide adequate stiffness to expand the elements into their operational shape, and maintain that general shape during operation, while allowing flexibility to accommodate peristalsis.
As mentioned above, a preferred device has adjustability or adaptability to match any changes in the patient over time. A variation of the above embodiments would be to allow the device to be adjustable via an adjustment element. This adjustability could be in the length, shape, angle or stiffness of the cardiac 12 , esophageal 36 , connecting 25 , and/or fixation elements 31 . Adjustability may be a desirable feature, whether manual or automated. For the present device, there may be numerous adjustment mechanisms. For example, it may be desirable to change the distance between the cardiac 12 and esophageal 36 elements to change the overall length of the device to increase compression of the cardia. This could be achieved by adjusting the length of the connecting element or the fixation element. For the three element device, the adjustment mechanism could be located on the esophageal, cardiac, connecting or fixation elements or any combination of the above. In all cases, the actuation mechanism could be enclosed in a sheath or tube to protect the stomach and to encase the actuation mechanism as needed. A sheath may not be required if the actuation mechanism is designed with smooth contours on its own.
Manual Adjustments:
As mentioned, the adjustment could be applied along the fixation element 31 that holds the device in place or to the connecting element 25 . For example, where the fixation connector 71 is a suture, it could thread through a holding feature (an anchor 72 ) located inside the stomach such as a disk or button. This button (anchor 72 ) could contain a threaded locking pin or a spring loaded locking pin 21 . See FIGS. 2A, 2B, 2C, and 2D . When an adjustment is required, the pin 21 could be released and the suture could be grasped with an instrument and pulled to change the suture length. When the proper length had been achieved, the locking pin 21 could be repositioned to lock the suture into place. The holding feature could also have a winding element 23 to allow the suture to be wound into the holding feature to reduce the length. Similarly, the suture could have positional features such as knots or bead that could be pulled through a cord stop feature and would prevent the suture from pulling backwards.
It may also be desirable to change the shape of the device, such as to increase the diameter or angle of the device. It may also be desirable to increase or decrease the stiffness of the device to increase resistance of the device against the tissue. This could be achieved by a modular stiffening member 24 or a modular piece. See FIGS. 3A, 3B, and 3C . The stiffening member could be fixed with a suture or placed into a connection pocket, or modular connector 39 after the device was in place to add additional stiffness to the proximal cardia. The stiffening member 24 could be in the shape of a tear drop or oval and be relatively flat in profile. The stiffener could be placed on the outside or inside surface of the cardiac element. When the stiffener was connected to the device it will flex to the curvature of the cardia and fundus and act like a spring to apply additional pressure against the proximal cardia or upper stomach. The preferred material for this member would be Nitinol, but could be made from other materials. This member could be made of a variety of shapes, profiles and stiffnesses. This feature could also be achieved by applying a spacer or conical liner 26 to the existing cardiac element. This piece could have a different profile or stiffness and attach to the existing fixation to apply to greater force to increase resistance.
Another variation of this embodiment would be to allow spacers 26 to be placed in between the cardiac element and the cardiac wall. Such a spacer 26 may fit into a pocket or feature of the cardiac element to apply outward force for additional pressure against the cardia. The spacers could be made from solid or hollow sections of polymers, silicone, foam, wire mesh or the like. The spacers could also be constructed of self expanding Nitinol features or springs that could apply pressure to the cardia or upper stomach, but give during peristalsis. See FIGS. 4A, 4B, and 4C . These self expanding Nitinol spacers 26 could have a variety cross-sectional shapes, angles, and resistance to allow for a range of compression to be applied to the cardia. See FIGS. 4D, and 4E . Such Nitinol spacers 26 may be wire mesh, coated wire mesh, a wire mesh incorporated into a material such as silicone, or other suitable construction to maintain its shape while retaining some flexibility. FIG. 4B shows an example where multiple spacers 26 could be used to fit in between the fixation element 31 or one large spacer 26 could be used as shown in FIG. 4C . The spacer 26 could be removed endoscopically with a collapsing drawstring and then replaced with a different spacer 26 to change the amount of pressure applied to the cardia or upper stomach. As shown in FIGS. 4D and 4E , the spacer 26 could be self expanding material, shaped like a one sided arch, a hemicone, a hemi-frusto-cone, a generally conical shape or other suitable shapes.
Another variation would be to have a spacer 26 in the form of an inflatable body 27 attached to the top of the cardiac element in the cardia or upper stomach. See FIGS. 5A, 5B, and 5C . The inflatable body 27 could be in the shape of a portion of a frusto-cone to provide local focused adjustment to the proximal cardia. There could be several spacers 26 in the form of inflatable bodies 27 attached by a fluid path as in FIG. 5B or there could be one inflatable body 27 as in FIG. 5C . This may be advantageous depending on where the fixation element 31 is attached to the device, the cardia and esophagus. This inflatable body 27 could be accessed through a self sealing membrane or inflation element 28 . The self sealing membrane could be an injection port or it could be a self sealing surface on the inflatable body 27 , or the entire inflatable body 27 could be comprised of a self sealing surface. In all descriptions below, the term inflation element can also refer to an injection port or to an area on the inflatable body 27 with a self sealing membrane. The self sealing membrane could also be a self sealing valve such as a slit valve which can be accessed by a blunt needle or tube to allow access to add or remove fluid. FIG. 5A shows an inflation element 28 that is attached to the device and can be accessed by a blunt needle or small tube instrument to add and remove fluid. As fluid is added, the inflatable body 27 inflates in profile to compress the cardia to create a sensation of satiety.
An alternative would be to have an inflation element 28 that is attached by a length of tubing 29 . The tubing 29 could be straight or coiled. FIG. 6 shows a coiled tube or retractable leash 29 with an inflation element 28 or valve attached to the end of the leash. This would allow the leash to be accessed endoscopically by an instrument, and then extracted up the esophagus for access outside the body. Using an instrument, the inflation element 28 or valve could be accessed to add or remove fluid, and then placed back down the esophagus and into the stomach.
Another embodiment to adjust the length of the fixation element 31 or connecting elements 25 could use spacers. In this embodiment, the fixation element 31 may employ a first anchor 70 with a fixed profile, a connector 71 , and a second anchor 72 that can change in profile in the form of a toggling T-bar 20 as shown in FIGS. 7A and 7B . Alternatively, the anchor 72 could be equipped with a collapsible basket 30 that can change profile from long and narrow for pushing through a small opening and changing provide to wide and flat to secure the anchor as shown in FIGS. 7C and 7D . Either the T-bar fixation 20 or the collapsible basket fixation 30 allow the fixation to pass through the esophageal member, esophagus, cardiac member and cardia and then allow then change the profile of an anchor 72 inside the stomach. For example after placement, the T-bar 20 could be grasped and then modular spacers placed above it to adjust the tension placed on the suture and cardia. FIG. 8A shows a spacer 26 above the T-bar 20 connection. Other means of fixation could also be used. The spacer 26 could also be an inflatable body 27 that could expand to act like a spacer to apply more compression to the cardia. This inflatable body 27 could be accessed through an inflation element 28 , not shown, to add or remove fluid. See FIGS. 8B and 8C .
Another variation of a 3 element embodiment is shown in FIG. 8D and has elements that contact the lower esophagus and the proximal cardia. FIG. 8D shows a side view of this embodiment and 8 E shows an isometric view. The esophageal element 36 that contacts the lower esophagus could be a portion of a steep frusto-cone or tube. The cardiac element 12 could be a portion of a flattened frusto-cone or tube. Although the esophageal and cardiac elements of this embodiment are shown as portions of frusto-cones, the members of these elements could be a variety of different shapes, including substantially planar. One of the features of this embodiment is an esophageal and cardiac elements are non-lumenal, meaning they do not form a lumen. These esophageal and cardiac elements could be constructed of silicone, a combination of silicone and Nitinol, or other suitable materials or combinations of materials. These esophageal and cardiac elements could be connected by a shaped connecting element 25 such as a wire form, strut or could be seamlessly integrated into one piece such as with narrow panel. The portion that connects the esophageal and cardiac members could be formed in a right angle or less (an acute angle) to apply compression to the upper cardia. The portion of the connecting element that passes through the gastroesophogeal junction may be low profile to allow the esophageal sphincter to close. FIG. 8E shows an example of the connecting element 25 as a shape set Nitinol wireform with an angle. Since the wireform is low profile made with small diameter wire, the wires could flex and would allow the GE junction to close during peristalsis. The device would be collapsible so it could be placed down the esophagus and then fixed into place from inside the esophagus for a fully endoscopic procedure. The fixation element 31 could comprise one or more fixation connectors 71 held in place by anchors 70 , 72 . The anchors 70 , 72 could be fixed to the esophageal and cardiac elements 12 , 36 alone, or could be fixed to those elements and the esophagus and upper stomach or cardia, or any combination thereof. Then the fixation connector 71 can be passed from inside the esophagus through the esophageal member 36 of the device through the cardia to the cardiac member 12 to fix it in place. See FIG. 8D . More than one point of fixation could be placed to hold the device in place and to apply pressure to the upper stomach.
This device could then contain several types of adjustments. For example, the fixation element 31 that attaches the device in place could comprise an anchor comprising a toggle T-bar 21 . This would allow the toggle to pierce through the esophageal member 36 , esophagus 32 , cardiac member 12 and cardia and then allow the toggle to rotate to create fixation inside the stomach. After placement, the T-bar 21 could be grasped and then a modular spacer or spacers 26 placed above it to adjust the tension placed on the suture and cardia. FIG. 8D shows a spacer 26 above the T-bar 20 connection. Other means of fixation could also be used. The spacer could also be an inflatable member that could expand to act like a spacer to apply more compression to the cardia as shown in similar previous embodiments. This inflatable member could be accessed through an injection site 28 to add or remove fluid.
Another adjustment feature could be to place a spacer 26 in the form of an inflatable member 27 on top of the cardiac element 12 of the device that could be accessed through an inflation element 28 . This inflation element 28 could be a self-sealing septum of a port or it could be incorporated into the balloon surface itself. The inflation element 28 could also be a valve, which may include a self-sealing membrane, that can be accessed by a blunt ended needle to allow fluid to be added or removed. As mentioned previously, the inflation element could be connected to the inflation member 27 by a tube and this tube could be straight tubing or coiled tubing 29 to allow the valve to be pulled up the esophagus and accessed outside the body. As fluid is added the balloon inflates in profile to compress the cardia to create a sensation of satiety. Similarly, fluid could be removed to reduce the sensation of fullness. FIGS. 5A, 5B 5 C 6 A, 6 B and 6 C,show how a similar balloon could perform on this embodiment.
Another variation of this embodiment would be to allow spacers 26 to be placed into a pocket or feature of the cardiac element 12 to apply outward force for additional pressure against the cardia. The spacers could be made from solid or hollow sections of polymers, silicone or foam. The spacers could also take the form of a shape set self expanding Nitinol feature that could apply pressure to the cardia, but give during peristalsis. These self expanding Nitinol features could have a variety cross-sectional shapes, angles, and resistance to allow for a range of compression to be applied to the cardia. As shown in FIGS. 4A, 4B, 4C, 4D and 4E , the spacer 26 could be self expanding material, shaped like a one sided arch, a hemicone, a hemi-frusto-cone, a generally conical shape or other suitable shapes. The spacer 26 could be removed endoscopically with a collapsing drawstring and then replaced for a different spacer to change the amount of pressure applied to the cardia.
Another embodiment of this device could allow the connecting element 25 to be modular and replaceable with different angles or positions to increase the compression on the esophageal and cardiac elements 36 , 12 . The esophageal and cardiac members 36 , 12 could both be fixed as shown in FIG. 8D , but the connecting element 25 could be modular. The connecting element 25 could comprise a wire, such as a shape set Nitinol wire that could fit inside of a pocket or feature on the esophageal element 36 and also fit into a pocket or feature on the cardiac element. The wire would attach and apply pressure to the cardia based on the shape set angle. If the pressure were not great enough, the connecting element 25 could be removed and replaced with another that had a more acute angle. Similarly, there could be several positional features of pockets to allow a variety of assembly lengths, angles and configurations with the modular connecting element in place. In another variation, the shape set wire could attached directly to the fixation and not require a separate esophageal or cardiac element. Although Fig, 8 E shows a connecting element made from a single member, the connecting element could be comprised of several members to allow for ease of modularity or attachment.
The device could also be adjusted by other manual means by using a gastroscopic instrument to come into direct contact with the device, in order to adjust the pressure applied by the cardiac element to the cardia wall.
The instrument could act as a screw driver to rotate a member to thread the two elements closer or farther apart. The instrument could also act as a pusher or puller to activate a pulley mechanism or a clipping mechanism. For example, the third element could be strut with multiple positional features such as holes, grooves, teeth or wedging. The device could have a feature to engage the ratchet teeth or positional features such as a pin or clip. The instrument could retract the pin or compress the clip and then reposition this feature in the next available location. The instrument could also deliver heat directly to a heat-expanding mechanism (such as one made of Nitinol) for expansion, or a wax or wax-like expansion member.
For example, the Nitinol clip could clip into a positional location on the strut. The instrument could heat the clip to release and then reposition it into a different location, remove the heat and allow the clip to re-engage the positional feature to lock it into place.
The instrument could also have an inflatable balloon to allow for physical contact with the device to disengage a feature for repositioning into another location. There could be several other means for manually actuating the design for repositioning.
As another variation of the above embodiments, the manual expansion mechanism could be adjusted remotely by an apparatus outside the body, and/or automated. The expansion could be achieved by a small motor that could be driven by an implanted power source or driven by a remote power source such as induction. Energy could also be supplied by an RF signal, kinetic energy, ultrasound, microwave, cryogenic temperatures, laser, light, or thermal power. Power could also be supplied by a battery or implantable power cells that utilize glucose or other means for fuel.
The automated expansion could also be achieved by a pump, a syringe type plunger, a piezoelectric crystal, a bellows, a Nitinol motor, a pH responsive material that changes shape, thermal expansion of a gas, fluid or solid (example wax) expansion, magnet forces or any other type automated expansion or compression mechanism.
The control for activating this mechanism could be a remote control using a radiofrequency signal which can pass through tissue. The remote control could also be achieved by magnetic fields, time varying magnetic fields, radio waves, temperature variation, external pressure, pressure during swallowing, pH of any frequency or any other type of remote control mechanism.
Actuation Elements
Stepper Motor:
To adjust the distance between the cardiac and esophageal elements 12 , 25 to increase the direct force onto the upper stomach or cardia, thereby adjusting the pressure applied by the cardiac element to the cardia wall, the adjusting element could modify the length of the fixation or connecting element 31 , 25 . These elements could be entirely or partially comprised of a flexible, semi-flexible or rigid screw 33 . An actuation element, such as a stepper motor 34 could be placed onto the flexible thread and could drive forward or back to allow the fixation and/or connecting element to draw together or push apart the elements. See FIGS. 9A and 9B . These figures represent a threaded element that can be drawn together or apart. As an alternative, the motor could be modified to contain a lumen to accept a suture or flexible connecting member 71 with a fixation anchor that changes profile 72 or another means of fixation that can pass through a lumen and then expand beyond the lumen for fixation.
The adjusting element may require power to drive the actuation element, in this case the motor. The power could be supplied by an implanted power source such as a battery or it could be powered externally by induction through the coupling of an external antenna and an internal antenna.
An option would be to embed the internal antenna into any or all of the elements. This would allow for fewer structures in the design by encasing the antenna inside of one or more of the existing elements. The antenna could be a simple ring at the top or bottom or obliquely on either element or it could be placed in the wall of the device. The internal antenna could also be attached by a tether, free floating inside the esophagus, stomach or intestine. These could be made from materials to make them MRI compatible and/or MRI safe. This feature could be applied towards any actuation method where it is powered by induction.
For induction, an external hand held controller 86 may be required to transmit power for coupling. See FIGS. 10A and 10B . The controller 86 could be set up to auto detect the internal antenna's presence and identify when coupling between the two antennas was adequate to allow for transmission and powering to take place, and to inform the user of function. This external controller 86 could then be used to display the distance that the stepper motor had been advanced or retracted to allow the physician to control the adjustment. Similarly, the external controller 86 could be used for communication and control signals as an interface between the physician and the placed device. This feature could be applied towards any actuation method powered by induction.
An external antenna would be required for induction and could be placed into an external handheld controller 86 . This could be placed directly against or close to the patient's body at the height of the internal bariatric device. See FIG. 10A . The antenna could be housed with the other controller electronics in a single unit. This feature could be applied towards any actuation method powered by induction.
Another alternative would be to have the external antenna in the form of a belt 87 that would wrap around the patients abdomen at the height of the device to better align the antennas for improved coupling. This feature could be applied towards any actuation method powered by induction. See FIG. 10B .
The location of the actuation mechanism could also be inside any of the elements, or above or below any of them, or another location as would be best suited for the anatomy and function of the device. This feature could be applied towards any actuation method. Actuation could be accomplished by allowing the screw to be pushed or pulled inside any of the elements to embed the adjustment mechanism internally to one of the other elements. Other actuations mechanisms such as those listed above or others could also be used for this adjustment.
Induction could also be powered by an intragastric instrument. The instrument could have a flexible shaft that could fit through the mouth and down the esophagus or down the working channel of a gastroscope. Once the instrument was placed within or near the esophagus or stomach, it would allow the instrument to be in close proximity with the actuation mechanism in the device. The end of the instrument could have antenna(e) to allow for inductive powering and/or communication with the actuation mechanism for adjustment. This feature could be applied towards any actuation method.
Piezoelectric Motor
The adjustment for adjusting the pressure applied by the cardiac element to the cardia wall could also be achieved by a piezoelectric element or motor. See FIGS. 9A and 9B . These figures represent a threaded element that can be drawn together or apart. This feature could be applied to the connecting or fixation elements.
There are several types of piezomotors that could be used for linear actuation. For example, a motor from NewScale Technologies (www.newscaletech.com) called the Squiggle Motor could be used which is very low profile and can be actuated when powered. Other motors or actuation mechanisms could also be used, and the Squiggle motor is just used as an example. In this example, there is a rigid screw 33 that passes through the center of a threaded piezoelectric “tube” or element. When powered the piezoelectric element flexes side to side along the central axis to create an oscillating “hula hoop” action which causes it to translate axially along the rigid screw 33 . The Squiggle motor could be attached to the esophageal, cardiac, connecting element or fixation elements 36 , 12 , 25 , 31 to advance or retract the cardiac and/or the esophageal elements 36 , 12 . Alternatively, the Squiggle motor could be placed in between any of the elements. Alternatively, more than one Squiggle motor could be placed at these locations. One of the advantages of a piezoelectric motor is that it would allow the device to be MRI compatible and safe. As mentioned with the stepper motor 34 above, the piezoelectric motor could be powered by an internal power source such as a battery or it could be powered by remote induction. The remote induction could be by a handheld external controller 86 or it could be by a gastroscopic instrument placed down the esophagus. This motor could be encased in other materials to keep it dry and protected from the stomach environment.
Another embodiment of a piezoelectric actuated motor would be to have a rotating piezoelectric member that could thread along one or two threaded members similar to a worm gear.
Another embodiment of a piezoelectric actuated motor would be to have a piezoelectric crystal that elongates or flexes to actuate another member.
All of the piezoelectric motors may contain a sealed housing such as an expandable metal or plastic bellows to prevent moisture of fluid from contacting the piezoelectric elements.
Magnetic Actuation
As mentioned above in the manual adjustment section, another adjustment mechanism for adjusting the pressure applied by the cardiac element to the cardia wall could use magnets.
For example, at least a portion of the connecting or fixation element 25 , 31 could be a semi-flexible thread or rigid threaded member 81 with a magnetic nut 79 placed over it. Another strong magnet, named a controller magnet 80 , could be placed in close proximity to the implanted magnet nut 79 to cause it to rotate. The rotation of the controller magnet could create a magnetic field which would cause the internal magnet to turn allowing it to advance and retract along the threaded member. See FIGS. 9C and 9D .
The controller magnet 80 could either be external to the body or it could be placed on the end of a gastroscopic instrument for close proximity.
The controller magnet 80 could be a magnet or an electromagnet to increase the intensity of the field and to improve magnetic coupling to ensure actuation.
The controller magnet 80 could also be multiple magnets to improve magnetic coupling.
Nitinol Actuation
The adjustment element could also be actuated by Nitinol or a substance with similar properties. When a current is passed through Nitinol, it heats and causes the Nitinol to change its shape. Nitinol can expand into a variety of different shapes. A linear actuator could be made from Nitinol to advance or retract along an actuation member.
Heat could be generated from an implanted battery or it could be delivered by induction.
The cardiac, esophageal, connecting or fixation 12 , 36 , 25 , 31 element could have multiple positional features such as holes, grooves, teeth or a wedging feature. A Nitinol clip could have a feature to engage these positional features. The Nitinol clip could be heated to change shape to allow it to advance or retract into different positional features to increase or decrease the length.
There are other Nitinol actuations that could be provided as well.
Ultrasound Motor
Another adjustment mechanism could be by use of an ultrasound motor or one powered by external ultrasound. This could use external ultrasound equipment to send sonic waves into the body to actuate the motor. This would also provide an MRI compatible option without requiring an internal power source or induction.
Hydraulic Actuation
The adjustment element could also be actuated through hydraulic means for radial expansion, linear actuation, shape change or stiffness change as previously described. The cardiac or esophageal element 12 , 36 could be inflated with a fluid to increase the profile, diameter or length of the device to increase pressures against the upper stomach or cardia. It could increase in volume by accessing a self sealing membrane such as a self sealing drug delivery port, self sealing membrane on the expandable body, or a self sealing valve attached to the device. The inflation could be achieved by a piezoelectric pump, a peristaltic pump, a positive displacement pump or a syringe pump.
Piezoelectric pump: The pump could be comprised of a piezoelectric element which can flex to propel fluid directly or a member that could propel fluid. For example, a piezoelectric disk could be captured in a housing with an incoming channel and an outgoing channel. The disk could be powered to cause it to flex into a dome shape to push fluid into the outgoing channel. A valve would be required to close the incoming channel to ensure directional flow to the outgoing channel. Similarly, the piezoelectric Squiggle motor as described above could be used to linearly actuate a fluid up or down a tube to hydraulically actuate position.
Stepper motor pump: Actuation could be achieved by a stepper motor where the motor linearly actuates to compress a reservoir or syringe to move fluid within a tube or constrained volume.
Wax expansion pump: Fluid could also be propelled by a wax expansion mechanism. When wax is heated to melting it expands by approximately 30%. A solid plug of wax could be heated to expand and drive fluid through a valve to hydraulically actuate lengthening. The lengthening structure could be made to move only in one direction, so that when the wax cools it will not contract. The wax expansion could also be used to actuate other adjustment mechanisms.
Peristaltic pump: The members could also be driven by a peristaltic pump. In this mechanism, the external diameter of a cylindrical actuator could be used to compress a length of tubing to create an occlusion. The cylindrical actuator could be rotated along the tube to drive fluid forward or backwards inside the tube. The peristaltic pump could also be actuated by a stepper motor or by a piezoelectric element or other.
Gas expansion/propellant pump: The length could also be actuated by a gas expansion pump where a gas like Freon or others could be used to expand when exposed to a higher temperature. Similar principles to the devices like the Codman pump could be used. This change in volume could drive the pump forward. Similarly, there could be compressed gas constrained in a pressure vessel with a valve. The valve could be remotely activated to allow gas to propel a syringe, fluid or to compress a constrained volume.
Positive displacement pump: There are implant grade positive displacement pumps that are available on the market for drug delivery that could be used to displace a specific amount of fluid for hydraulic inflation of the adjustment element.
Syringe pump: A syringe pump could be made by advancing fluid through a syringe. The syringe could be actuated by a stepper motor, a piezoelectric actuator, a magnet or by a Nitinol actuator as described above.
Hydrogel: the adjustment element could also be inflated by use of a hydrogel to absorb fluids and could be actuated by changes in temperature, pH or tonicity to change shape or volume
Hypertonic fluid: the adjustment element could also be inflated by using a hypertonic fluid in the inflation area and allowing it to absorb fluid across a semi permeable membrane.
Mechanical means for diametrical or profile changes. Similar to the inflation, elongation, and shortening embodiments described above, the device could change diameter by various actuation mechanisms. All of the above-described mechanisms could also be adapted for use for a diametric change instead of a linear change.
As a variation of the embodiments discussed above, the device could have a sensor that could sense a parameter such as pressure, motion, peristalsis, tension, pH, temperature, chemical or other appropriate parameters, or various parameter combinations. The sensor could output a signal to be used by an actuation element to actuate an adjustment element, to a memory element such as a microchip, or be read by a remote reader or remote controller.
Sensors 88 could be used to gather important patient data to understand fit, performance, patient status, whether an adjustment needs to be performed, and as a guide while an adjustment is performed. For ease of use and compatibility with the body, wireless sensors would be preferred. In some applications, it may be desirable to sense a parameter without the need for adjustability. In other applications, adjustability for adjusting the pressure applied by the cardiac element to the cardia wall may be a desirable feature. The sensors 88 could be in direct tissue contact, intermittent tissue contact or could monitor the intraluminal pressure inside GI tract. The data could be used for no other reason than to just monitor patient status and performance. FIGS. 11A and 11B depict sensors 88 , which could be embedded in any of the element surfaces for direct tissue contact, non-tissue contact or it could be tethered to any of the elements to allow it to be suspended inside the GI tract. Based on the sensed parameter, the device could be adjusted. The adjustment could have an open or closed loop system increasing or decreasing the applied force, pressure or sensed parameter. The sensed parameter could detect whether the device was not at an ideal condition, and could then send a signal to a control mechanism for automatically adjusting the system. This mechanism could be under physician control (open system) or without physician control (closed system). The adjustment could also be a manual adjustment where the parameters are being monitored to guide the adjustment. It could also control the shape of the cardiac, esophageal, connecting, and/or fixation elements 12 , 36 , 25 , 31 to vary stiffness, size, length, form or shape. In general, the sensor 88 could sense a parameter and then adjust the device as needed to bring the sensed parameter into the ideal range. There could be an algorithm that controls the ideal parameter or it could be based on a parameter range. The device would be adjustable to meet the needs of the patient.
In an open loop system, the physician would have control of when the device would adjust the pressure applied by the cardiac element to the cardia wall. The device could have its own internal power source, or it could be passive and only inductively powered when in close proximity to an external controller 86 under the supervision of a physician. For example, in the clinic the physician could have a remote controller 86 with the ability of powering the device inductively, and then begin to monitor the sensors 88 feedback signals to see physical parameters of the patient at baseline such as pressure of the device against the cardia. The sensor monitoring could also be performed while the patient is eating or drinking, or not eating or drinking As the patient consumes, the esophageal and stomach peristaltic waves will increase in intensity as they propel the food or drink from the mouth to the stomach. A sensor 88 could detect when these waves increase in amplitude, frequency, and pressure. The parameter could read on the external controller by the physician, and then the physician could send a signal to the automated expansion mechanism in the device to adjust the device. The physician could then query the sensor 88 again to determine whether the device was in the ideal settings and whether the pressure against the cardia or sensed parameter was optimized. The physician could iteratively control the amount of adjustment and monitor the parameters until the ideal condition was met. Where the device has its own power source, the physician would still have the control to wake up the device, query the sensors and then adjust the device as described above. The only difference would be that the device was powered by the power source and not require inductive power from outside.
Alternatively, the physician could read the parameter signals while under his supervision, but have the sensors 88 send a signal directly to the automated expansion mechanism to adjust the pressure applied by the cardiac element to the cardia wall until the device was within the ideal parameters. The data collected could be analyzed by the controller for averages, minimums, maximums and standard deviations over time and use an algorithm to determine the ideal settings. The controller could then monitor and adjust on its own until the ideal conditions were met, but while the physician was present to verify all conditions and verify patient acceptance.
In a closed loop system, the device would be active with its own integrated power source. The device could wake up at routine intervals to monitor or could monitor all the time. The data collected could be analyzed for averages, minimums, maximums and standard deviations over time and use an algorithm to determine the ideal settings. As the patient begins to consume food or drink, the device sensors would detect the sensed parameter and signal the automated expansion/contraction mechanism to adjust the device as needed. In this embodiment, the device could be fully automated and would not require intervention from an outside individual.
In either the open or closed loop system, there could be multiple sensors 88 on the device to determine the pressure or force areas, or other sensed parameters on the device and where it needs to be varied to meet the ideal conditions for the stomach. In the case where the fixation and/or connecting 31 , 25 element has multiple members, this could be used to align the device in the stomach to provide a custom fit and response for each person. There could also be a mechanism to adjust the alignment of the cardiac and/or esophageal elements 12 , 36 relative to the connecting and/or fixation elements 25 , 31 . The sensor(s) 88 could have a built in power source or it could have a remote power source such as induction so that it would only wake up and activate when an external controller was brought near.
The device could have integrated memory to allow storage of patient and device data. This could include but is not limited to the serial number, the patient's information such as name, patient number, height, weight; the physician's name, the adjustment history including the date and time, the amount adjustment and the sensed parameters. For the active device, there could be 24 hour data recording of key parameters or there could be data collected at key intervals throughout the day to detect when the patient is eating and whether they are being compliant with their eating. It could record weight tracking, BMI or other data as needed which could be queried by an external controller. This data could also be downloaded into a physician's patient tracking database for ease of patient tracking Similarly, this data could be downloaded and tracked on an internet tracking website, where the patient could log on and see their history and progress. The patient could add information to the website such as weight or an eating log, adverse events or other conditions that the physician or patient would like to track.
In the open system, the physician could choose to collect and record data as needed at the time of the adjustment such as weight, date, time, and adjustment amount or other.
For an open loop system, the device could be adapted to allow for remote adjustments over the phone. This would be especially advantageous for patients living in rural areas where they are far from their physician's office. It could also be for convenience of having an adjustment without having to travel to the physician's office. This would allow a physician to discuss the patient's progress with the patient directly and then query the device sensor to see how the device performance is. Based on the feedback of the device, the physician could then adjust the patient.
In yet another embodiment, the device could have an emitter element for dispensing a drug, hormone or bioactive agent to further induce satiety, weight management or other disease management such as diabetes. The drug could be a weight management drug currently on the market or one to be developed. Similarly, it could be a satiety hormone or other bioactive agent. In the published literature, there is a growing mass of information on satiety hormones. The bioactive agent could be applied by the emitter element through a drug eluting coating, a reservoir with a pump, or a permeable membrane placed on the device where the drugs could pass from the device into the gut. The emitter element could release such substances in response to a signal from a sensor, a timed basis, or other release criteria. The device could have a tube that trails into the intestines to allow the drug to be delivered downstream where the pH is higher and would not destroy the bioactive agent.
The device could have a surface finish or macrotexture for gripping the stomach. If the device could grip the inner mucosa of the stomach or esophagus, it could elongate or expand to further stretch the stomach or esophagus in key areas to induce further satiety as needed. For example, the cardiac element could be a conical spiral or other shape with a surface texture that lightly grips the mucosa and or stomach musculature. If the spiral were made of Nitinol or other temperature-sensitive substance, the device could expand the spiral by a variation of temperature. By applying a temperature variation, such as by drinking a hot liquid or otherwise, the device could expand and cause a satiety response. The surface could be multiple protuberances, barbs, a rough bead blast, or other finishes suitable for gripping the stomach wall.
As a variation of the device, it could incorporate electrical stimulation to the stomach musculature, stomach nerves or the vagus to further improve satiety stimulation and weight loss. Energy used for this stimulation could be RF, ultrasound, microwave cryogenic, laser, light, electrical, mechanical or thermal. The device could have leads incorporated that could embed into the stomach wall or be surgically placed around a nerve, or the stimulation could be applied directly through surface contact of the device to the stomach mucosa.
Single Cardiac Member:
Another embodiment has a single cardiac member that is fixed to the cardia or other region of the stomach with an anchor and applies pressure to the cardia or upper stomach. All of the improvements described above including adjustability mechanisms, manual adjustability, remote adjustability, sensors, data collection, memory, and others may be applied to such devices.
For example, some bariatric devices have a member with a flat button anchor 70 with a T-bar 20 attachment into the cardia. In such a device, an adjustment feature may be applied to increase or decrease the amount of compression applied to the cardia. As mentioned above, several adjustment mechanisms for adjusting the pressure applied by the single cardiac member to the cardia wall could be used such as a stepper motor, a piezoelectric crystal element, hydraulic adjustments, gas or solid expansion, variable tension springs, Nitinol actuation, or any other adjustment noted above. Similarly, the device could be adjusted to change shape such as to increase the surface contact to the cardia or it could change the stiffness to increase resistance. All of these embodiments can be placed and removed endoscopically with a gastroscope and instruments down the esophagus.
FIG. 12 shows an embodiment of a single cardiac 13 member where one or more of these single cardiac 13 members could be fixed into the cardia directly at the site where pressure is to be applied. In this embodiment, there is a button anchor 70 with a connecting element 71 that pierces through the cardia with a T-bar 20 which then toggles flat to hold it in place. It also contains a flexible disk or distribution element 61 to distribute the load across a greater surface area than just the button. This also shows sensors 88 that could be located so they contact the patient's tissue or could be located on the outside of the device to monitor the intraluminal pressure. This could be used for monitoring the patient's baseline data, or gathering a variety of other data.
FIGS. 13A, 13B, 13C, 13D and 13C show several options of fixation elements 31 for fixing the single cardiac member 13 to the cardia. 13 A shows a corkscrew or tacker type fixation which would allow the device to be threaded into the place. FIG. 13B shows an elongated anchor 72 with multiple arms that are elongated and collapsed for placement, and 13 B shows the same device in its deployed state where the anchor 72 arms curl or spring into a wide, atraumatic profile. The arms are made of shape memory or super elastic material or spring material that changes shape once an elongation force is removed from the device. For example, the device may be placed into a sleeve that holds the curled arms straight. As the arms are advanced out of the sleeve, they puncture through the tissue and then change shape to hold the device in place. In a variation, FIGS. 13D and 13E show another anchor 72 that has shape memory or super elastic qualities where the deployed fixation element 72 shown in a flat spiral shape in 13 D, can be completely straightened by placing it into a sleeve and then advancing it until it pierces through the cardia and then springs back into the shape of 13 D. FIG. 13E shows the same fixation element with a slightly elongated shape 51 to allow it to pierce the cardia and then spring back into the shape in FIG. 13D . These are examples of fixation elements, and other mechanisms could be used for fixation.
FIGS. 13F and 13G show an adjustment element 60 that could be used for adjusting the length of the member across the cardia to control the amount of compression applied to the cardia, to adjust the pressure applied by the single cardiac member to the cardia wall. This embodiment shows a distribution element 61 to distribute load across a larger area. This distribution element 61 could be a flat, flexible disk or it could also be a conical shape, spherical, or other shape to improve load distribution or distribution profile across the area. The distribution element 61 could be of a variety of materials which are very soft to firm such as silicone, polymers, foams, Nitinol or it could be a combination of any or other suitable materials. This element could have a single central shaft or connecting element 71 as shown in FIG. 13F or it could have 2 connecting elements 71 that anchor the device for rotational stability as shown in FIG. 13G . The adjustment element 60 could rotate around a central shaft or it could rotate between the 2 shafts. Similarly, the element could have a plurality of shafts for fixing to the cardia.
FIGS. 14A, 14B, and 14C depict 3 different embodiments for actuating a single cardiac member 13 . Although the fixation anchor 70 is shown in the drawing as a button, the anchor could also be flat, conical, spherical or other shape. Several adjustment elements could be used for adjusting the pressure applied by the single cardiac member to the cardia wall. FIG. 14A shows a stepper motor 34 that is inductively powered and controlled. The stepper motor could then thread up and down the central shaft to compress the cardia tissue as needed. A sensor 88 could be applied to this embodiment. Optional locations for a sensor 88 are shown. As mentioned above, these embodiments could have 2 or more shafts. FIG. 14B shows a magnetic actuation for adjustment. In this embodiment, there could be a threaded magnetic element 79 that could be rotated by placing a controller magnet 80 in close proximity. As the controller magnet 80 is rotated, its magnetic field causes the magnetic element 79 to rotate. As mentioned above, the controller magnet 80 could be an electromagnet to increase the magnetic coupling or it could include multiple magnets. FIG. 14C shows a piezoelectric element 62 , where a piezoelectric element is able to oscillate and rotate to increase or decrease compression against the cardia. A piezoelectric element 62 could also be designed to flex to move the adjustment to different positional locations. FIG. 15A shows another piezoelectric element 62 . In this embodiment, the piezoelectric motor 62 is encased in a metal or sealed bellows 63 to seal the element from moisture, if needed. For all the embodiments, they may need to be encased in an acid-resistant and/or moisture resistant barrier. FIG. 15B shows a hydraulic and manual actuation mechanism. In this embodiment, the cardiac member has a self sealing membrane or inflation element 28 that connects to an inflatable balloon. By using a non-coring Huber tipped needle, the needle could be placed down the esophagus and pierce the self sealing membrane to inject or remove saline to expand or contract the balloon to alter the compression. The inflation element could also contain a self sealing valve. In FIG. 15C , another manual adjustment mechanism is shown where the threaded button 64 can be accessed by a screwdriver and rotated along the threaded member 81 . This would allow the button to be moved up and down to increase or decrease compression against the cardia. Any type of tool and screw or bolt head feature could be incorporated into the threaded button 64 , including Torx, Phillips, polygonal sockets or external bolt heads, or other suitable bolt or screw heads. Gripping feature such as macrotexture could be added to the cardia contacting surface of the fixation element 31 to grip the cardia to prevent it rotating while 64 was being rotated.
A sensor could be placed on the surface of on any element of the device to contact the patient's tissue, or not placed to contact the patient's tissue to gather intraluminal pressure of the stomach, esophagus or intestinal tract, or placed to contact the tissue intermittently. The form of the device could be a single button attached to the cardia or it could be a device with a wall or coil that shapes a cone.
Another alternative would be to connect several single cardiac members with another element such as a loop, band or balloon. See FIG. 16A . In this case, the loop or single cardiac connecting element 65 could be adjusted in length to create a force against the single cardiac member 13 to increase tension against the device, thereby adjusting the pressure applied by the single cardiac member to the cardia wall. The length of the loop could contain an adjustment element 60 which could be expanded to create a greater stretch to engage the stretch receptors. The length of the loop could also be reduced to engage the stretch receptors. The element could pass through a hole or engage a feature in each of the single cardiac members 13 . The length of the loop could be adjusted by all of the various methods already described in this invention such as using a stepper motor, magnetic actuation, a piezoelectric element, hydraulic adjustments, gas or solid expansion, variable tension springs, Nitinol actuation, or any other adjustment noted above. FIGS. 16A, 16B, and 16C shows options for adjustability such as use of a motor 34 , magnetic actuation of a magnetic nut 79 by a controller magnet 80 or an expansion joint 75 using inflation by a linearly expanding balloon, but other options for adjustability may be used.
FIGS. 17A, 17B, and 17C show an embodiment of a cardiac button 82 which comprises a plurality of penetration prongs 83 which are preferably claw like structures with two ends, hingeably coupled at one end with a coupling element 84 in a generally radial pattern. The generally radial pattern could also vary from true radial, such as 2 sets of parallel prongs at the corners of a square. The penetration prongs 83 could have a long narrow profile, and could be straight, curved, or have a hook or curl at the free end. When the penetration prongs 83 are in an expanded state, their free ends may extend beyond the diameter of their connection point to the cardiac button 82 , giving them a splayed appearance as in FIG. 17B . When in a compressed state the free ends of the penetration prongs 83 may approach each other and may even touch, as shown in FIG. 17C . The penetration prongs 83 could be made of a material with spring or super elastic properties to allow them to compress, or a spring mechanism may be incorporated into the cardiac button 82 . The penetration prongs may be compressed into the closed state for placement into the cardiac tissue, and then expand into the deployed open state. This would allow for distension of the cardiac tissue. In another embodiment, the penetration prongs 83 could be constructed so that they are in the expanded open state for placement and then collapse to the deployed closed state after placement. This would allow for compression of the cardia tissue. When the embodiment is in the compressed closed state, it can pierce through the cardia for placement and then take the deployed expanded state open to cause the cardia to stretch to engage the stretch receptors and cause satiety. FIG. 17D shows where the element in the expanded open state has penetration prongs 83 that curl into an atraumatic profile. Similarly this device could work in compression where the device is placed in the expanded open state and then closes to compress the tissue engage the stretch receptors. This embodiment could be further improved by having adjustability such as any of the adjustability features already mentioned above. An alternative to this embodiment would be to make the device that changes shape when exposed to a temperature or other stimuli change. This device could further contract or expand when exposed to a hot or cold liquid or stimuli to allow for a temporary adjustment. The adjustability mechanisms described above, including adjustability, remote adjustability, sensors, data collection, surface texture and adjustments over the phone, may be applied to such devices.
Another embodiment would be to have a single cardiac member 13 which only contacts the proximal cardia and is fixed in place with a fixation element 31 . This device may have the shape of a portion of a frusto-cone or tube and is fixed in place at each of the 4 corners of the element. Although the element takes the shape of a portion of a frustocone, it could take the shape of a flat panel, a portion of a tube, an oval, a disk or any other suitable shape. See FIGS. 18A and 18B . Although 4 points of fixation are shown, there be could be more or less fixation. This element could be thin walled and could be made from silicone, a combination of Nitinol and silicone, or other suitable materials or combinations of materials. Preferably, the device is self-expanding and would have adequate structure to impart force against the cardia or upper stomach when fixed at the corners, but would be flexible enough to accommodate peristalsis. Several types of fixation could be used, including and not limited to those previously disclosed. The procedure could be performed gastroscopically by placing the fixation from inside the stomach through the single cardiac member 13 , through the stomach wall, and to the outside of the stomach wall on the serosa. Since the device is self-expanding, it may be collapsed for placement down the esophagus and then reforms in the stomach where it can then be fixed into place. As shown in FIGS. 7A and 7B , the fixation element 31 could be an anchor 72 in the form of a t T-bar with a button on one side. This would allow the smooth button to be inside the stomach, and the T-bar to pierce the device and stomach wall. The fixation element 31 could also be an anchor 72 in the form of a collapsible basket as shown in FIGS. 7C an 7 D, which then expands to hold the fixation. The fixation element 31 could also be other types of expandable anchors, standard sutures or other types of fixation.
This device could then contain several types of adjustments for adjusting the pressure applied by the single cardiac member to the cardia wall. For example, there could be an inflatable body 27 that could be placed on top of the cardiac portion of the device and against the stomach wall that could be accessed through aninflation element 28 . See FIGS. 18A and 18B . This inflation element 28 could be a self-sealing septum of an access port, or the self sealing septum could be incorporated into the balloon surface itself. The inflation element 28 could also be a valve that can be accessed by a blunt ended needle to allow fluid to be added or removed. Similar to the embodiment in FIG. 6A , the inflation element 28 could be connected to the inflation member by a tube 29 . This tube could be straight or coiled, with or without a housing, to allow the valve to be pulled up the esophagus and accessed outside the body. As fluid is added, the balloon inflates and compresses the cardia to create a sensation of satiety. After the balloon has been adjusted, the tubing can then retract and be placed back into the stomach. The tubing may be retracted into a housing, which may have a coiling mechanism. The tubing, with or without the housing, is preferably configured to stay in the stomach and not pass through the pylorus. FIGS. 18C and 18E show the inflatable body 27 in the deflated state, while FIGS. 18D and 18F show the inflatable body 27 in the inflated state.
Another variation of the embodiment would be to place spacers 26 into a pocket or feature of the single cardiac member 13 to apply outward force for additional pressure against the cardia or upper stomach to adjust the pressure applied by the single cardiac member to the cardia wall. The spacers could be made from solid or hollow sections of polymers, silicone or foam. The spacers could also take the form of shape set self expanding Nitinol features that could apply pressure to the cardia, but accommodate peristalsis. These self expanding Nitinol features could have a variety cross-sectional shapes, angles, and resistance to allow for a range of compression to be applied to the cardia. See FIG. 19 . Spacers similar to those shown in 4 D and 4 E could also be used in this embodiment, but other shapes could also be used. The spacer could be removed endoscopically with a collapsing drawstring and then replaced for a different spacer to change the amount of pressure applied to the cardia.
In another embodiment, an element may be used to contact the cardia, but may be fixed into place by a fixation element 31 in the fundus, body, or pyloric region of the stomach. This fixation could take place along the lesser curve, greater curve or midline of the stomach. FIG. 20 shows a side view of an embodiment where a cardiac element 12 is positioned at the proximal cardia. This cardiac element 12 is attached to a positioning element 66 which has a connecting joint 105 for attaching a fixation element 31 to fix the device to the stomach wall. The cardiac element is constructed with a self expanding Nitinol wire mesh pattern 50 . FIG. 21A shows a backside perspective view of this device and FIG. 21B shows a front view of this device. Preferably, the cardiac element is made of a self expanding structure to maintain its form in the stomach while accommodating peristalsis. The positioning elements are also preferably made from a shape memory or super elastic material to maintain structure while accommodating peristalsis. With self expanding elements, the device may be collapsed for placement down the esophagus and then expand once in the stomach for fixation to the stomach wall. FIG. 22 shows a side view of an alternative embodiment where the positioning element 66 , connecting joint 105 , and fixation element 31 are located along the lesser curve. FIGS. 23A and 23B show a backside perspective view and front view of this embodiment. Adjustability, sensors, remote control and all other improvements and features previously disclosed herein apply to this embodiment.
The bariatric device may have an adjustment element that is equipped with a temporary expansion/contraction element 90 that may allow for temporary adjustment based on activation of a material property, sensor 88 or mechanism of the device. This could be applied to any of the above-discussed embodiments. FIGS. 24A shows a cardiac element in the unexpanded state and 24 B shows the cardiac element in the expanded state. It may be desirable for the temporary expansion/contraction element 90 to adjust only upon eating, and then retract after eating. It may be desirable for the device to adjust upon eating and then retract after eating. It may be desirable for the device to adjust with the pH cycle of the patient where pH will be higher prior to eating and then lower after eating. This would allow for intermittent stimulation of the stretch receptors to avoid receptor fatigue over time. For example, the material could be heat sensitive using materials such as Nitinol, which could expand after consuming a cold or hot liquid. The time and duration of the adjustment could be varied up on the desired response.
Similarly, the device could have a sensor 88 or material that is pH or glucose sensitive or detect the presence of food, which could activate the temporary expansion/contraction element 90 to expand when a certain threshold for pH has been reached or glucose, carbohydrates, protein or fat is present after eating. Similarly, this temporary expansion/contraction element 90 could be activated by a magnetic field such as swallowing a magnetic pill that could temporarily expand the device. In this example, the magnetic pill would be small enough and shaped appropriately for passage through the gastrointestinal tract, and be biocompatible. The patient could consume the electromagnetic pill when a satiety signal was desired. It may also be desirable for the device to adjust based on time or sleep cycle such that the device 10 adjusts at specific times of the day or when the patient lays horizontal. Other parameters or mechanisms to trigger the temporary expansion could be used.
Another alternative would be to suspend these devices from either the left or right crura of the diaphragm, or both instead of fixing directly to the stomach wall or esophageal wall.
Devices for Placement with a Gastric Band or Gastric Bypass
All of these devices could be modified for use with a gastric band or bypass patient. See FIGS. 25, 26 and 27 . FIG. 25 shows a 3 element embodiment with a gastric band. This may be desirable in a patient with a gastric band or bypass where the weight loss has slowed or weight gain has started. In all cases, the devices may need to be sized appropriated to fit within the reduced size of a gastric bypass or gastric band pouch. Although the figures show a gastric band, it is intended to also represent a reduced pouch size of a gastric bypass, a sleeve gastrectomy or other bariatric procedure. Due to the reduced lumen or constriction of the gastric band or bypass below the pouch, the device may be placed without fixation into the stomach wall. FIG. 26 shows how a single cardiac member 13 could be used with a small pouch. FIG. 27 shows an embodiment where a cardiac element 12 could be placed above the gastric band to contact the cardia or upper stomach. This also shows that the geometry is large enough to prevent migration of the device past the band. The embodiment shows a spherical profile or ellipsoid profile to better match the pouch geometry, but other shapes and profiles could be used. This device could be placed temporarily and could be replaced by different shapes or sizes. This feature would be particularly interesting for failed gastric bypass patients who do not have the opportunity for a reversal or for gastric band patients who do not want to undergo surgery, but want to stimulate satiety. This device could be made from silicone, polymers, Nitinol or a combination of any of these. Preferably, this device is made from a self expanding structure to provide pressure against the cardia, but accommodate peristalsis. Self expansion would also allow the device to compressed for placement down the esophagus and then expand into its operational shape and collapse for retrieval.
Placement
As mentioned above, a tube, catheter, or sheath may be required to protect the anatomy during placement of the device down the esophagus and into the stomach. For the small single cardiac embodiments, a sheath may not be required due to the small size. Where protection is require, it could be a simple flexible tube to aid in straightening and compressing the device while it is being introduced. Insertion of the device into the tube would require compression of the device into a narrow, streamlined shape. A standard gastroscopic tool could be used to push or pull the device down the tube. Similarly, a custom gastroscopic tool or sheath could be used to introduce the device into the stomach through the esophagus or other narrow opening.
Removal
For removal, a flexible tube such as a standard overtube could be used with a standard or custom endoscopic tool. The tube may be placed down the esophagus and the tool then placed down the lumen of the overtube. Endoscopic scissors or cautery could be used to cut fixation where necessary and a standard grasper or snare could grasp the device and pull it up the tube. The device would be straightened by the overtube for removal from the stomach and esophagus. The device may be flexible and small enough in profile to pull up the overtube with a standard grasper.
In another embodiment, the elements may incorporate a collapsing mechanism designed to collapse the element into a compact shape for removal. For example, a constriction member comprising a wire or thread may be sewn spirally around, through, or inside the length of one of the elements. The ends of the constriction member may be connected. When the constriction member is pulled, it tightens the circumference of the element like a drawstring, which collapses the element down to a narrow profile that can be safely removed through the esophagus or other narrow opening, or ease its placement into a tube for removal. The constriction member could be made from Nitinol, stainless steel wire, polypropylene, PTFE thread, EPTFE thread or PTFE coated threads or other suitable materials. The constriction member could be integrated into the elements in a variety of patterns such as a continuous spiral, two spirals of reversing orientation, a single loop or other.
The foregoing description of the preferred embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.
INDUSTRIAL APPLICABILITY
This invention may be industrially applied to the development, manufacture, and use of bariatric devices for weight loss purposes. | A bariatric device for use in inducing weight loss, comprising a cardiac element and a fixation element wherein the fixation element attaches the cardiac element to the upper stomach to allow the cardiac element to apply at least intermittent pressure to the upper stomach which produces a satiety signal to the user, giving the recipient a feeling of fullness and reducing his or her hunger feelings. The device may also contain an esophageal element which is connected to the cardiac element by a connecting element. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/878,738, filed Sep. 9, 2010 (issued as U.S. Pat. No. 9,175,534 on Nov. 3, 2015), which is a continuation-in-part of U.S. patent application Ser. No. 12/540,924, filed Aug. 13, 2009 (issued as U.S. Pat. No. 7,823,632 on Nov. 2, 2010), which is a continuation- in-part of U.S. patent application Ser. No. 12/484,211, filed Jun. 14,2009, which claims benefit of U.S. Provisional Patent Application Ser. No. 611131,874, filed Jun. 14, 2008, each of which are incorporated herein by reference and to which priority is hereby claimed.
BACKGROUND
[0002] The present disclosure generally relates to methods and apparatus for mill cutting through wellbore tubulars, including casing or similar structures.
[0003] When oil and gas wells are no longer commercially viable, they must be abandoned in accord with government regulations. Abandonment requires that the installed tubulars, including all strings of tubing, pipe, casing or liners that comprise the multiple, nested tubulars of the well must be severed below the surface or the mud line and removed. Using explosive shape charges to sever multiple, nested tubulars in order to remove them has negative environmental impacts, and regulators worldwide are limiting the use of explosives. Therefore, a need exists for effective alternatives to the use of explosives for tubular severance in well abandonment.
[0004] Mechanical blade cutting and abrasive waterjet cutting have been implemented in response to new restrictive environmental regulations limiting the use of explosives.
[0005] Existing mechanical blade cutters utilized from the inside of the innermost casing, cutting out through each successive tubular of the multiple nested tubulars, requires multiple trips in and out of the wellbore. Such mechanical blade cutters require a rotary rig or some means of rotary drive in order to rotate the work string to which the mechanical blade cutter is attached. Rotary drive systems are both cumbersome and expensive to have at the work site. Existing mechanical blade cutters are deficient because, among other reasons, the mechanical blade cutters may break when they encounter non-concentric tubulars. Another deficiency is the limitation on the number of nested tubulars that may be severed by the mechanical blade cutter at one time or trip into the wellbore. An “inner” and “outer” string may be severable, if generally concentrically positioned in relation to each other. However, there is no current capability for severing a multiple non-concentrically (eccentrically) nested tubulars that provides consistent time and cost results in a single trip into the wellbore.
[0006] Most advances in the mechanical blade cutting art have focused on cut chip control and efficiency, rather than focusing on the fundamental issues of blade breakage and required, multiple, undesired trips of the apparatus in and out of a well. Thus these fundamental problems of existing mechanical blade cutting persist.
[0007] When cutting multiple, nested tubulars of significant diameters, for example 9% inches outside diameter through 36 inches outside diameter, with at least two other nested tubulars of different sizes dispersed in between, the mechanical blade cutter must be brought back to the surface where successive larger cutting blades are exchanged for smaller cutting blades. Exchanging the smaller blades for larger blades allows the downhole cutting of successively larger diameter multiple, nested tubulars.
[0008] To access the downhole mechanical blade cutter, the user must pull the entire work string out of the wellbore and unscrew each work string joint until the mechanical blade cutter is removed from the bottom of the work string. After exchanging the mechanical blade cutter for a larger cutting blade, the work string joints are screwed back together, one after another, and tripped back into the well bore. The mechanical blade cutter trip back into the wellbore to the previous tubular cut location for additional cutting is compromised because the length of the work string varies due to temperature changes or occasionally human error in marking or counting work string joints. Consequently, it is difficult to precisely align successive cuts with earlier cuts.
[0009] Many installed multiple, nested tubular strings in wells are non-concentric, meaning that the nested tubulars are positioned off center in relation to the innermost tubular. This is often the case because the outer tubulars do not have the same center diameter as the inner tubular. As a result of the multiple, nested tubulars being stacked or clustered to one side, i.e. non-concentric to each other, the density or amount of material being cut will vary circumferentially during cutting. Mechanical cutter blades sometimes experience breakage when cutting multiple, nested tubulars positioned nonconcentrically in relation to each other. The blade cutter often breaks from the contact with the leading edge of a partial segment of the casing that remains after another segment of that casing has been cut away. The remaining portion of the casing forms a “C” or horseshoe-type shape when viewed from above. The blade cutter extends to its fullest open cut position after moving across a less dense material or open space (because that material has been cut away) and when the blade cutter impacts the leading edge of the “C” shaped tubular, the force may break off the blade. The breaking of a cutter blade requires again tripping out and then back into the well and starting over at a different location in the well bore in order to attempt severing of the multiple, nested tubulars. Non-concentric, multiple, nested tubulars present serious difficulties for mechanical blade cutters. Severing non-concentric multiple, nested tubulars may take a period of days for mechanical blade cutters.
[0010] Existing abrasive waterjet cutters also experience difficulties and failures to make cuts through multiple, nested tubulars. Primarily, existing solutions relate to abrasive waterjet cutting utilizing rotational movement in a substantially horizontal plane to produce a circumferential cut in downhole tubulars. However, the prior art in abrasive waterjet cutters for casing severance often results in spiraling cuts with narrow kerfs in which the end point of the attempted circumferential cut fails to meet the beginning point of the cut after the cutting tool has made a full 360 degree turn. In other words, the cut does not maintain an accurate horizontal plane throughout the 360 degree turn, and complete severance fails to be achieved. Another problem encountered by existing abrasive waterjet cutting is the inability to cut all the way through the thicker, more widely spaced mass of non-concentrically positioned tubulars. In this situation, the cut fails to penetrate all the way through on a 360 degree circumferential turn. A further disadvantage of traditional abrasive waterjet cutting is that in order to successfully cut multiple, nested tubulars downhole, air must be pumped into the well bore to create an “air pocket” around the area where the cutting is to take place, such that the abrasive waterjet tool is not impeded by water or wellbore fluid. The presence of fluid in the cutting environment greatly limits the effectiveness of existing abrasive waterjet cutting.
[0011] Existing systems provide, verification of severance by welding “ears” on the outside of the top portion of the tubulars under the platform, attaching hydraulic lift cylinders, heavy lift beams, and then lifting the entire conductor (all tubulars) to verify complete detachment has been achieved. Basically, if the tubulars are able to be lifted from the well bore, it is assumed the severance was successful. When working offshore, this lifting verification process occurs before even more costly heavy lift boats are deployed to the site. This method of verification is both time-consuming and expensive.
[0012] There exist methods to mill windows via longitudinal, vertical travel in casing. However, these milling methods do not completely sever multiple, nested non-concentric tubulars for well abandonment. One such rotary milling method uses a whipstock, which must be deployed before the window milling process can begin. A rotary mill is then actuated against one side of a tubular along with a means of vertical travel, enabling a window to be cut through the tubular. However, this method does not permit 360 degree circumferential severance of multiple, nested tubulars and is not suited for the purpose of well abandonment.
[0013] This invention provides a safe and environmentally benign means of completely severing multiple, nested tubulars for well abandonment including overcoming the difficulties encountered by mechanical blade cutting, abrasive waterjet cutting or other means of tubular milling currently available.
BRIEF SUMMARY OF THE INVENTION
[0014] This invention provides methodology and apparatus for efficiently severing installed multiple, nested strings of tubulars, either concentric or eccentric, as well as cement or other material in the annuli between the tubulars, in a single trip into a well bore in an environmentally sensitive manner without the need for a rig.
[0015] The invention utilizes a computer-controlled robotic downhole rotary mill to effectively generate a shape(s) or profile(s) through, or completely sever in a 360 degree horizontal circumferential plane, the installed tubing, pipe, casing and liners as well as cement or other material that may be encountered in the annuli between the tubulars. This process occurs under programmable robotic, computerized control, making extensive use of digital sensor data to enable algorithmic, robotic actuation of the downhole assembly and robotic rotary mill cutter.
[0016] The downhole assembly is deployed inside the innermost tubular to a predetermined location and, under computer control, a rotary mill cuts outward radially and vertically, cutting a void (or swath) and completely severing the installed tubing, pipe, casing and liners as well as cement or other material that may be encountered in the annuli between the tubulars. The complete severance process occurs during one trip into the well bore.
[0017] Although this system is designed for precise W-axis movement in a 360 degree horizontal plane, due to the wide swath or void it generates when removing material in said horizontal plane, it does not require the exact alignment of the starting and ending points in the 360 degree cut that are otherwise required by traditional waterjet systems. Traditional narrow-kerf abrasive waterjet systems often create a “spiral” cut because of an inability to maintain perfect alignment from the starting point to the ending point. This “spiral” cut causes severance attempts to fail because the starting point of the cut and the ending point of the cut did not meet.
[0018] Additionally, by cutting a void (or swath) into the tubulars, the severed casing will drop vertically at the surface platform, providing visual verification of the severance. The reach of the cutter, is designed to extend beyond the outermost casing with any number of additional tubulars inside this outermost casing being extremely eccentrically positioned. This solves the cutting “reach” problems that are encountered with abrasive waterjet cutting when the waterjet has difficulty cutting through the thickest, most widely spaced mass of the eccentrically positioned tubulars and cement.
[0019] The programmable computer-controlled, sensor-actuated rotary milling process will take less time to complete severance than mechanical blade cutters or existing abrasive waterjet cutting. The actively adjusted rotary milling, profile generation process prevents the impact breakage that plagues mechanical blade cutters encountering non-concentric, multiple, nested tubulars. Furthermore, this invention's capability of being deployed and completing the severance in one trip downhole provides a significant advantage over prior art.
[0020] Therefore, a technical advantage of the disclosed subject matter is the complete severing of tubing, pipe, casing and liners, as well as cement or other material, that may be encountered in the annuli between the tubulars in a single trip downhole.
[0021] Another technical advantage of the disclosed subject matter is providing visual verification of severance without employing additional equipment.
[0022] Yet another technical advantage of the disclosed subject matter is creating a wide void (or swatch) thereby removing substantial material such that the start point and end point of the void (or swath) do not have to precisely align for complete severance.
[0023] An additional technical advantage of the disclosed subject matter is avoiding repeat trips down hole because of cutter breakage.
[0024] Another technical advantage of the disclosed subject matter is efficiently severing non-concentrically (eccentrically) aligned nested tubulars.
[0025] Yet another technical advantage of the disclosed subject matter is accomplishing severance in less time and in an environmentally benign manner.
[0026] Still another technical advantage is providing electronic feedback showing cutter position and severance progress.
These and other features and advantages will be readily apparent to those with skill in the art in conjunction with this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The features, nature, and advantages of the disclosed subject matter will become more apparent from the detailed description set forth below when taken in conjunction with the accompanying drawings.
[0029] FIG. 1 depicts the robotic rotary mill cutter of the preferred embodiment.
[0030] FIGS. 2A and 2B , depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.
[0031] FIG. 3 depicts an expanded view of an inserted carbide mill of one embodiment.
[0032] FIG. 4A depicts a top view of multiple casings (tubulars) that are non-concentric.
[0033] FIG. 4B depicts an isometric view of non-concentric casings (tubulars).
[0034] FIG. 5A depicts a portion of the robotic rotary mill cutter as it enters the tubulars.
[0035] FIG. 5B depicts a portion of the robotic rotary mill cutter as it is severing multiple casings.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Although described with reference to specific embodiments, one skilled in the art could apply the principles discussed herein to other areas and/or embodiments.
[0037] Throughout this disclosure casing(s) and tubular(s)are used interchangeably.
[0038] This invention provides a method and apparatus for efficiently severing installed tubing, pipe, casing, and liners, as well as cement or other encountered material in the annuli between the tubulars, in one trip into a well bore.
[0039] Reference will now be made in detail to the present embodiments of the disclosure, 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 (elements).
[0040] To help understand the advantages of this disclosure the accompanying drawings will be described with additional specificity and detail.
[0041] The method generally is comprised of the steps of positioning a robotic rotary mill cutter inside the innermost tubular in a pre-selected tubular or plurality of multiple, nested tubulars to be cut, simultaneously moving the rotary mill cutter in a predetermined programmed vertical X-axis, and also 360 degree horizontal rotary W-axis, as well as the spindle swing arm in a pivotal Y-axis arc.
[0042] In one embodiment of the present disclosure the vertical and horizontal movement pattern(s) and the spindle swing arm are capable of being performed independently of each other, or programmed and operated simultaneously in conjunction with each other. The robotic rotary mill cutter is directed and coordinated such that the predetermined pattern is cut through the innermost tubular beginning on the surface of said tubular with the cut proceeding through it to form a shape or window profile(s), or to cut through all installed multiple, nested tubulars into the formation beyond the outermost tubular.
[0043] A profile generation system simultaneously moves the robotic rotary mill cutter in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm in a pivotal Y-axis arc to allow cutting the tubulars, cement, and formation rock in any programmed shape or window profile(s).
[0044] The robotic rotary mill cutter apparatus is programmable to simultaneously or independently provide vertical X-axis movement, 360 degree horizontal rotary W-axis movement, and spindle swing arm pivotal Y-axis arc movement under computer control. A computer having a memory and operating pursuant to attendant software, stores shape or window profile(s) templates for cutting and is also capable of accepting inputs via a graphical user interface, thereby providing a system to program new shape or window profile(s) based on user criteria. The memory of the computer can be one or more of but not limited to RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, floppy disk, DVD-R, CD-R disk or any other form of storage medium known in the art. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC or microchip.
[0045] The computer controls the profile generation servo drive systems as well as the milling cutter speed. The robotic rotary mill cutter requires load data to be able to adjust for conditions that cannot be seen by the operator. The computer receives information from torque sensors (see 52 , and 53 of FIGS. 2A and 2B ) attached to Z-axis, W-axis, Y-axis, and milling spindle drive motor, and makes immediate adaptive adjustments to the feed rate and speed of the vertical Z-axis, the 360 degree horizontal rotary W-axis, the spindle swing arm pivotal Y-axis and the RPM of the milling spindle motor.
[0046] Software in communication with sub-programs gathering information from the torque devices, such as a GSE model Bi-Axial transducer Model 6015 or a PCB model 208-M133, directs the computer, which in turns communicates with and monitors the downhole robotic rotary mill cutter and its attendant components, and provides feeds and speeds simultaneously or independently along the vertical Z-axis, the 360 degree horizontal rotary W-axis, as well as the pivotal spindle swing arm Y-axis arc movement.
[0047] The shape or window profile(s) are programmed by the operator on a program logic controller (PLC), personal computer (PC), or a computer system designed or adapted for this specific use. The integrated software via a graphical user interface (GUI) or touch screen, such as a Red Lion G3 Series (HM1s), accepts inputs from the operator and provides the working parameters and environment by which the computer directs and monitors the robotic rotary mill cutter.
[0048] In the preferred embodiment, the vertical Z-axis longitudinal computer-controlled servo axis uses a hydraulic cylinder, such as the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor for ease of vertical Z-axis longitudinal movements, although other methods may be employed to provide up and down vertical movement of the robotic rotary mill cutter.
[0049] In a still further embodiment of the present disclosure the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a ball screw and either a hydraulic or electric motor, such as a computer controlled electric servo axis motor, the Fanuc D21001150 servo, with encoder feedback to the computer system by an encoder (see 50 in FIG. 2A ) such as the BE1 model H25D series incremental optical encoder. Servo motors and ball screws are known in the art and are widely available from many sources.
[0050] In a still further embodiment of the present disclosure, the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a rack and pinion, either electrically or hydraulically driven. Rack and pinion drives are known in the art and are widely available from many sources.
[0051] In the preferred embodiment, the rotational computer controlled W-axis rotational movement is an electric servo motor, although other methods may be employed. The rotational computer-controlled W-axis servo motor, such as aFanuc model D21001150 servo, provides 360-degree horizontal rotational movement of the robotic rotary mill cutter through a specially manufactured slewing gear.
[0052] Also in the preferred embodiment, the Y-axis pivotal milling spindle swing arm computer-controlled servo axis uses a hydraulic cylinder for ease of use, although other methods may be employed. The Y-axis pivotal milling spindle swing arm computer-controlled servo axis, may utilize the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor (see 51 in FIG. 2B ) inside the hydraulic cylinder to provide position feedback to the computer controller for pivotal spindle swing arm Y-axis arc movement.
[0053] In a still further embodiment of the present disclosure an inertia reference system such as, Clymer Technologies model Terrella6 v2, can provide information that the robotic rotary mill cutter is actually performing the movements sent by the computer controller as a verification reference. If the reference shows a sudden stop, the computer can go into a hold action stopping the robotic rotary mill cutter and requiring operator intervention before resuming milling operations.
[0054] The methods and systems described herein are not limited to specific sizes, shapes, or models. Numerous objects and advantages of the disclosure will become apparent as the following detailed description of the multiple embodiments of the apparatus and methods of the present disclosure are depicted in conjunction with the drawings and examples, which illustrate such embodiments.
[0055] FIG. 1 depicts the robotic rotary mill cutter 1 . The robotic rotary mill cutter 1 , shows the position of the vertical Z-axis, and the 360-degree horizontal rotary W-axis, and the milling spindle swing arm pivotal Y-axis.
[0056] FIGS. 2A and 2B , depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.
[0057] Referring to FIG. 2A , a collar 2 is used to attach the umbilical cord (not shown) and cable (not shown) to the body of robotic rotary mill cutter 1 . Collar 2 may be exchanged to adapt to different size work strings (not shown). Additionally, the collar 2 provides a quick disconnect point in case emergency removal of the robotic rotary mill cutter 1 is necessary. After the robotic rotary mill cutter 1 is in the cut location, locking hydraulic cylinders 3 are energized to lock the robotic rotary mill cutter 1 into the well bore (not shown). In the preferred embodiment, after the locking hydraulic cylinders 3 have been energized, Z-axis hydraulic cylinder 6 is moved to a down position by extending piston rod 4 allowing the Z-axis slide 5 to extend. This permits the robotic rotary mill cutter 1 to begin cutting at the lowest point of the cut and be raised as needed to complete the severance.
[0058] Referring to FIG. 2B , additional locking hydraulic cylinders 7 are available should additional stabilization (if energized) or movement (if not energized) are desired. W-axis servo motor 8 rotates the W-axis rotating body 10 under control of the computer (not shown). W-axis rotating body 10 houses the milling spindle swing arm 14 and the milling spindle swing arm 14 is driven by motor 11 also housed in the W-axis rotating body 10 . Milling spindle swing arm 14 is driven by motor 11 through a half-shaft 12 such as Motorcraft modeI6L2Z-3A427-AA.
[0059] Half-shaft 12 has a c.Y. joint (not shown) that allows milling spindle swing arm 14 to pivot in an arc from pivot bearing 13 that goes through W-axis rotating body 10 . Milling spindle swing arm 14 is moved by Y-axis hydraulic cylinder 16 . The rotation of W-axis rotating body 10 requires a swivel joint 9 , such as Rotary Systems Model DOXX Completion, to allow power and sense lines (not shown) to motor 11 , Y-axis hydraulic cylinder 16 , and load cell 54 sense wires (not shown). Carbide cutter 15 is mounted to the milling spindle swing arm 14 and is moved by Y-axis hydraulic cylinder 16 into the cut under computer control.
[0060] FIG. 3 depicts an expanded view of one embodiment of an inserted carbide mill 17 that could be attached to milling spindle swing arm 14 . Other milling units with different material and/or cutting orientation could be utilized depending on the particular characteristics of the severance to be performed.
[0061] FIG. 4A depicts a top view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.
[0062] FIG. 4B depicts an isometric view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.
[0063] FIG. 5A depicts a portion of the robotic rotary mill cutter 1 as it enters the nested multiple casings (tubulars) 18 .
[0064] FIG. 5B shows the nested multiple casings (tubulars) 18 with the void that has been created by the robotic rotary mill cutter 1 . The profile generation system (not shown) simultaneously moved the robotic rotary mill cutter 1 in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm 14 in a pivotal Y-axis arc to allow cutting of the tubulars, cement (not shown), and formation rock (not shown) in any programmed shape or window profile(s) thereby cutting through the multiple casing (tubulars) 18 , cement (not shown) or other encountered material in casing annuli (not shown).
[0065] The disclosed subject matter covers the scope of functionality in a holistic way. Although described with reference to particular embodiments, those skilled in the art, with this disclosure, will be able to apply the teachings in principles in other ways. All such additional embodiments are considered part of this disclosure and any claims to be filed in the future. | A methodology and apparatus for cutting shape(s) or profile(s) through well tubular(s), or for completely circumferentially severing through multiple tubulars, including all tubing, pipe, casing, liners, cement, other material encountered in tubular annuli. This rigless apparatus utilizes a computer controlled, downhole robotic three-axis rotary mill to effectively generate a shape(s) or profile(s) through, or to completely sever in a 360 degree horizontal plane wells with multiple, nested strings of tubulars whether the tubulars are concentrically aligned or eccentrically aligned. This is useful for well abandonment and decommissioning where complete severance is necessitated and explosives are prohibited, or in situations requiring a precise window or other shape to be cut through a single tubular or plurality of tubulars. | 4 |
This is a continuation of copending application(s) Ser. No. 877,090 filed on May 1, 1990 now abandoned.
FIELD OF THE INVENTION
Technical Field
The present invention is directed toward water recycling systems and more particularly toward water recycling systems for use in residential bathrooms.
BACKGROUND OF THE INVENTION
Background Art
Residential water recycling systems are old in the art and generally involve the reuse of wash water to be used to flush toilets.
U.S. Pat. Nos. 3,112,467 to Call and 4,162,218 to McCormick both disclose water reuse systems for recovering and collecting used shower, sink and bath water. The water is collected at the drain pipes of the shower, bath or sink and transferred to a storage tank where it is later used to flush a commode.
West German patent No. 2,336,744 to Reinke and West German patent No. 3,828,528 to Hasse disclose a water recovery system for recovering used bath or shower water for use when flushing a toilet. The system has a collection device plumbed in the drain pipe of the tub and transfers water by means of a suction pump to a storage tank and then upon demand to a commode.
The above water recovery systems represent central water recovery systems for the entire home that requires a large capital expense to install. And since access to existing plumbing fittings that are under existing fixtures and/or behind existing walls, the retrofitting of a water recovery system into an existing home is very difficult and at least requires the removal of a tub and/or the shower stall. The large number of components and the central system nature of the many of these systems makes them expensive to install and maintain.
The present invention is directed to overcoming one or more of the problems discussed above.
SUMMARY OF THE INVENTION
In one aspect of the present invention a waste water recovery system for recycling shower/bath water for use with a tank-type toilet is provided. The system includes a storage tank with a suction pump to draw water into the storage tank. The system also includes a first float valve which is used to allow the tank to be filled and when the tank is filled to a desired level to preclude overflow. Recovered water from the storage tank is delivered to the toilet tank when needed by gravity. A collector is attached to the floor of a bath or shower which has a floor drain. The collector surrounds the floor drain and has an inlet and an outlet. The waste water enters at the inlet and is expelled at the outlet where it is drawn by the suction pump to the storage tank.
In a preferred embodiment of this aspect of the invention the collector is removably attachable by suction means to the floor of the bath or shower.
In another preferred embodiment of this aspect of the invention the storage tank has a reserve supply source to make up water when insufficient water is collected from the shower or tub. In another aspect of the invention a method of recycling shower/bath water is provided. The method consists of drawing used shower/bath water through a collector attached to the upper section of the floor of a shower or bath which has a floor drain. The next step is drawing water from the collector using a pump to the storage tank. The third step is directing the water from the storage tank to the tank of the tank operated toilet. In a preferred embodiment of this aspect of the invention a fourth step is provided which is the stopping of supply to the tank when the storage tank is full.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a preferred embodiment of the present invention when used in connection with a bath tub;
FIG. 2 is a plan view of the bathing area of the present invention showing the use of the invention with a shower;
FIG. 3 is a top view of a first embodiment of the collector of the present invention;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3;
FIG. 5 is an end view of a first embodiment of the collector of the present invention;
FIG. 6 is a top view of a second embodiment of the collector of the present invention;
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 6;
FIG. 8 is an end view of a second embodiment of the collector of the present invention;
FIG. 9 is a top view of a third embodiment of the collector of the present invention;
FIG. 10 is a cross-sectional view taken along line 10--10 of FIG. 9;
FIG. 11 is a cross-sectional view taken along line 11--11 of FIG. 9;
FIG. 12 is an end view of the third embodiment of the collector of the present invention;
FIG. 13 is a top view of a fourth embodiment of the collector of the present invention;
FIG. 14 is a cross-sectional view taken along the line 14--14 of FIG. 13;
FIG. 15 is a cross-sectional view taken along line 15--15 of FIG. 13; and
FIG. 16 is an end view of the fourth embodiment of the collector of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of a recovery system for recycling waste water 20 is shown generally in FIG. 1.
The recovery system 20 includes a storage tank means 22 which may be embodied in any type of water holding container e.g., a tank having a bottom 24 and upstanding sidewalls 26 forming a tank which will hold water. The tank 22 may be supported in an elevated position relative to a floor 28 of a bathroom 30 by resting the bottom 24 of the tank 20 on a shelf 32 or by any other suitable means. A supply means 34, for instance commercially available pipes and fittings made from metal or plastic, are connected between the tank 22 and a tank-type toilet 36.
The supply means 34 for example may include a first pipe 40 extending through a first opening 42 in the side wall 26 near the bottom 24 of the storage tank 22. The first pipe 40 is secured to the side wall 26 by means of a weld 44 or other suitable means to secure and seal the first pipe 40. Attached to the first pipe 40 is a first fitting 46. The first fitting 46 may either be an elbow or a "T". The first fitting 46 has a first outlet 50 and second outlet 52. The second outlet 52 is used to direct the gray water to a second tank-type toilet (not shown). The first outlet 50 is attached to a copper tubing 54, which is attached to a toilet reservoir fitting 70, which may be the standard inlet fitting 70 for the tank-type toilet 36. It should be noted that the supply means 34 may be fluidly connected to the tank-type toilet 36 at any location upstream from a toilet valve 72 which is located within a toilet reservoir 76.
In the practice of this invention a standard bathtub 80 has a floor 82 to which a floor drain 84 is attached. A drain pipe 86 is attached to the floor drain 84. The floor drain 84 also has a stopper or plug 90 in order that water may be allowed to accumulate in the tub 80. An overflow pipe 92 is attached to a side wall 94 of the bathtub 80. The overflow pipe 92 and the drain pipe 86 are connected to a T connector 96. The T connector 96 is further connected to drain lines of the household plumbing 100. A collector means or collector 102 is located on a top 104 of the floor 82 of the bathtub 80.
Referring to FIG. 2, the stopper or plug 90 is opened or removed in order that water may be expelled through the floor drain 84.
Referring to FIG. 3, the collector 102 has a general ring shape with a center opening 120 which is larger than the floor drain 84.
Referring to FIG. 4, the collector 102 has a bottom wall 122 with an inside diameter 124 and an outside diameter 126. An upstanding cylindrical vertical wall 130 extends upwardly from the inside diameter 124 of the bottom wall 122 of the collector 102 to an upper edge 132 of the vertical wall 130. A tapered cylindrical wall 134 extends from the outside diameter 126 of the bottom wall 122 of the collector 102 to the upper edge 132 of the vertical wall 130 of the collector 102, thereby forming a conduit 136 within the collector 102. An outlet means 138 is connected to the tapered cylindrical wall 134 of the collector 102 and has an opening 140 which is in fluid connection with the conduit 136.
Again referring to FIG. 3, a series of inlet means or elongated slots 142 are located in the tapered wall 134 of the collector 102. The slots 142 are preferably radially elongated and equally spaced around the collector.
Again referring to FIG. 4, a resilient inner lip 144 extends radially inward from the inside diameter 124 of the bottom wall 122 of the collector 102. An outer lip 146 extends radially outwardly from the outside diameter 126 of the bottom wall 122 of the collector 102. The inner lip 144 has an inner edge 147 which is co-planer with an outer edge 148 of the outer lip 146. The inner lip 144 and the outer lip 146 deform, seal and secure the collector 102 to the top 104 of the tub 80.
Referring to FIG. 5 the outlet 138 of the collector 102 has a circular outside diameter 150.
Again referring to FIG. 1, a hose 152 is connected to the outside diameter 150 of the outlet 138 of the collector 102. A filter 162 is connected to the hose 152. Tubing 164 is connected to the filter 162. The tubing 164 extends through the side wall 26 of the storage tank 20 at a second opening 165. A second seal 166 using welding or some other means is used to provide a water tight seal at the second opening 165. The tubing 164 is connected to a suction pump means such as a vacuum pump 167.
The pump 167 has an inlet line 168 which extends downwardly into the storage tank 22 to a point near the bottom 24 of the tank 22.
A first switch 170 has a 110 volt inlet hot line 171 and a first 110 volt outline line 172 which is electrically connected to a first terminal 174 on a value operating means or valve 176. A first 110 volt neutral line 178 is connected to a second terminal 180 on the pump 167. The valve 176 has a sensor such as a first float 182 connected to a second switch 184. A second 110 volt outlet line 186 is electrically connected to the pump 167 at a third terminal 187. A reserve water supply means 188 such as standard household plumbing is connected to the storage tank 22 by means of a third opening 190 in the side wall 26 of the storage tank 22 and is sealed by a third seal 192 such as via weldment to prevent leakage of water through the tank 22. A reserve supply valve 194 is connected to the reserve supply means 188 and has a water level sensor such as a second float 196 attached to the reserve supply valve 194. In a preferred embodiment the supply means 188 has an outlet 198 located above the water level of the tank 22.
The collector 102 of FIGS. 3, 4 and 4 may be secured to the top 104 of the floor 82 of the bathtub 80 by means of adhesive 200 as shown in FIGS. 6, 7 and 8.
Referring to FIG. 6, a collector 202 has an opening 220 which is larger than the floor drain 84.
Referring to FIG. 7, the collector 202 has a bottom ring 222 which has an inside diameter 224 and an outside diameter 226. An upstanding vertical wall 230 extends upwardly from the inner diameter 224 of the bottom ring 222 of the collector 202. The vertical wall 230 has an upper edge 232. A tapered cylindrical wall 234 extends between the outside diameter 226 of the bottom ring 222 of the collector 202 to the upper edge 232 of the vertical wall 230 of the collector 202, thereby forming a conduit 236 within the collector 202. An outlet means 240 is connected to the tapered cylindrical wall 234 the collector 202 and has an opening 242 which is in fluid communication with the conduit 236. The collector 202 is firmly secured by adhesive 200 to the top 104 of the floor 82 of the tub 80.
Again referring to FIG. 6, a series of inlet means or elongated slots 244 are located in the tapered wall 234 of the collector 202. The slots 244 are preferably radially elongated and equally spaced around the collector.
Referring to FIG. 8, the outlet 240 of the collector 202 has a circular outside diameter 260.
The outlet 240 may be connected to the hose 152 as shown in FIG. 2.
The circular collectors 102 and 202 as shown in FIGS. 3, 4, and 5 and FIGS. 6, 7 and 8, respectively, serve to act as a dam around the floor drain 84 as shown in FIG. 2 in order that a water level 264 generally at or above the level of the elongated slots 144 and 244 is formed.
When using the bathtub 80 with the collector 102 placed around the drain 84 as shown in FIG. 2 water may remain in the tub after the stopper or plug 90 has been removed from the floor drain 84. Consequently a U-shaped non-circular collector 302 as shown in FIG. 9 is disclosed as an alternative.
Referring to FIG. 9, The collector 302 has a semicircular section 304 and right and left linear sections 306 and 308 extending tangentially from right and left ends 310 and 312, respectively, of the semicircular section 304. The semicircular section 304 has an inside diameter 314 and an outside diameter 316. The linear sections 306 and 308 have right and left inner edges 318 and 320, respectively, and right and left outer edges 322 and 324, respectively.
Referring to FIG. 10, an upstanding wall 326 extends at the semicircular section 304 upwardly from a planer bottom 328 at the inside diameter 314 of the collector 302 to a top edge 332 of the collector 302. A tapered wall 334 extends from the top edge 332 of the upstanding wall 326 to the bottom 328 of the collector 302 at the outside diameter 316 thereby forming a passageway 336.
Referring to FIG. 11, the upstanding depending wall 326 also extends from the bottom 328 of the collector 302 at the right and left inner edges 318 and 320 of the right and left linear sections 306 and 308 (FIG. 9), respectively, upwardly to the top edge 332 of the collector 302. The tapered wall 334 extends from the top edge 332, downwardly and inwardly toward the right and left outer edges 322 and 324 (FIG. 9) of the linear sections 306 and 308, respectively, of the collector 302, providing right and left conduits 338 and 340 which connect with passageway 336 to form a collector inlet passage 342.
Referring to FIG. 12, an outlet means in the form of a tubular conduit 344 extends upwardly and outwardly from the tapered wall 334 of the collector 302 and has an opening 346 which has an outside diameter 348.
Again referring to FIG. 10, extending downwardly and inwardly from the bottom 328 of the collector 302 at the inside diameter 314, the right inner edge 318 and the left inner edge 320 of the semicircular section 304, the right linear section 306 and the left linear section 308, respectively, is an inner lip 360. An outer lip 366 extends downwardly and outwardly from the bottom 328, at the outside diameter 316, the right outer edge 322 and the left outer edge 324 of the semicircular section 304, the right linear section 306 and the left linear section 308, respectively, and has an outer edge 370 which is co-planar with an inner edge 372 of the inner lip 360.
The collector of FIGS. 9, 10, 11 and 12 may be secured to the top 104 of the floor 82 of the bathtub 80 by means of adhesive 400 as shown in FIGS. 13, 14, 15 and 16.
Referring to FIG. 13, a collector 402 has a semicircular section 404 and right and left linear sections 406 and 408 extending tangentially from right and left ends 410 and 412, respectively, of the semicircular section 404. The semicircular section 404 has an inside diameter 414 and an outside diameter 416. The right and left linear sections 406 and 408 have right and left inner edges 418 and 420, respectively, and right and left outer edges 422 and 424, respectively.
Referring to FIG. 14, an upstanding wall 426 extends at the semicircular section 404 upwardly from a planer bottom 428 at the inside diameter 414 of the collector 402 at a top edge 432 of the collector 402. A tapered wall 434 extends from the top edge 432 of the upstanding wall 426 to the bottom 428 of the collector 402 at the outside diameter 416 thereby forming a passageway 436.
Referring to FIG. 15, the upstanding wall 426 also extends from the bottom 428 of the collector 402 at the right and left inner edges 418 and 420 (FIG. 14) of the right and left linear sections 406 and 408, respectively, upwardly to the top edge 432 of the collector 402. The tapered wall 434 extends from the top edge 432 downwardly and inwardly toward the right and left outer edges 422 and 424 (FIG. 14) of the right and left linear sections 406 and 408, respectively, of the collector 402, providing right and left conduits 438 and 440 which connect the conduit 436 to form a collector inlet passage 442.
Referring to FIG. 16, an outlet means in the form of a tubular conduit 444 extends upwardly and outwardly from the tapered wall 434 of the collector 402 and has an opening 446 which has an outside diameter 448.
When utilizing the recovery system 20 as shown in FIG. 1, the collector 102 or 202 is placed on the top 104 of the floor 82 of the bathtub 80 and water is added to the tub to a position slightly below the overflow pipe 92. The water recovery system 20 is not energized until the bathing is completed. When the bathing is complete, rather than normally removing the stopper or plug 90 from the floor drain 84 to drain the bath water through the drain pipe 86, the first switch 170 is flipped from the off position to the on position. Turning the first switch 170 to the on position permits the flow of electricity through the first 110 volt outlet line 172 to the first terminal 174 where the valve 178 is located. The sensor 182 on the valve 178 senses the condition of the tank 22 being full. If the tank 22 is full, the sensor 182 flips the second switch 184 into an open position stopping the flow of electricity through the second 110 volt outlet line 186 in order that the vacuum pump 167 will not draw water from the bathtub 80 and overfill the tank 22.
If, on the other hand, the tank 22 is not full, the sensor 182 will permit the second switch 184 to close completing the circuit including the hot line 171, the first outlet line 172 and the second outlet line 186 in order to allow the vacuum pump 167 to draw water from the bathtub 80 and fill the tank 22.
The water is then drawn from the collector 102 through the hose 152 to the filter 162. The filter 162 separates particulate contamination from the water that accumulates in the water from the bathing process in order that the plumbing components, in particular the vacuum pump 167, are not damaged or clogged. Water at the filter 162 continues on through the tubing 164, through the vacuum pump 167 and into the tank 22.
If the water in the tank 22 falls below a minimum level 500 the second float 196 is lowered to a point that opens the reserve supply valve 194 which permits water to flow through the reserve water supply means 188 and into the tank 22 at the outlet 198.
The flushing of the tank-type toilet 36 is accomplished by normal means as in the standard household tank-type toilet 36 by having the water in the toilet reservoir 76 quickly emptied creating a flushing action to the toilet 36.
In order to refill the toilet reservoir 76 the toilet valve 72 opens permitting water to flow from the first pipe 40 located near the bottom 24 of the storage tank 22 through the "T" 46, the tubing 66 and the toilet reservoir fitting 70 to the toilet valve 72 which remains in the open position until the toilet reservoir 76 is filled. Once the toilet reservoir 76 is filled, the toilet valve 72 shuts stopping the flow of water from the storage tank 22 to the toilet reservoir 76.
The use of the collector 102 that may be placed on the top 104 of the floor 82 of the bathtub 80 by either of two simple means, adhesion or suction, providing for a simple and easy retrofit which does not require the removal of the bathtub 80 from the bathroom 30 nor access to the drainpipe 86 beneath the bathtub 80.
By locating the tank 22 within the same bathroom 30 which has the tank-type toilet 36 and the bathtub 80, all plumbing connections and electrical connections can be performed within the same room and, if all electrical wiring and plumbing are located external to the walls, the entire installation can be completed without any disturbance to the dry wall or any other structures within the room.
The use of the valve 176 having the sensor 182 which operates the second switch 184 to deenergize the vacuum pump 167 when the tank 22 is full avoids over filling and overflowing of the tank 22 when the use of water for the bathtub 80 greatly exceeds the use of water for the tank-type toilet 36.
Referring to FIG. 2, the bather first turns the first switch 170 as shown in FIG. 1 on to energize the vacuum pump 167 and then begins to shower. The collector 102 or 202 is placed centrally over the floor drain 84 so that the center opening 120 is over the floor drain 84. The bather then turns the showerhead 110 on and water begins to collect in the bathtub 80 until the water level 264 reaches the point where the water enters the collector 102 through the elongated slots 142 as shown in FIG. 3. The water then exits the collector 102 through the opening 140, enters the hose 152 and progresses as earlier described into the tank 22. If the vacuum pump 167 cannot draw water through the collector 102 or 202 with sufficient flow rate to equal that of water leaving the showerhead 110, water spills over the upper edge 132 of the collector 102 and cascades into the center opening 120 and down the floor drain 84.
When the showering has ended a certain amount of water from the bathtub 80, i.e. to the water level 264 will remain in the bathtub 80 unless the collector 102 is then removed from the bathtub 80 in order that the water can flow down the floor drain 84.
If removal of the collector 102 is impractical, an alternative is to utilize the collector 302 or 402 which has a U-shaped configuration which permits drainage of the water level of the bathtub 80 when the showering is complete.
The use of the doughnut shaped connector 102 or 202 when used with the bathtub 80 having the showerhead 110, permits the flow of water in the bottom of the bathtub 80 to cascade over the upper edge 132 of the collector 102 to avoid an excessively high water level in the bathtub 80 during the showering.
The use of the U-shaped collected 302 or 402 or the placement of the collector 102 or 202 in an area other than near the floor drain 84, prevents the accumulation of water in the bathtub 80 when the bathing is over.
The presence of the filter 162 in the plumbing between the collector 102 and the vacuum pump 167 prevents damage to the vacuum pump 167 and the valves 72 and 178 from contamination in the gray water.
The use of the reserve supply means 188 connected with the second float 196 and the reserve supply valve 194 with an outlet 198 in the tank 22 provides for reserve water supply in the event that the use of the water for the tank-type toilet 36 greatly exceeds the use of water for bathing.
The use of the recovery system 20 of the present invention permits for the incremental installation of a water recovery system in the single bathroom 30, in order that investment costs for a conversion to recovery systems can be extended over a longer period of time.
The use of the removable collector 102 and external wiring and plumbing, as well as the tank 22 located within the bathroom 30 minimizes the cost of the installation by minimizing the quantity of plumbing and wiring required, minimizing the cost of the installation of the wiring and the plumbing and eliminating the need for any plaster, dry wall or other structural work.
Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings and the appended claims. | A waste water recovery system for recycling shower/bath water for use in a tank-type toilet is provided. The system includes a storage tank with a suction pump to draw water into the storage tank. The system also includes a valve which is used to timely shut off the pump when the tank is full. Recovered water from the storage tank is delivered to the toilet tank when needed. A collector which surrounds the floor drain is removably attachable either by adhesive or suction means to the floor of a bath or shower and has an inlet and an outlet. Waste water is drawn by a suction pump from the outlet of a collector to the storage tank. | 4 |
BACKGROUND AND SUMMARY
The invention relates to in-mold decorating, and more particularly to in-mold decorating with laser etching.
In-mold decorating is known in the art. A flat thin plastic substrate, such as polycarbonate, polyester, etc. is provided in extruded sheet form, typically 0.005 to 0.030 inch thick. One or more ink layers are then printed on the substrate, which ink layers may be printed to provide desired graphics. The flat substrate is then formed into a contoured three-dimensional workpiece, which forming may be aided by heat, i.e. thermal-forming, or without heat, i.e. cold forming. The substrate may then be cut into a plurality of subpieces, for example each containing one or two contoured items. The substrate, or each subpiece if so cut, is then placed in an injection mold, followed by closing of the mold, then injection of molten plastic against the workpiece to fuse therewith and form an injection molded part, following by opening of the mold, and removal of the part from the injection mold. Laser etching is also known in the art. The laser is used to ablate designated portions of ink layers to provide a desired graphic.
The present invention provides an in-mold decorating and laser etching method combining the best aspects of in-mold decorating and of laser etching and affording both lower manufacturing cost and higher image quality. In a further desirable aspect, the invention enables numerous applications and functional features, including both daytime and nighttime display of the same graphic on the same item, different color displays for nighttime and daytime of the same graphic on the same item, separate displays for nighttime and daytime on the same item, different color and multicolor dual displays for nighttime and/or daytime on the same item, semi-transparent or blank displays and selective color displays of the same graphic on the same item, and numerous manufacturing sequencing options for cost effectiveness.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a layering sequence for in-mold decorating and laser etching in accordance with the invention.
FIG. 2 is an assembled perspective view of the layered substrate of FIG. 1 .
FIG. 3 is a sectional view taken along line 3 — 3 of FIG. 2 .
FIG. 4 is a perspective view showing the substrate of FIG. 3 after forming into a contoured three dimensional workpiece.
FIG. 5 is a perspective view of the workpiece of FIG. 4 after a cutting step.
FIG. 6 is a schematic sectional view illustrating injection molding.
FIG. 7 is a sectional view taken along line 7 — 7 of FIG. 6 .
FIG. 8 is a view similar to FIG. 7, and illustrates an alternate embodiment.
FIG. 9 is a perspective view illustrating the injection molded part after the injection molding of FIGS. 6 and 7.
FIG. 10 is a perspective view from below of the part of FIG. 9 .
FIG. 11 is a sectional view taken along line 11 — 11 of FIG. 10, and illustrates laser etching.
FIG. 12 is a top view of the part of FIG. 11 after laser etching.
FIG. 13 is a sectional view taken along line 13 — 13 of FIG. 12 .
FIG. 14 is an enlarged view taken along line 14 — 14 of FIG. 12 . FIG. 14 illustrates daytime viewing.
FIG. 15 is a side view partially in section illustrating an application of the part of FIGS. 12 and 13.
FIG. 16 is like FIG. 15 and shows another mode of operation.
FIG. 17 is like FIG. 15 and shows a further mode of operation.
FIG. 18 is like FIG. 14 and illustrates nighttime viewing.
FIG. 19 is like FIG. 1 and shows another embodiment.
FIG. 20 is like FIG. 14 and illustrates daytime viewing for the combination of FIG. 19 .
FIG. 21 is like FIG. 20 and illustrates nighttime viewing.
FIG. 22 is like FIG. 1 and shows a further embodiment.
FIG. 23 is like FIG. 14 and illustrates daytime viewing for the combination of FIG. 22 .
FIG. 24 is like FIG. 23 and illustrates nighttime viewing.
FIG. 25 is like FIG. 1 and shows a further embodiment.
FIG. 26 is like a portion of FIG. 13 and illustrates the formed part for the combination of FIG. 25 .
FIG. 27 is like FIG. 14 and illustrates daytime viewing for the combination of FIG. 25 .
FIG. 28 is like FIG. 27 and illustrates nighttime viewing.
FIG. 29 is like FIG. 1 and shows a further embodiment.
FIG. 30 is similar to a portion of FIG. 9 and illustrates the formed part for the combination of FIG. 29 .
FIG. 31 is like FIG. 1 and shows a further embodiment.
FIG. 32 is like FIG. 3 and shows the substrate layering for the combination of FIG. 31 .
FIG. 33 is like FIG. 12 and illustrates a top daytime view of the part formed by the combination of FIG. 31 .
FIG. 34 is a sectional view taken along line 34 — 34 of FIG. 33 .
FIG. 35 is like FIG. 33 and illustrates a top nighttime view.
FIG. 36 is a sectional view taken along line 36 — 36 of FIG. 35 .
FIG. 37 is like FIG. 2 and shows a further embodiment.
FIG. 38 is like FIG. 4 and shows the contoured workpiece for the combination of FIG. 37 .
FIG. 39 is a perspective view of the structure of FIG. 38 after cutting into a plurality of subworkpieces.
FIG. 40 is like FIG. 9 and illustrates the formed part from the construction of FIG. 39 .
FIG. 41 is like FIG. 12 and illustrates the part of FIG. 40 after laser etching.
FIG. 42 is a perspective view of the part of FIG. 41 .
FIG. 43 is a rear elevational view of the part of FIG. 41 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a flat thin sheet plastic substrate 50 , for example polycarbonate, polyester, etc., extruded in sheet form, and typically 0.005 to 0.030 inch thick. A translucent white layer 52 is printed on substrate 50 . Layer 52 is preferably screen printed on substrate 50 , though other methods may be used for applying such layer, and other layers, to be described, including offset printing, roll coating, and other methods of applying or coating a layer. Layer 52 is preferably printed with a translucent white catalyzed ink to achieve a high melt temperature and abrasion resistance. Following printing of layer 52 , opaque layers 54 and 56 and hard coat layer 58 are printed on the substrate, to provide the layered structure shown in FIGS. 2 and 3. Each of opaque layers 54 and 56 is a black screen printing ink. A single opaque layer may be sufficient, though two layers are preferred, to minimize pinhole leakage, and maximize opacity. Hard coat layer 58 is transparent and preferably has a high abrasion resistance. Layer 52 is printed with laser-vaporization-resistant ink. Layer 54 , 56 , 58 are printed with laser-vaporization-susceptible inks. In FIGS. 2 and 3, layers 52 , 54 , 56 , 58 are collectively designated by reference character 60 .
Layered flat substrate 50 , FIG. 2, with layering 60 thereon, is formed into a contoured three dimensional workpiece 62 , FIG. 4 . The forming is preferably aided by heat in accordance with known thermal-forming techniques, and preferably also aided by vacuum and/or pressure in accordance with known thermo-vacuum forming techniques. Alternatively, the substrate may be cold formed into a contoured three dimensional workpiece. The layered and formed substrate is then cut, e.g. in accordance with known die-cutting techniques, to trim and remove the portion of the substrate which will not be used in the final part, to yield the workpiece 62 shown in FIG. 5 . The workpiece is then placed in an injection mold 64 , FIG. 6, followed by injecting of molten plastic against the workpiece to fuse therewith and form an injection molded part, followed by removal of the part from the injection mold.
Injection molding is known, and will be only briefly described. The mold has a female mold half 66 and a male mold half 68 defining a mold cavity 70 therebetween receiving workpiece 62 . The mold is initially open, with mold halves 66 and 68 separated. Workpiece 62 is placed in female mold half 66 , whereafter one or both of the mold halves are moved towards each other to close the mold. FIGS. 6 and 7 show the mold in its closed condition. Plastic resin, preferably polycarbonate, pellets 72 are introduced at hopper 74 into cooling zone 76 of heating cylinder or barrel 78 . An actuator 80 has an extendable and retractable plunger or ram or piston 82 pushing the pellets into injection chamber 84 in heating zone 86 , wherein the pellets are melted to molten plastic and spread by torpedo or spreader 88 and injected through nozzle 90 and sprue or runner 92 into cavity 70 , all as is known. The injected molten plastic in cavity 70 fuses with workpiece 62 to form an injection molded part. After cooling, the mold is opened, and the part removed from the mold. FIG. 8 shows an alternate embodiment, wherein one of the mold halves, such as female mold half 66 , includes knife edge projections such as 94 cutting the contoured substrate of FIG. 4 during the mold closing step, to eliminate the die-cutting step between FIGS. 4 and 5.
FIGS. 9 and 10 show the molded part 96 removed from the mold. The molded part includes substrate 50 , printed layers 60 , and fused and hardened plastic base 98 , FIGS. 11 and 13, which had filled mold cavity 70 . In the embodiment shown, male mold half 68 includes blocking surfaces 100 , 102 , FIG. 7, engaging substrate 50 at respective designated windows, 104 , 106 , FIGS. 10, 13 , in alignment with white translucent layer 52 and blocking impingement of molten plastic against substrate 50 at such respective window. Molded part 96 is then etched with laser 108 , FIG. 11, at laser beam 109 to provide a designated graphic in the opaque layers on the part, for example “UP” at 110 and “DN” at 112 , FIG. 12 . Various types of lasers are commercially available for such etching applications, for example one of which is “Insta Mark Laser Marking Systems”, Insignia Icon Stylus, Control Laser Corporation, 7503 Chancellor Drive, Orlando, Fla., USA 32809. As noted above, hard coat layer 58 and opaque layers 56 and 54 are printed with laser-vaporization-susceptible ink, whereby such layers ablate away as etched along the desired graphic by laser 108 . White translucent layer 52 is printed with laser-vaporization-resistant ink and hence does not ablate away.
FIG. 14 illustrates the daytime visual display of molded part 96 . Incoming ambient light at 114 is reflected by layer 52 back towards the user or viewer at 116 . Thus, layer 52 provides a daytime color showing the designated graphics “UP” and “DN” as white lettering against the black background of opaque layers 54 , 52 through transparent outer hard coat layer 58 .
FIG. 18 illustrates the nighttime visual display in conjunction with the application illustrated in FIGS. 15-17. Molded part 96 is in the form of a toggle or paddle button nested in an automotive instrument cluster panel 118 , FIG. 15, and having a central molded stem 120 engaging switch 122 for actuating the latter between a first position, FIG. 16, illuminating light bulb 124 , and a second position, FIG. 17, illuminating light bulb 126 . Part 96 rocks about integrally molded trinions 128 , 130 . In the central neutral position shown in FIG. 15, neither light bulb 124 nor 126 is illuminated, and daytime viewing is as shown in FIG. 14, with both “UP” and “DN” being visible by reflection of ambient light as white lettering against a black background. In the nighttime operational mode illustrated in FIG. 16, “UP” on leftward rocking of molded part rocker button 96 as shown at arrow 132 , light bulb 124 is illuminated, and light therefrom passes through substrate 50 and white translucent layer 52 as shown at arrow 134 , FIG. 18, providing an illuminated white “UP” graphic at 110 . Likewise, when rocker button molded part 96 is rocked rightwardly as shown at arrow 136 in FIG. 17, light from illuminated bulb 126 shines through substrate 50 and layer 52 , providing an illuminated white “DN” graphic at 112 . In each of the rocked positions of FIGS. 16 and 17, the light passing through layer 52 at 134 in addition to the reflective ambient light at 116 , FIG. 14, provides additional and brighter indication of the condition of the switch, including during daytime. This provides feedback to the user or driver of whether the switch is in its up or down actuated position. For example, during daytime, in the position of FIG. 16, the graphic “UP” at 110 will be brighter than the graphic “DN” at 112 , and hence the user will know the switch is in its activated “UP” condition for the controlled function, e.g. power window activated “UP”. At nighttime, in the position of FIG. 16, the “UP” graphic at 110 will be visible due to the through-transmitted light at 134 , and the “DN” graphic at 112 will not be visible, and hence the noted feedback will be provided to the user.
In another embodiment, both light bulbs 124 and 126 are always illuminated at nighttime, e.g. when the driver turns on his parking lights or headlights. In this embodiment, both the “UP” graphic at 110 and the “DN” graphic at 112 are visible to the driver, including at nighttime due to transmitted light 134 . The driver may thus select which function is desired, e.g. window “UP” or window down. Other combinations are possible.
Substrate 50 has first and second oppositely facing surfaces 140 and 142 , FIG. 1 . First surface 140 faces the user. In backlit applications, e.g. FIGS. 15-18, second surface 142 faces the backlight, 124 , 126 . These definitions of first and second surfaces are commonly used in the printing art, for example first surface printing, second surface printing, and so on. In the embodiments described thus far, the noted layers are printed on the first surface, and the molten plastic from runner sprue 92 is injected against the second surface. The laser etching step is performed by directing the laser beam 109 at the first surface. In an alternate embodiment, color layer 52 is printed on second surface 142 , i.e. on the opposite side of the substrate from the opaque layers 54 , 56 , to be described.
FIG. 19 shows a further embodiment with first and second color layers 52 and 144 printed on substrate 50 . Layer 52 is a translucent daytime color ink, preferably white as noted above. Layer 144 is printed with a nighttime color ink, for example amber, or other colors as desired. In daytime, FIG. 20, the part displays to the user the daytime color at the graphic, as shown by reflected ambient light 114 , 116 . At nighttime with a backlight, the part displays to the user the nighttime color at the graphic, for example ambient as shown at 134 in FIG. 21 . In FIG. 19, color layers 52 and 144 are printed on opposite sides of the substrate.
In an alternate embodiment as shown in FIGS. 22-24, layers 144 and 52 are printed on the same side of the substrate, which may be the first surface as shown, or alternatively may be the second surface. The daytime color at the graphic is white as shown in FIG. 23 at reflected ambient light 114 , 116 . The nighttime color at the graphic is amber as shown in FIG. 24 at 134 from the backlight.
FIG. 25 shows an embodiment similar to FIG. 19, except that color layer 144 has been replaced with two layers 146 and 148 of different color, one for each window 104 and 106 , FIGS. 26 and 13. Each window has a daytime reflective color as illustrated in FIG. 27 . Window 104 has a nighttime color provided by layer 146 , like that illustrated in FIG. 21 . Window 106 has a different nighttime color provided by layer 148 , FIG. 28 .
FIGS. 29 and 30 show a further embodiment reducing the amount of ink used, for cost savings. Layer 144 of FIG. 19 is reduced in size as shown at layer 150 in FIG. 29 to cover only the top of the molded part, which is the portion where the graphic is. Layer 52 may also be reduced in size.
FIGS. 31-36 show a further embodiment. FIG. 31 includes substrate 50 having the following layers printed thereon: opaque layer 152 ; amber layer 154 ; translucent white layer 156 ; smoked translucent ink layer 158 ; opaque layer 160 ; transparent hardcoat layer 58 . Layers 152 , 154 , 158 are in alignment with window 104 . Layers 156 , 160 are in alignment with window 106 . The molded part is laser etched to provide the graphics shown in FIG. 35 at the resistive heater symbol at 162 , and the text graphic “MIRR HEAT” at 164 , for example, for a rocker or paddle switch controlling an electrically heated side mirror on an automobile. In daytime, smoked translucent layer 158 reflects ambient light as shown at 166 , 168 , FIG. 34, and blocks user view of graphics thereunder. The respective half of the rocker button part aligned with window 104 thus appears blank as shown in FIG. 33 at rocker button portion 170 , i.e. graphic 162 is not visible. Also in daytime, white translucent layer 156 reflects ambient light as shown at 172 , 174 , FIG. 34, such that the user sees the etched graphic “MIRR HEAT” at 164 aligned with window 106 . This is shown in FIG. 33 at rocker button half 176 where the user sees graphic 164 “MIRR HEAT” during daytime, which graphic is white because layer 156 is the color white. Other colors may be chosen. At nighttime, with illuminated backlights, the resistive heater symbol graphic on rocker button half 170 is visible as shown in FIG. 35 at 162 . The graphic color is amber due to the transmitted light as shown at 178 passing through amber layer 154 from the backlight. The other graphic “MIRR HEAT” at 164 at rocker button half 176 is also visible due to light at 180 , FIG. 36, passing through white layer 156 from the backlight.
FIG. 37 is similar to FIG. 2 and shows a further embodiment with a plurality of sets of layers 60 printed on substrate 50 . The substrate is formed, FIG. 38 into a three dimensional substrate, similarly to FIG. 4 . The substrate is cut, preferably by die cutting, into a plurality of workpieces, one of which is shown at 190 in FIG. 39 . Each of the workpieces is placed in an injection mold and molded as above described. Each workpiece 190 has at least one product portion, for example product portions 192 , 194 , to be formed into the respective part, and a registration portion 196 at the periphery of the product portion and which may link a pair of product portions as shown. Workpiece 190 with both product portions 192 and 194 and registration periphery portion 196 is placed in the mold, with registration portion 196 in registration with the mold. A second cutting step is performed, preferably by knife edges such as 94 , FIG. 8, in the mold and during the mold closing step to further cut the substrate prior to the injecting step, FIG. 6 . The noted second cutting step at least partially detaches registration portion 196 from product portions 192 , 194 . During the forming step from the construction of FIG. 37 to the construction of FIG. 38, registration marks such as 198 and 200 are formed in registration portion 196 . The registration marks are three dimensional deformations of substrate 50 at registration portion 196 . Further registration marks such as 202 and 204 are formed during the first mentioned cutting step between the constructions of FIGS. 38 and 39. Registration marks 202 , 204 are openings cut through substrate 50 at registration portion 196 during the noted first cutting step. After the noted second cutting step during closing of the mold, and the molding operation, the mold is opened, and each part removed, to provide the molded parts as above described, and as shown at 206 , FIG. 40 . Designated graphics such as 208 , 210 , FIG. 41, are then laser etched in the opaque layers 52 , 54 on the part at respective windows 212 , 214 , FIG. 43, formed by blocking surfaces 100 , 102 in the mold, as above described.
It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims. | An in-mold decorating and laser etching method prints a plurality of layers on a flat thin sheet plastic substrate, including combinations of opaque and colored, including translucent and smoked, forms the substrate into a contoured three dimensional workpiece, injection molds the workpiece to an injection molded part, and laser etches a designated graphic in the opaque layer on the part. | 1 |
This is a divisional of co-pending application Ser. No. 06/692919 filed as PCT/CH83/00138, Dec. 8, 1983, U.S. Pat. No. 4,908,269.
FIELD OF THE INVENTION
The invention pertains to a crimped polyester yarn obtained from cold drawn polyester-POY (Partially Oriented Yarn), as well as a process for its manufacture, and the application of such yarns.
BACKGROUND OF THE INVENTION
German Patent DE-AS 1,291,852 (U.S. counterpart being U.S. Letters Pat. No. 2,979,883) pertains to a process for the manufacture of fibers, yarns or films from crystallizable polyester, by the following steps: (a) slow melt spinning, (b) subsequent warm drawing and (c) thermal shrinkage. The thus obtained fibers, yarns or films may be irreversibly lengthened by moderate heat treatment, without having a tension exerted thereon. Once lengthened, these fibers do not return on their original length by cooling and drying.
Moreover, Japanese Application 0 055 268 discloses the cold drawing of a polyester yarn in a draw ratio of 1.05-1.35, while the yarn is being spun at a rate ranging between 4000 and 7000 m/min. Notwithstanding the above references, the literature does not disclose the possibility of subjecting such yarns to aftertreatment processes.
SUMMARY OF THE INVENTION
The present invention pertains to a new yarn which is manufactured by the aftertreatment of a cold-drawn polyester-POY.
Specifically, the present invention pertains to a crimped polyester yarn, obtained from cold-drawn polyester-POY yarn, characterized in that the stress/strain course between 10 and 30% elongation, resulting from the stretch test, corresponds to a secant modulus of 0-100%.
As used herein, the term "secant modulus" refers to the end value of a straight line, defined by the stress at 10 and 30% elongation, parallel shifted to stress 0 at elongation 0. The unity corresponds to the percentage portion of the breaking stress by 100% theoretical elongation. The definition of the term "secant modulus" will be further explained in relation with FIG. 1. Briefly, FIG. 1 shows a stress/strain diagram having a marked plateau zone between points 3 and 4. This plateau zone characterizes the yarn according to the present invention.
The yarns of the present invention are twistless and totally shrunk. Although twistless, these yarns are, nevertheless, crimped. The crimp imparted on the novel yarns is three dimensional, optically interesting and presents a fine appearance. Moreover, the crimp of the individual yarn fibrils is also irregular.
As used herein, the term "polyester-POY" refers to endless, cold-drawn yarns which are spun at a rate between 2000 and 5000 m/min. This cold-drawing process takes place at room temperature on a draw machine (e.g., a draw-twist or draw-wind machine) at a draw ratio ranging from 1.2 to 2.2. The denier of the individual yarn filaments is not critical.
The invention further pertains to a process for the manufacture of the above-mentioned crimped yarns, wherein the cold-drawn polyester-POY is subjected to a thermal treatment. This thermal treatment can be carried out in air, vapor or an inert liquid.
As used herein, the term "inert liquid" refers to a liquid which: (a) does not dissolve the polyester-POY, and (b) does not react with the polyester-POY. Water is a presently preferred "inert liquid", if such is employed. During this thermal treatment process, the cold-drawn polyester-POY shrinks substantially (i.e., up to 60%).
Although there is substantial shrinkage during the aforementioned thermal treatment process, the shrinkage force of the cold-drawn polyester-POY is, nevertheless, very small. Thus, the smallest stresses could reduce or even prevent the cold-drawn polyester-POY from shrinking. In view of relatively small shrinkage force, the thermal treatment of the polyester-POY is carried out: (a) under tensionless conditions, and/or (b) under controlled overfeed. If employed, the overfeed varies from between 20 and 100%, preferably, between 40 and 80%.
The thermal treatment of the cold-drawn polyester-POY preferably takes place in a "shocking way". The term "shocking way", when used to describe a particular thermal treatment process, refers to either a sudden, short-term warming up process of the yarn, or a process wherein the yarn is introduced into a warm bath.
One method of thermally treating the cold-drawn polyester-POY is by subjecting it to air which has been heated to a temperature of more than 80° C., preferably, to a temperature ranging between 140 and 220° C., while, simultaneously, subjecting the yarn to a controlled overfeed ranging between 20-100%, preferably, between 40-80%. A convection heater is especially useful for practicing this method of thermally treating the cold-drawn polyester-POY yarn.
If the thermal treatment is carried out by subjecting the yarn to steam or an inert liquid, the thermal treatment is maintained at a temperature of more than 60° C., preferably, at a temperature ranging from 90°-100° C. This thermal treatment will be carried out while the yarn is under tensionless conditions, and while the yarn is being subjected to a controlled overfeed ranging from 20-100%, preferably, from 40-80%. As used herein, the term "steam" refers to either saturated steam or overheated water steam.
The crimp of the yarn according to the present invention is irregular and stress sensitive. Accordingly, any further processing of the yarn should be carried out under a stress less than about 0.5 cN/dtex. This is possible or normally the case with all present knitting, weaving and warp-knitting machines.
The invention further pertains to employing the crimped yarn resulting from the process disclosed herein in conventional knitting, weaving and warp-knitting processes.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is more fully explained by referring to the figures briefly described below:
FIG. 1 is a stress/strain diagram of a yarn according to the invention, as well as the representation of the secant modulus and how it is determined.
FIG. 2 is a stress/strain diagram of the raw material and of the yarn prepared in accordance with the present invention.
FIG. 3 is a stress/strain diagram of the raw material and of the yarn prepared in accordance with the present invention.
FIG. 4a is a photograph of a false twist textured yarn;
FIG. 4b is a photograph of a yarn prepared in accordance with the present invention; and
FIG. 4c is a photograph of a flat yarn.
FIG. 5 is a photograph illustrating the characteristic surface structure of a yarn prepared in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows stress/strain curve A of a polyester yarn prepared in accordance with the present invention. This yarn is a half mat, round yarn, tested according to DIN 53834, first part.
Point 1 on curve A represents the breaking stress in Newtons. Point 2 on this same curve represents the breaking elongation in percentage.
The yarn is characterized by the plateau zone between points 3 and 4 on curve A. A straight line, B, is drawn between point 3, wherein elongation is 10%, and point 4, wherein elongation is 30%. Line B is extrapolated to the point where elongation is zero and the theoretical elongation of 100% (i.e., point 5).
In order to calculate the secant modulus of the yarn, line B is parallel shifted so that, when stress is zero, elongation is also zero. This parallel shifted line is identified as line C.
By looking at the point where line C intersects elongation at 100% (i.e., point 6), the secant modulus (s) of the yarn can be determined. Specifically, according to FIG. 1, the thus obtained stress by 100% theoretical elongation is calculated and is expressed as a percentage of the effective breaking stress (point D). In FIG. 1, the secant modulus (s) equals 23.5%.
FIG. 2 shows curve F (i.e., stress/strain diagram of a cold-drawn polyester-POY), and curve G (i.e., a stress-strain diagram of a thermally treated cold-drawn polyester-POY). The thermal treatment took place and in a "shocking way", under tensionless conditions, and in warm water.
FIG. 3 shows curves H and I which are stress/strain diagrams of polyester yarns prepared in accordance with the invention. These yarns were thermally treated while being subjected to a 40% and 80% overfeed, respectively. Both tests took place with polyester yarns, half mat, round (denier of the cold-drawn polyester-POY dtex 84 f 15) at a temperature of 200° C. The heating device employed was a convection heater. The speed was at 110 m/min. Lines H and I , which correspond with curves H and I, respectively, give a value of the secant modulus where "s" equals 46.4% and 11.3%, respectively.
FIG. 4b shows a yarn prepared in accordance with the present invention; FIG. 4a shows a false twist textured polyester yarn; and, FIG. 4c shows a flat yarn. The irregularity of the crimp of the individual yarn fibrils is clearly evident from comparing FIG. 4b to FIGS. 4a and 4c.
FIG. 5 shows a Scanning-Electronic-Microscope photograph of a yarn prepared in accordance with the present invention. The magnification of the yarn in FIG. 5 was 2100 : 1. The transverse surface lines, which result when practicing the process of this invention, are clear from this photograph.
EXAMPLES
The invention will be more fully explained by the following examples.
Example 1 (Three-step Process)
Here, a polyester-POY dtex 150 f 15 was manufactured at a speed of 3100 m/min. The drawing took place with a ratio of 1:1.93 at 652 m/min, and at room temperature, on a draw-twist machine.
Subsequently, the bobbins were shrunk in a shocking way on a fixing machine and a poststabilizing machine, respectively, while in a convection heater maintained at 200° C. The heat length was 63 cm.
The withdrawal speed of the yarn was at 110 m/min. The delivery speed varied between 154 m/min and 198 m/min. The lower limit (i.e., 154 m/min) corresponds to a 40% overfeed with a 28.6% shrinkage (see, FIG. 3, curve H); and the upper limit (i.e., 198 m/min) corresponds to an 80% overfeed with a 44.4% shrinkage (see, FIG. 3, curve I).
The properties of the yarn prepared in accordance with the aforementioned process are set out in Table 1, below.
TABLE 1______________________________________ 40% overfeed 80% overfeed______________________________________Secant modulus "S" (%) 46.4 (H.sub.1) 11.3 (I.sub.1)Breaking stress (N) 3.7 3.4Breaking 72 107elongation (%)Boiling shrinkage 0.2 +1.8at 98% C (%)Hot shrinkage +4.3 +11.0at 160° C. (%)______________________________________ + = extension
Example 2 (Two-step process)
Here, polyester-POY dtex 170 f 36 was manufactured at a speed of 3100 m/min. These bobbins were continuously cold-drawn and shrunk in a shocking way. The manufacturing conditions for this yarn are set out in Table 2, below.
TABLE 2______________________________________ Variant A Variant B______________________________________Entering in the 91 m/min 229 m/mindraw-zoneDraw-ratio 1:1.75 1:1.75Withdrawal rate 160 m/min 400 m/minConvection heater:Temperature of the 220° C. 220° C.shrinking zoneLength of the heater 1.20 m 1.20 mOverfeed/Shrinkage 60% / 37.5% 60% / 37.5%Winding rate 100 m/min 250 m/min______________________________________
The properties of the yarn prepared in accordance with this process are set out in Table 3, below.
TABLE 3______________________________________ Variant A Variant B______________________________________Secant modulus "S" (%) 65.6 23.3Breaking stress (N) 3.2 3.9Breaking 67 92elongation (%)Boiling shrinkage 1.2 +2at 98% C (%)Hot shrinkage +1.5 +9at 160° C. (%)______________________________________ + = extension
The yarns prepared in accordance with the present invention are useful, for example, in knitting, weaving and warp-knitting processes. These yarns can also be twisted and/or sized for weaving warp use. | A process for the manufacture of a crimped polyester yarn obtained from a polyester partially-oriented yarn comprising fabricating a partially-oriented polyester yarn by a high-speed process, cooling the partially-oriented polyester yarn, cold drawing the cooled yarn, and subjecting the cold drawn polyester yarn to a thermal treatment under tensionless conditions or under controlled overfeed conditions. | 3 |
BACKGROUND
[0001] A power cable is an assembly of two or more electrical conductors, usually held together with a sheath. The assembly may be used for transmission of electrical power. Power cables may be installed, for example, as permanent wiring within buildings, buried in the ground, run overhead or exposed. Flexible power cables may be used for portable devices, mobile tools and machinery.
[0002] Cables may include three major components: conductors, insulation and protective jacketing. The makeup of individual cables may vary according to application. The construction and material may be determined by the working voltage, current-carrying capacity and environmental conditions.
[0003] Power cables may use stranded copper or aluminum conductors. Small power cables may use solid conductors. The cable may include un-insulated conductors for circuit neutral or ground (earth) connection.
[0004] The overall assembly may be round or flat. Non-conducting filler strands may be added to the assembly to maintain its shape. Special purpose power cables for overhead or vertical use may have additional elements such as steel or Kevlar structural supports.
[0005] Common types of general-purpose cables are regulated by national and/or international codes. These codes define the various wire alloys that may make up a cable, its insulation type and characteristics, including its resistance to chemicals and sunlight.
[0006] Commonly-used power cables may contain an un-insulated bare wire for connection to earth ground. Three prong power outlets and plug-cords require a grounding wire. Extension cables often have an insulated grounding wire.
[0007] ROMEX is a cable made of solid copper wires with a nonmetallic plastic jacket containing a waxed paper wrapped inner group of at least a pair of 600 volt THWN plastic insulated service wires and a bare ground wire. A common ROMEX cable may thus have three wires: a neutral wire (colored white), a wire providing power to the load (colored black) and a bare grounding wire.
[0008] Another common ROMEX variant has a neutral, identified by white coloring, two phase wires: a first conductor (black) and a second conductor (usually red), and an un-insulated copper grounding wire. This type may be generally used for multiple switching locations of a common or shared lighting arrangement, such as for switches located at either end of a hallway, or on both upper and lower floors for stairway lighting.
SUMMARY
[0009] A method for monitoring a temperature change of a power distribution circuit having a power line and return line includes measuring an output current and output voltage of the power distribution circuit at an input to a load electrically connected to the power distribution circuit, and determining a change in temperature of at least one of the power line and return line based on a change in at least one of the output current and output voltage.
[0010] An automotive vehicle having a power storage unit capable of receiving power from a power distribution circuit having a power line and return line includes a monitoring circuit capable of being electrically connected between the power distribution circuit and the power storage unit. The monitoring circuit is configured to measure an output current and output voltage of the power distribution circuit, and determine a change in temperature of at least one of the power line and return line based on a change in at least one of the output current and output voltage.
[0011] A battery charger capable of receiving power from a power distribution circuit having a power line and return line, and capable of transferring the power to a battery includes a monitoring circuit. The monitoring circuit is configured to measure an output current and output voltage of the power distribution circuit at the battery charger, and to determine a change in temperature of at least one of the power line and return line based on a change in at least one of the output current and output voltage.
[0012] A method for monitoring a temperature change of a power distribution circuit having a power line and return line includes measuring an output current or output voltage of the power distribution circuit at an input to a load electrically connected to the power distribution circuit, measuring an input current and input voltage to the load, and determining a change in temperature of at least one of the power line and return line based on a change in at least one of the output current, output voltage, input current and input voltage.
[0013] While example embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the invention. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic diagram of an automotive vehicle according to an embodiment of the invention.
[0015] FIG. 2 is a schematic diagram of a battery charger according to an embodiment of the invention.
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1 , an embodiment of an automotive vehicle 10 , e.g., hybrid electric, electric, etc., includes a traction battery 12 , electric machine 13 , battery charger 14 and chassis 15 . As apparent to those of ordinary skill, the traction battery 12 may provide motive power for the vehicle 10 via the electric machine 13 .
[0017] The battery charger 14 may include a pair of coils 16 , 18 , a bridge rectifier 20 , transistor 22 , diode 24 and inductor 26 . As apparent to those of ordinary skill, the transistor 22 , diode 24 and inductor 26 form a buck regulator 27 and may be used to regulate the current from the bridge rectifier 20 to the traction battery 12 .
[0018] The coil 18 includes a power terminal 28 and a return terminal 30 . The coil 18 may be electrically connected with an electrical outlet 32 via a power cable 34 . The electrical outlet 32 of FIG. 1 is a 120 V wall outlet. In other embodiments, the electrical outlet 32 may be a 240 V wall outlet, a multiphase wall outlet, etc. As known in the art, the turn ratio of the coils 16 , 18 may depend on the voltages associated with the battery 12 and outlet 32 .
[0019] The coil 16 may be electrically connected with the traction battery 12 through the bridge rectifier 20 , transistor 22 and inductor 26 . As known in the art, the bridge rectifier 20 (or diode bridge) may be an arrangement of four diodes in a bridge configuration. This arrangement may provide the same polarity of output voltage for any polarity of input voltage. In this embodiment, the bridge rectifier 20 converts alternating current input into direct current output.
[0020] The power cable 34 includes a power line 36 , return line 38 and ground line 40 . The power line 36 is electrically connected with the power terminal 28 . The return line 38 is electrically connected with the return terminal 30 . The ground line 40 is electrically connected with the chassis 15 . In the embodiment of FIG. 1 , the power line 36 delivers current from the outlet 32 to the coil 18 and the return line 38 delivers current from the coil 18 to the outlet 32 .
[0021] The battery charger 14 may also include a microprocessor 42 , current sensors 44 , 45 and voltage sensors 46 , 47 . The microprocessor receives current and voltage information from the current sensors 44 , 45 and voltage sensors 46 , 47 . In the embodiment of FIG. 1 , the current sensor 44 senses current through the coil 18 and return terminal 30 and the voltage sensor 46 senses voltage between the return terminal 30 and ground line 40 . The current sensor 45 senses current to the traction battery 12 and the voltage sensor 47 senses voltage across the traction battery 12 . Other arrangements, however, are also possible. As an example, the voltage sensor 46 may be positioned to sense voltage between the power terminal 28 and return terminal 30 . As another example, the current sensor 44 and/or voltage sensor 46 may be positioned to sense current and/or voltage between the bridge rectifier 20 and transistor 22 . Other configurations are also contemplated.
[0022] The microprocessor 42 may determine a change in temperature of the power and/or return lines 36 , 38 based on, for example, the current and voltage measured by the current and voltage sensors 44 , 46 . The instantaneous resistance, R, of a wire having a temperature coefficient of resistance, α, may be related to a change in temperature, ΔT, of the power and/or return lines 36 , 38 by the following relation:
[0000]
R
=
R
i
(
1
+
αΔ
T
)
,
or
(
1
)
Δ
T
=
Δ
R
α
R
i
(
2
)
[0000] where R i is the initial resistance of the wire. In terms of voltages and currents, equation (2) may be rewritten as
[0000]
Δ
T
=
(
V
I
-
V
i
I
i
)
(
I
i
V
i
)
(
1
α
)
,
or
(
3
)
Δ
T
=
(
VI
i
V
i
I
-
1
)
(
1
α
)
(
4
)
[0000] where I and V are the instantaneous current and voltage measured respectively by the sensors 44 , 46 , and I i and V i are the initial current and voltage measured respectively by the sensors 44 , 46 . Based on equation (4), the microprocessor 42 may determine a change in temperature of the power and/or return lines 36 , 38 based on the current and voltage measured by the current and voltage sensors 44 , 46 . In other embodiments, the battery charger 14 may control the current flow through it to keep it generally constant, in a known fashion, and thus the microprocessor 42 may determine a change in temperature of the power and/or return lines 36 , 38 based only on the voltage measured by the voltage sensor 46 . In still other embodiments, the microprocessor 42 may determine a change in temperature of the power and/or return lines 36 , 38 based on the voltage measured between the power terminal 28 and return terminal 30 . As apparent to those of ordinary skill (using the notation described above),
[0000]
R
i
=
V
LN
-
-
V
LN
i
+
2
I
(
5
)
R
=
V
LN
-
-
V
LN
+
2
I
(
6
)
[0000] where V LN − is the instantaneous voltage between the power terminal 28 and return terminal 30 just before current begins passing through the battery charger 14 , V LNi + is the instantaneous voltage between the power terminal 28 and return terminal 30 just after current begins passing through the battery charger 14 , and V LN + is the instantaneous voltage between the power terminal 28 and return terminal 30 at any time after current begins passing through the battery charger 14 . Substituting equations (5) and (6) into equation (2) (and simplifying) yields
[0000]
Δ
T
=
(
V
LN
-
-
V
LN
+
V
LN
-
-
V
LNi
+
-
1
)
(
1
α
)
(
7
)
[0000] Based on equation (7), the microprocessor 42 may thus determine a change in temperature of the power and/or return lines 36 , 38 based on the voltage measured between the power terminal 28 and return terminal 30 .
[0023] Alternatively, a temperature or change in temperature of the power and/or return lines 36 , 38 may be determined in any suitable fashion. For example, temperature sensors (not shown), e.g., Wheatstone bridge, diode junction, etc., in communication with the microprocessor 42 and connected with the power and/or return lines 36 , 38 may detect and communicate the temperature of the power and/or return lines 36 , 38 to the microprocessor 42 .
[0024] The microprocessor 42 may turn on and turn off the transistor 22 to control the flow of current to the traction battery 12 . The microprocessor 42 may thus control the flow of current through the power and/or return lines 28 , 30 via the transistor 22 .
[0025] The power, P in , into the coil 18 is equal to the power, P out , out of the coil 16 (assuming negligible losses):
[0000] P i =P out (8)
[0000] In terms of currents and voltages, equation (8) may be rewritten as
[0000] ( I rms ·V rms )cos θ= I BAT ·V BAT (9)
[0000] where I rms and V rms are the root mean square current into and root mean square voltage across the coil 18 respectively, I BAT and V BAT are the current into and voltage across the traction battery 12 (the current and voltage measured by sensors 45 , 47 respectively), and Cos θ is the phase angle between I rms and V rms . (As apparent to those of ordinary skill, Cos θ is typically equal to 1 in systems with unity power factor correction.) Assuming V rms and V BAT are generally constant and according to equation (9), changes in I BAT will result in changes to I rms . That is, decreasing the duty cycle of the transistor 22 to reduce I BAT will reduce I rms . (The microprocessor 42 may thus also determine a change in temperature of the power and/or return lines 36 , 38 based on the current and voltage measured by the current sensor 44 , 45 and voltage sensor 47 . For example, equation (9) may be rearranged to solve for V rms and substituted into (7)).
[0026] To maintain the temperature of the power and/or return lines 28 , 30 within a desired range, the microprocessor 42 may begin to cycle the transistor 22 , in a known manner, as the temperature and/or change in temperature of the power and/or return lines 28 , 30 begins to approach an upper end of the range. For example, the microprocessor 42 may begin to cycle the transistor 42 to reduce the current flow if the change in temperature of the power and/or return lines 28 , 30 exceeds 35 degrees C. Alternatively, the microprocessor 42 may begin to cycle the transistor 42 to reduce the current flow if the temperature of the power and/or return lines 28 , 30 is within 7 degrees C. of the upper end of the range. Any suitable control scheme, however, may be used.
[0027] As illustrated, the charger 14 is integrated with the vehicle 10 . In other embodiments, however, the charger 14 may be remote from the vehicle 10 . For example, the charger 14 may be a stand alone unit that may be plugged into the electrical outlet 32 and vehicle 10 . Other arrangements are also possible.
[0028] Referring now to FIG. 2 , numbered elements that differ by 100 relative to numbered elements of FIG. 1 have descriptions that are similar, although not necessarily identical, to the numbered elements of FIG. 1 .
[0029] An embodiment of a battery charger 114 includes a bridge rectifier 120 , boost regulator 121 , buck regulator 127 and microprocessor 142 . The bridge rectifier 120 is electrically connected with the boost regulator 121 . The boost regulator 121 is electrically connected with the buck regulator 127 . The microprocessor 142 may control the boost and buck regulators 121 , 127 . The circuitry of the bridge rectifier 120 , boost regulator 121 and buck regulator 127 may take any suitable form.
[0030] The bridge rectifier 120 may be electrically connected with an electrical power outlet (not shown) and convert alternating current input into direct current output. As apparent to those of ordinary skill, the microprocessor 142 may control the boost regulator 121 , in a known fashion, to regulate the direct current output by the bridge rectifier 120 for power factor correction. Based on current and/or voltage measurements by the sensors 144 , 146 , the microprocessor 142 may control the buck regulator 127 , using techniques similar to those described above, for power distribution temperature management. Of course, other arrangements and/or configurations are also possible.
[0031] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. | A method for monitoring a temperature change of a power distribution circuit having a power line and return line includes measuring an output current and output voltage of the power distribution circuit at an input to a load electrically connected to the power distribution circuit, and determining a change in temperature of at least one of the power line and return line based on a change in at least one of the output current and output voltage. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
FIELD OF THE INVENTION
The present invention relates to the downloading of content for mobile telecommunications devices. More particularly, embodiments of the present invention provide for the authentication of users who attempt to download content.
BACKGROUND OF THE INVENTION
Users of mobile telecommunications devices can download content for their devices such as ring tones, screen savers, games, and other applications. These items might reside on computing equipment maintained by a provider of the telecommunications service. Alternatively, the telecommunications provider might wish to make content provided by third parties available to its customers. As used herein, the term ‘content provider’ can refer to either a telecommunications provider providing its own content or a third party making its content available to customers of a telecommunications provider.
Under current procedures for a content provider making content available to customers, the content provider might load the content into a content catalog, such as an electronic media application for presenting the offerings of the provider. The catalog would be accessible to customers through their mobile telecommunications devices so that customers could download content from the catalog to their mobile telecommunications devices (also known as handsets).
A content provider might wish to restrict access to its content so that only legitimate customers are allowed to download content. Therefore, it might be desirable to authenticate customers who attempt to download content to ensure that the customers are allowed to receive the content. Many commercially available authentication systems, such as public key infrastructure (PKI), require a great deal of computing capacity and memory. Such systems typically cannot be efficiently implemented on mobile telecommunications devices where computing capacity and memory might be limited.
SUMMARY OF THE INVENTION
According to one embodiment, a system is provided for securely downloading content to a mobile telecommunications device. The system includes a mobile application to enable the mobile telecommunications device to send a request for content identified on a telecommunication provider system. The system includes a content application maintained by the content provider to retrieve content and promote delivery of the content to the mobile telecommunications device. The system also includes a challenge component and a response component, the response component communicates with the mobile application and encodes a challenge data. The challenge component communicates with the content application. The challenge component sends the challenge data to the mobile application and decodes the challenge data received from the mobile application to validate the response for delivery of the content to the mobile application
According to another embodiment, a method is provided for authentication of a requesting entity by an authenticating entity to download content. The method includes downloading, from a telecommunication provider system by a portable device, an application in response to identifying content to download to the portable device. The method includes sending a request for content from the portable device to a content provider system. The content provider system maintains the content to download to the portable device. The method includes obtaining, by the content provider system, challenge data, and communicating the challenge data to the portable device. The method also includes encoding, by the portable device, the challenge data, and receiving the encoded challenge data by the content provider system. The method also includes decoding the challenge data to validate the portable device.
In another embodiment, the present disclosure provides a method for authentication of a requesting entity by an authenticating entity. The method includes the requesting entity sending to the authenticating entity a request for data. The authenticating entity retrieves a time data based on a current time of a system of the authenticating entity. The authenticating entity sends the retrieved time data to the requesting entity. The method also includes the requesting entity returning the retrieved time to the authenticating entity. The authenticating entity determines a received time and calculates a time difference between the retrieved time data and the received time when the retrieved time is received by the authenticating entity. The method also includes when the time difference is less than a predetermined threshold, the authenticating entity accepts the requesting entity as authentic.
These and other features and advantages will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the presentation and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings in detailed description, wherein like reference numerals represent like parts.
FIG. 1 is a block diagram of a system for securely downloading content to a mobile telecommunications device.
FIG. 2 is a flowchart of a method for securely downloading content to a mobile telecommunications device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It should be understood at the outset that although an exemplary implementation of one embodiment of the present invention is illustrated below, the present system may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the exemplary implementations, drawings, and techniques illustrated below, including the exemplary design and implementation illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
Embodiments of the present invention allow a content provider to authenticate a user who attempts to download content to a handset. Authentication is achieved through a challenge and response protocol that consumes only a minimal amount of computing capacity and memory and is therefore suitable for mobile telecommunications devices. Since mobile telecommunications devices typically do not have sophisticated session management capabilities, this technique provides a lightweight procedure for preventing unauthorized downloads. Standard network sign-on protocols are used to authenticate the handset and the user prior to any attempts to download content. The procedures described herein are a secondary authentication to prevent, for example but not limited to, an unauthorized user from obtaining content or gaining access by pretending to be an authorized user.
In an embodiment, when a user requests content to be downloaded, an application that manages communication with a content provider may be downloaded to the user's handset. In one embodiment, the application is a J2ME application but in other embodiments other types of applications appropriate for mobile telecommunications devices could be used. The application contains a key that can be used to encrypt and decrypt communications with the content provider. The content provider has the same key so that the content provider can encrypt and decrypt messages to and from the J2ME application. The specific key that is included with the application is also provided to the content provider. Periodically newly downloaded applications may be provided with new keys and the new key would also be provided to the content provider. In this manner, the keys change periodically for added security.
A single key, code, string or passkey, may be used for all applications and content providers, or each content provider and corresponding application may use a different key, or other combinations may be used. It will be appreciated that a number of other techniques for generating, managing, handling, and passing keys, as well as encrypting and decrypting the keys may be used and are well known to those skilled in the art. These techniques include public key encryption/decryption, but some techniques may require less robust systems which may be preferable for some embodiments of the present disclosure. For example, the key may be a hard-coded string or set of information and may use private key encryption/decryption systems, one-time pads, or encryption techniques such as, but not limited to, XORing the data string.
After being downloaded to the handset, the J2ME application sends a request for the selected content to the content provider. The content provider then uses a challenge and response procedure to establish the authenticity of the user. A valid response by the J2ME application to the content provider's challenge indicates that the handset on which the J2ME application resides is legitimate.
In an embodiment, when a server hosted by the content provider receives the request for content, the server retrieves the current time from its internal clock. The server then sends the time to the J2ME application in the handset as the authentication challenge. Upon receiving the time, the J2ME application uses its key to encrypt the time. The J2ME application then returns the encrypted time to the server as its response to the challenge. The server attempts to decrypt the time using its key, which, if the request for content is legitimate, is the same as the key used by the J2ME application to encrypt the time. Successful decryption of the time by the server indicates that the correct key was used to encrypt the time. In such a case, the handset passes a first authentication step.
Given enough time and computing capacity, an unauthorized user might be able to discover the key that is used to encrypt and decrypt messages between a handset and a content provider. Such a user might then use the key to download content without compensation to the content provider. To prevent this, an additional authentication step can be taken to further ensure the authenticity of a handset. The server hosted by the content provider can compare the time it sends as a challenge to the handset to the time when it receives the encrypted time back from the handset.
The passage of an extended period of time between the sending of the challenge and the receipt of the response may allow an unauthorized user enough time to discover the encryption key by brute force code-breaking methods. To prevent such a breaking of the code, a response can be considered invalid if it is not returned within a predefined period of time. The handset is determined to be illegitimate in such a case and it is not allowed access to the requested content. If only a small amount of time passes between the sending of the challenge and the receipt of the response, it is assumed that there was not enough time to break the code. The handset is then determined to be authentic and it is allowed access to the requested content.
In one embodiment, the same key is used for all handsets serviced by a telecommunications provider. In other embodiments, each third-party content provider uses a different key.
In the above discussion, the content provider sends a time in an unencrypted message to the J2ME application and the J2ME application returns the time in an encrypted form to the content provider. One of skill in the art will recognize that the reverse situation could also be implemented. That is, the content provider can encrypt the time using its key and send the encrypted time to the J2ME application. The J2ME application could then decrypt the time using its key and return the decrypted time to the content provider. A request for content could be considered valid if the J2ME application is able to successfully decrypt the time.
In addition, while the above discussion has focused on the downloading of content to mobile telecommunications devices, one of skill in the art will recognize that this authentication protocol could be used in other settings where a lightweight authentication protocol is desired. That is, the system and method of encrypting and decrypting a time and denying authentication if the encryption or decryption does not occur successfully within a predetermined period of time consumes very little computing capacity and memory and is therefore applicable in numerous situations where more cumbersome authentication protocols are inappropriate.
FIG. 1 illustrates an embodiment of a system by which content can be securely downloaded to a mobile telecommunications device. The mobile telecommunications device, or handset 10 , is used to request content via path 40 . The request is typically sent to a content catalog, which is referred to as a content vending machine 20 in FIG. 1 . As described above, a J2ME application designed to retrieve content can reside in the vending machine 20 . The vending machine 20 returns the J2ME application to the handset 10 via path 50 . In other embodiments, the J2ME application may be resident on the handset 10 and may not need to be downloaded.
The J2ME application, which is now resident on the handset 10 , sends a request for the selected content to a content provider 30 via path 60 . The content provider 30 might be the telecommunications provider that provides service to the handset 10 or might be a third party. The request for content contains the file name of the requested content, which is typically maintained in a secure file system hosted by the content provider. Upon receipt of the request, a server side application hosted by the content provider 30 attempts to verify the authenticity of the J2ME application making the request.
To do so, the server side application retrieves, for example, its internal clock time and sends the time, via path 70 , to the J2ME application on the handset 10 . This constitutes a security challenge to the handset 10 . The J2ME application encrypts the time using an encryption key that was downloaded with the J2ME application and returns the encrypted response, via path 80 , to the server side application. The server side application then attempts to decrypt the response. Successful decryption in a short period of time indicates that the J2ME application has a legitimate key and that it is unlikely that an unauthorized user would have had sufficient time to discover the key by illicit means. In such a case, the handset 10 is considered authentic.
Upon authentication of the handset 10 , the server side application performs a direct file system lookup within its local file system for the requested file. When the requested file is found, the server side application downloads the requested content to the handset 10 via path 90 .
An embodiment of a method by which content can be securely downloaded to a mobile telecommunications device is illustrated in FIG. 2 . In box 110 , an application sends a request for content to a content provider. In box 120 , the content provider retrieves its internal time. The content provider sends the time to the application in box 130 . In box 140 , the application encrypts the time. The application then returns the encrypted time to the content provider in box 150 . The content provider decrypts the time in box 160 and, in box 170 , calculates the difference between the retrieved time and the time that the retrieved time was returned from the application. In box 180 , the content provider considers the request authentic if it is able to decrypt the time and if the difference in time is below a predetermined threshold.
While several embodiments have been provided in the present disclosure, it should be understood that the System and Method for Securing System Content by Automated Device Authentication may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein, but may be modified within the scope of the appended claims along with their full scope of equivalents. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
Also, techniques, systems, subsystems and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown as directly coupled or communicating with each other may be coupled through some interface or device, such that the items may no longer be considered directly coupled to each but may still be indirectly coupled and in communication with one another. Other examples of changes, substitutions, and alterations are ascertainable by on skilled in the art and could be made without departing from the spirit and scope disclosed herein. | A system is provided for securely downloading content to a mobile telecommunications device. The system includes a mobile application to enable the mobile telecommunications device to send a request for content identified on a telecommunication provider system. The system includes a content application maintained by the content provider to retrieve content and promote delivery of the content to the mobile telecommunications device. The system also includes a challenge component and a response component, the response component communicates with the mobile application and encodes a challenge data. The challenge component communicates with the content application. The challenge component sends the challenge data to the mobile application and decodes the challenge data received from the mobile application to validate the response for delivery of the content to the mobile application. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/547,100, filed Feb. 24, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to heating, ventilating, and air conditioning (HVAC) systems that utilize a pressurized fluid for generating heat, air conditioning, and electric current.
[0004] 2. Description of the Related Art
[0005] Many applications require the generation and transferring of heat. Examples that require the generation of heat to warm a fluid medium (i.e. water or air) include systems for heating buildings, clothes dryers, and water heating units. Such known configurations utilize various heat sources. Known heat sources include electrical resistance elements and oil, natural-gas, coal, and other burners.
[0006] Electrical resistance elements are inexpensive, develop high temperatures in short time periods, and can be readily supplied with electrical operating power. However, such resistance elements have high power consumption rates and are therefore costly to operate compared to other available heating systems. Oil and gas burner units can be more cost effective to operate than electrical resistance based units, but oil and gas burner units also have their drawbacks such as limitations based on availability of the respective combustible fluids in particular localities, the potential for operating cost fluctuations based on various global factors and the bulkiness of the overall units.
[0007] The above problems show that each of the commonly known heating configurations has its associated advantages and disadvantages. In general, operational efficiencies must be compromised if operational costs are to be minimized. Furthermore, the overall compactness of prior-art units represents a significant limitation.
[0008] U.S. Pat. No. 5,979,435 proposes a solution using a heated liquid medium. The heated liquid medium is pressurized, released, and heated through friction. The heated fluid is used to donate heat to other systems.
[0009] If hydraulic fluid is used in a system like the one proposed in U.S. Pat. No. 5,979,435, many limitations become obvious. While the patent teaches using water and air as fluids, hydraulic fluid is required for reasons of heat capacity and pressurization. To create a heat transfer equaling conventional heaters, a system utilizing hydraulic fluid requires pressures above 17.25 mPA (2500 psi) and temperatures above 140° C. However, at these temperatures and pressures, hydraulic fluid breaks down. Furthermore, when heated by the frictional heaters, the hydraulic fluid foams. In addition, the pumps needed to create the pressure cause cavitation, which adds gas to the fluid. When gas bubbles exist in the plumbing, hammering and knocking occurs. When the gas is vented from the hydraulic fluid, the fumes are noxious. Finally, hydraulic fluid is toxic and poses risk whenever applied near people, especially, in homes.
[0010] Experiments have shown that a system taught by U.S. Pat. No. 5,979,435 run with hydraulic fluid at a temperature below 140° C. to avoid break down only allowed 0.189 m 3 /s (400 ft 3 /min) of air to be heated. This amount of heat exchange is not sufficient for most household applications.
[0011] Therefore, there exists a need for a heating system that uses a liquid medium for heat that supplies sufficient heat within traditionally sized systems to replace traditional systems and that does not produce noxious fumes and risks of toxic spills.
SUMMARY OF THE INVENTION
[0012] An object of the invention is to develop an all-electrical based (i.e. non fossil fuel burning) heating system with a low operating cost. The system will take in cold, fresh, moist air and heat it to a comfortable room temperature without significantly removing the moisture from the air. This system not only makes heat, but also provides energy for additional tasks. The system raises the fluid temperature to compensate for increases in work output. The heating system receives cold air at very low temperatures with the capacity to raise the indoor temperature to 80° C. or higher. This will allow for greater fresh air intake and stale air venting.
[0013] A generator is also a component of this system. The generator provides electricity that can be used by an auxiliary heater. The generator is powered by a turbine that is turned by the pressurized fluid. The electricity created by the generator also can power the power controller (i.e. CPU), the electric-powered valves, and the drive pump. Unused power can be stored in batteries or fed to the power grid. By recapturing some of the power input, the generator directly reduces the primary electrical power required to run the heating system, as well as mechanically heat the fluid.
[0014] The system operates at lower pressures than normally used in hydraulic systems. The system has an electric motor that drives a fluid pump. This pump pressurizes the system and provides flow for a fluid motor that turns a gearbox that provides the proper RPM for the generator. The fluid then flows to a second fluid motor that mechanically turns the blower. The blower draws air through an air filter, through a heat exchange unit, and forces it through the duct system into areas to be heated. If the required fluid temperature drops below a minimum, an auxiliary electrical heater element brings the fluid to the required temperatures as controlled by a thermostat. Next, the fluid flows through the heated air exchange unit to a ported valve system that will allow the warm fluid to continue the heating process by an optional or primary radiant heating system. The fluid then flows back to the reservoir and the initial fluid drive pump to repeat the next cycle.
[0015] In accordance with the objects of the invention, a heating system is provided. The heating system includes a fluid, tubing, a drive pump, a generator, and an air handler. The fluid is pressurized by the drive pump and circulated through the tubing. The generator creates electricity and is connected to the tubing downstream of the drive pump. The pressurized fluid turns the generator and thereby heats the pressurized fluid. The air handler is connected to the tubing downstream of the generator and has a heat exchanger and a fan. The heat exchanger is heated by the fluid. The fan is turned by the fluid and thereby heats the fluid and blowing air to be heated through the heat exchanger.
[0016] The fluid is a proprietary fluid. For use in cold locations, the fluid should have a pouring temperature no greater than −43° C. To guarantee that the fluid continues to work even in abnormally high, yet foreseeable, temperatures, the fluid should have a boiling point greater than 316° C. To provide quiet operation and prevent formation of noxious fumes, the fluid should not foam or cavitate under operating conditions. Specifically, the fluid should not foam and cavitate at a temperature below 60° C. and a pressure below 3.45 mPa.
[0017] A further object of the invention is to provide a heating system that has enough heat capacity to heat at least 0.236 m 3 /s, and more preferably at least 0.473 m 3 /s, of air to at least 30° C. above an intake temperature.
[0018] It is a further object of the invention to provide a heater that heats air immediately upon startup. To prevent a lag between drive-pump startup and heat, an electrical heater can be disposed in the heat exchanger. The heat exchanger heats the fluid to a set temperature, preferably at least 37.8° C. The electrical heater can also be used to supplement the heat of the fluid during sustained operation that requires extra amounts of heat capacity. A further object of the invention is to provide an electrical heater that heats the fluid to at least 43.3° C. When the fluid is heated to 43.3° C., for most airflows, the air is heated to at least 40.6° C.
[0019] In accordance with a further object of the invention, electricity generated by the generator can be used to power the electrical heater. Alternatively, the electrical heater can be fed by a primary source such as a battery or power grid.
[0020] In accordance with a further object of the invention, a radiant heater can be connected to the tubing downstream of the air handler. The radiant heater would include a radiator that allows heat to be radiated from the fluid. The radiant heater can be buried in the flooring or walls.
[0021] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0022] Although the invention is illustrated and described herein as embodied in a pressurized liquid and a fluid-turbine generator, 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.
[0023] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The FIGURE is a partial schematic and partial diagrammatic view of the system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring now to the single FIGURE of the drawing, it is seen that a heating system has a (non-electrical) circuit formed by a power pack, which is connected to an air handler, which is connected to a radiant heat module, which is connected to the power back.
[0026] The sole FIGURE of the application shows a preferred embodiment for a heating and cooling system. Generally, except where specified below, the heating and cooling system is formed by a closed (i.e. recycling) circuit of piping that carries a fluid. The heating and cooling system includes several subsystems: a power pack 100 , an air-conditioner cycle 200 , an air handler 300 , and radiant heater 400 .
[0027] The power pack 100 includes a fluid tank 101 . The fluid tank 101 acts as a reservoir for collecting fluid, holding extra fluid, and providing fluid as needed. In addition, the fluid tank 101 allows a space for expansion of the fluid upon return. The fluid tank 101 has a fluid tank outlet 102 . The fluid tank outlet 102 is connected to a first drive pump 103 . The first drive pump 103 pressurizes the fluid through the system. Pressures between 2.07 Mpa and 3.45 Mpa (i.e. 300-500 psi) are generated by the first drive pump 103 . The first drive pump 103 is powered by a motor 104 . The motor 104 is preferably an electrical motor. In particular, an axial field motor like the one taught in U.S. Pat. No. 5,982,074 is used. The horsepower of the drive pump 103 and motor can be tailored to the application. For applications, requiring greater heat exchange, a larger horsepower motor 104 is used.
[0028] The accelerated fluid reaches a generator junction 105 in the piping. The accelerated fluid can be passed through a generator 106 and/or a bypass valve 107 . The bypass valve 107 diverts flow from the generator 106 when open. When the bypass valve 107 is closed, the fluid turns a generator turbine 108 . The generator turbine 108 is mechanically coupled to a gearbox 109 . Preferably, the gearbox 109 is a speed doubler. The gearbox 109 turns the generator 106 . The generator 106 produces electrical current as it is turned. The generator 106 is preferably an axial field generator, like those described in U.S. Pat. No. 5,982,074, which is incorporated by reference. In alternative embodiments, the generator can be an alternator or other means for converting mechanical energy to electrical energy. The generator 106 is connected to a power controller 110 . The fluid leaves the generator and/or bypass valve at the generator junction 111 .
[0029] The generator 106 restricts flow through the generator turbine 108 and creates friction, which increases the fluid temperature in the system. This heating reduces the dependence on an ancillary heater (i.e. heater 307 ). When used, the generator 106 and the output power controller 110 direct power as required to optimize and reduce the demand on the incoming primary power. The power controller 110 can open and close the bypass valve 107 to throttle the generator 106 .
[0030] The power controller 110 controls the generator fluid bypass valve 107 to adjust the speed of the generator 106 as required and buffer system on/off cycles. The power controller 110 thereby optimizes the output power of the generator 106 and reduces the required primary power.
[0031] From the generator junction 111 , the fluid flows to the air-conditioner split 201 . An air-conditioner control valve 202 controls the flow of fluid that reaches a chiller 204 . An air-conditioner bypass valve 203 diverts flow from the chiller 204 when the air-conditioner 200 is not operating. An air-conditioner check valve 205 prevents fluid from flowing backward into the chiller 204 . The fluid flowing from the chiller 204 and/or the air-conditioner bypass valve 203 joins at the air-conditioner junction 206 .
[0032] Although not detailed, the air conditioner involves a typical air conditioner system with a refrigerant compressor, a blower, and an evaporator/heat exchanger. The coolant system is separate from the pressure fluid system. The compressor motor and air-conditioner blower are powered by the pressurized fluid. In a further possible embodiment, refrigerant for the air-conditioner is the same fluid that is pressurized and used throughout the system.
[0033] From the air-conditioner junction 206 , the fluid reaches the air handler 300 at the air-handler split 301 . A third drive pump 302 is downstream of the air-handler spit 301 . A bypass valve 303 allows diversion of fluid from the third drive pump 302 .
[0034] The air handler 300 includes a cabinet 304 . The cabinet 304 is sized to comply with standard sized air handlers. Within the cabinet 304 , a blower assembly 305 is disposed. The blower assembly 305 includes a fan 306 , which is preferably a drum fan. The fan 306 is connected to a fan turbine 302 . The fan turbine 302 is turned by the pressurized fluid. As it spins, the fan turbine 302 turns the fan 306 . As the fan turbine 302 spins the fluid becomes further heated. The fan 306 pushes air through the heat exchanger 308 . An electrical heater 307 heats the fluid if necessary; typically the electrical heater 307 is necessary if extremely low temperatures exist or when the electric motor has not been active for a long time. The heat exchanger 308 heats the air pushed by the fan 306 . The fluid pressure drops significantly after passing through the heat exchanger 308 . An air filter 309 filters the heated air following the heat exchanger 308 . The heated air passes through a plenum, which is not shown, and can be distributed throughout a building by air ducts, which are also not shown.
[0035] The heat exchanger 308 is preferably a multi-staged unit. The fluid flow is controlled so a maximum heat exchange can take place between the fluid and air flow. The moisture level in the incoming air flow is maintained and will not be sufficiently altered by the heating system. However, if moisture control is required, a humidifier can be added to the air handler 300 .
[0036] Although FIG. 1 shows one heat exchanger, more heat exchangers can be included to increase the heat transfer.
[0037] In addition, multiple air handlers 300 can be connected in parallel or series with each other. By having more than one air handler 300 , more zones can be heated. Furthermore, each air handler can have a respective thermostat 307 controlling it.
[0038] Multiple thermostats 307 allow for zones within to be heated to different temperatures.
[0039] After the air handler 300 , the fluid reaches the radiant heater 400 . The radiant heater 400 has a radiant heater split 401 . At the radiant heater split 401 , the fluid can be diverted between the radiator 402 and the radiant heater bypass 403 . A radiant-heater bypass valve 404 controls the flow through the radiant-heater bypass 403 . When the radiant-heater bypass valve 404 is open, the fluid flows through the radiant-heater bypass 403 . When the radiant-heater bypass valve 404 is closed, the fluid cannot flow through the bypass 403 . Similarly, a radiator valve 405 controls flow of the fluid through the radiator 402 . The radiator 402 is formed by at least one pipe; when more than one pipe is used, the pipes are typically disposed parallel to each other. For radiant floor heating, the radiator 402 is disposed within the flooring, foundation, or wall of the room to be heated. A radiator check valve 406 is placed downstream from the radiator 402 and prevents the fluid from flowing backward into the radiator 402 . The radiator bypass 403 joins fluid from the radiator 402 at the radiant-heater junction 407 .
[0040] From the radiant heater 400 , the fluid returns to an inlet 110 of the fluid tank 101 of the power pack 100 . The fluid collects in the fluid tank 101 . A fluid filter 112 interconnects the return 500 and the fluid tank 101 . The fluid filter 112 strains particles in the fluid and separates them from the fluid entering the fluid tank 101 .
[0041] Steel hydraulic piping is used to connect the power pack 100 to the air-conditioner 200 and to the air handler 300 . Pressures after the air handler 300 are significantly less 0.069 Mpa to 0.10 Mpa (10 to 15 psi) are typical. The radiant heater 400 and the return 500 can be manufactured from standard copper plumbing because the fluid has significantly less pressure.
[0042] The preferable fluid is a fluid sold under the trade name HCL-3. The fluid is preferably a proprietary high-viscosity, biodegradable, non-toxic, non-hazardous, synthetic hydraulic and heat transfer fluid. The fluid is made with the thermally and oxidatively stabile non-toxic and non-hazardous base fluids. The combined fluid is further enhanced with additives that extend the fluid life and thermal performance over other competitive synthetic fluids. Proprietary chemistry for this product also provides for even higher operating temperatures, in both open and closed systems. The fluid is approved by the USDA for H-1 applications and fully complies with the requirements of the FDA Rule § 178.3570 (21 CFR 178.3570). This is a biodegradable fluid, which is non-toxic and non-hazardous, and does not form carbon in most specifications. The properties of the fluid are Viscosity cSt @ 316° C. (600° F.) using Test Method D-445. The fluid has a pour point −43° C. (−45° F.)
[0043] The power controller 110 preferably includes a central processing unit that evaluates and controls the various functions of the system.
[0044] For example, thermostats 207 , 310 , and 408 are connected by wiring to the power controller 110 . When the thermostat 207 detects a temperature above a set temperature, the power controller opens the air-conditioner control valve 202 and closes the air-conditioner bypass valve 203 . In addition, the power controller 110 activates the electric motor 104 to pressurize the fluid. When the thermostat 207 detects that the room temperature has reached the set point, the power controller closes the air-conditioner control valve 202 and opens the air-conditioner bypass valve 203 . If no other system requires pressurized fluid, the power controller 110 deactivates the electric motor 104 .
[0045] If the thermostat 307 detects a room temperature below a set point, the power controller 110 activates the air handler 300 .
[0046] The power controller 110 activates the air handler 300 by powering the electric motor 104 to pressurize the fluid. The power controller 110 closes the air-handler bypass valve 303 . The temperature of the fluid at the heat exchanger 308 is measured by the thermocouple 311 . If the fluid temperature at the thermocouple is too low, the electric heater 307 is activated by the power controller. The power controller 110 closes the bypass valve 107 to divert fluid through the generator 106 ; the generator 106 provides the electrical power for the electric heater 307 . When the thermostat 307 detects that the room temperature has reached the set point, the power controller opens the air handler bypass 303 and deactivates the heater 307 if the heater 307 is on. If no other system requires pressurized fluid, the power controller 110 deactivates the electric motor 104 .
[0047] The power controller 110 activates the radiant heater 400 when the thermostat 408 reads a room temperature below a set point. The power controller 110 activates the electric motor 104 to pressurize the fluid. After the fluid passes the generator 106 and the heat exchanger 308 , the fluid will have gained enough heat to work as a medium for radiating heat. The power controller 110 opens the radiator valve 405 and closes the radiant-heater bypass valve 404 to allow the heated fluid to flow through the radiator 402 . When the room temperature reaches the set point, the power controller 110 closes the radiator valve 405 and opens the radiant-heater bypass valve 404 . If no other system requires pressurized fluid, the power controller 110 deactivates the electric motor 104 . | A heating, ventilating, and air-conditioning system utilizes a pressurized fluid to generate heat and drive the components of the system. As the pressurized fluids turns the components heat is generated. The heat in the fluid can be transferred to air via a heat exchanger and/or a radiant heater. A generator is turned by the pressurized fluid and generates electricity for an auxiliary fluid heater and operation of the system and/or backfed to a battery or power grid. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a lock for doors, hinged covers or the like, particularly on motor vehicles, having a rotary fork latch which captures a closure member and engages in closed position with a locking pawl.
Such an arrangement is known from Federal Republic of Germany OS 37 17 013. The closure member which is arranged on the door engages in the rotary fork latch during the closing movement of the door and swings the latch into a position which secures the closure member. The final position of rotation of the rotary fork latch is secured by the locking pawl which so engages the rotary fork latch that the latter cannot turn by itself in backward direction. Only when the engagement of the locking pawl with the rotary fork latch has been intentionally removed by suitable means, does the rotary fork latch swing back and release the closure member for the opening of the door. The rotary fork latch and the locking pawl are developed as flat parts, preferably as steel-plate stampings. The fact is disadvantageous that, upon transverse forces on the lock, the rotary fork latch and locking pawl can slide laterally towards each other, as a result of which the lock opens by itself. Such transverse forces can occur on a motor vehicle, for instance, in the event of extreme loads on the chassis (twisting) or can be brought about by forceful manipulations (breaking-in).
SUMMARY OF THE INVENTION
The object of the invention is, therefore, to provide a lock of the aforementioned type which remains in securely locked position even under the action of transverse forces.
This object is achieved in accordance with the invention in the manner that the rotary fork latch and the locking pawl are in a form-locked engagement which is active in the direction towards the support pin of the rotary fork latch. Therefore, as soon as forces or components of forces in the direction of the support pin of the rotary fork latch act on the lock, the rotary fork latch and the locking pawl will rest against each other as a result of the form-locked connection so that lateral sliding of the parts cannot occur. Even upon the application of force, the cooperating parts cannot be deformed laterally with respect to each other since even in the event that one part should bend, the other part will be carried along as a result of the form-locked connection.
In accordance with a further development of the invention, the form lock is formed by a projection-recess arrangement. The form-locked engagement is preferably assumed in the closed position of the rotary fork latch.
It is immaterial for the lock in accordance with the invention whether the rotary fork latch and locking pawl are arranged on the door and the closure member is arranged on the frame or whether the rotary fork latch and the locking pawl are arranged on the frame and the closure member is accordingly arranged on the door. It is merely important that the form lock in accordance with the invention is effective in the transverse direction in which the sliding away of rotary fork latch and locking pawl is to be avoided. To this extent, this form lock may be present in the one transverse direction or else in the opposite transverse direction, it being furthermore possible, as an alternative for this, for both transverse directions to be secured by a corresponding form-locked engagement.
In accordance with the invention, the arrangement can be such that the rotary fork latch is provided on the end of its arm which crosses the path of movement of the closure member with a projection which extends from its wide side and cooperates with an edge-open recess extending from the wide side of the locking pawl. In the event that a securing in both transverse directions is to be provided, the projection will be allowed to enter into a recess in the wide-side wall.
In accordance with a preferred embodiment, the rotary fork latch and the locking pawl are mounted overhung and swingable in a bracket, the projection and recess lying on the side facing away from the bracket. If, accordingly, the rotary fork latch is displaced by corresponding transverse forces in the direction towards the bracket, then the projection rests against the wall of the recess extending parallel to the wide side of the locking pawl, as a result of which a firm interlocking of the parts is assured.
In order to assure a slender structural shape it is contemplated that the thickness of the projection be smaller than the thickness of the rotary fork latch and that the depth of the recess be less than the thickness of the locking pawl. Accordingly, the broad sides of rotary latch and locking pawl can be flush with each other and the form lock desired in accordance with the invention can nevertheless be obtained.
Particularly great security against the action of transverse force results from the fact that rotary fork latch and locking pawl come against each other via corresponding resting surfaces in the closed position and that the form-locked engagement is formed in the direct vicinity of the resting surfaces. Thus, even a twisting of the rotary fork latch and/or of the locking pawl does not result in the elimination of form lock desired in accordance with the invention.
Finally, the arrangement can be such that the end of the other leg of the rotary fork latch forms a form-locked engagement which is active in the direction of the support pin of the rotary form latch also in a pre-engagement position with the locking pawl. The pre-engagement position is arranged in front of the closed position in the course of the closing movement of the door and sees to it that, even if the door has not been closed properly, it cannot spring open. Thus, according to the invention, this securing position of the door is not susceptible to the action of transverse forces.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail below on basis of two embodiments. In the drawing:
FIG. 1 shows a lock in accordance with the first embodiment, seen in the region of its inner parts, in open position with the corresponding closure member;
FIG. 2 is the following showing following FIG. 1, in which a rotary fork latch has moved into a pre-engagement position during the course of the closing of the door (not shown);
FIG. 3 shows the closed position of the lock;
FIG. 4 is a section along the line IV--IV of FIG. 3; and
FIG. 5 is a section through the form-locked connection in accordance with a second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The lock 1 shown in FIG. 1 has a bracket 2 adapted to be fastened at a suitable place (frame) of a vehicle or the like as well as a closure member 3 of lug shape arranged on the door side. The arrangement can also be such that the closure member 3 is arranged on the frame and the bracket 2 is arranged on the door. A slot 5, which is aligned with the closing path of the closure member 3 extends from the upper edge 4 of the bracket 2 and terminates at its upper edge in a funnel-shaped widening 6. Into the region of the slot 5 and its widening 6 there extends a rotary fork latch 8 having a fork mouth 7. For its swingable mounting, there is provided a stud 9 extending from the bracket 2. On the wide sides of the ends 10, 11 of the arms of the rotary fork latch 8, on the side thereof facing away from the bracket 2, there are formed projections 12, 13, the thickness of the projections 12, 13 being less than the thickness of the rotary fork latch 8.
A locking pawl 14 mounted for swinging on the other side of the slot 5 is developed with two arms and on its one arm forms a hook-shaped locking nose 15 which, in the open position of the lock 1, acts on the facing side surface 16 of the fork arm 17. A spring (not shown) urges the looking pawl 14 in clockwise direction, producing the aforementioned position of application. Directly below the locking nose 15 the locking pawl 14 is provided, on its side facing away from the bracket 2, with a recess 18 which is open at its edge and the depth of which is less than the thickness of the locking pawl 14. By the recess 18, there is formed a nose 24. For the opening of the lock, the other lever arm of the locking pawl forms a pawl tail 19 on which an opening mechanism (not shown) acts.
The manner of operation is as follows: Upon the closing of the door, the lower transverse arm 21 of the closure member 3 comes into the region of the widening 6 of the slot 5, enters into the fork mouth 7 of the rotary fork latch 8, and acts there against the inside 20 of the fork arm 17. (See FIG. 1). Upon the further closing movement and, therefore, deeper entrance of the closure member 3 into the slot 5, the lower transverse arm 21 swings the rotary fork latch 8, the side surface 16 of the fork arm 17 striking the locking nose 15 in the region of its control surface 22 and displacing the locking pawl 14 against the action of its spring during the course of the swinging motion of the rotary fork latch 8. In the pre-engagement position shown in FIG. 2, the locking nose 15 of the locking pawl 14 extends into the fork mouth 7 and rests, via said nose, against the inside 20 of the fork arm 17. The projection 12 of the end 10 of the arm forms a form lock in this position with the recess 18 of the locking pawl 14, thus assuring that transverse forces acting on the rotary fork latch 8 in the direction X can be taken up without damage since lateral sliding of the parts is prevented due to the application of the projection 12 against the wall 23 of the recess 18. In this way, the pre-engagement position is already secured so that, even if the door is not properly closed, it is prevented from springing open under the action of a transverse force. Upon the further closing movement, the lower transverse arm 21 of the closure member 3 causes a further swinging of the rotary fork Iatch 8, the arm end 11 thereof in its turn coming against the control surface 22 of the locking nose 15 and thus displacing the locking pawl 14. As shown in FIG. 3, the rotary fork latch 8 in the closed position rests in the region of its arm end 11 against the inside of the locking nose 15 and is therefore secured against swinging back. The lower transverse arm 21 is caught in this position in the region of the fork mouth 7. As was the case already in the pre-engagement position, also in the closed position there is a form lock between the rotary fork latch 8 and the locking pawl 14, the projection 13 of the arm end 11 resting in the recess 18 of the locking pawl 14. If the rotary fork latch is urged in direction X towards the bracket 2 by corresponding transverse forces, then the projection 13 rests against the wall 23 of the recess 18, said wall extending parallel to the wide side of the locking pawl 14, as a result of which a firm engagement of the parts is assured. Since this form-locked engagement is formed in the immediate vicinity of the resting surfaces of the locking nose 15 of the arm end 11, even a twisting of the rotary fork latch 8 and locking pawl 14 does not cause desired form lock to be eliminated. This is true both in the closed position and in the pre-engagement position. In both positions, therefore, a firm connection is always assured.
For the opening of the door, the locking pawl 14 must be swung into a position of release (see dash-dot showing in FIG. 3). This can be done, for instance, by key actuation or from the inside of the vehicle, for which purpose a rod or the like acts on the pawl tail 19 of the locking pawl 14. Upon actuation of the opening mechanism, the locking pawl 14 is swung in counter-clockwise direction. This then releases the rotary fork latch 8 which swings under spring action (not shown) into the open position and releases the closure member 3.
FIG. 5 shows a further embodiment. The arm end 11' of the fork latch 8' shown there forms on its end surface a central projection 13' produced by edge recesses, the width of which projection is less than the width of the rotary fork latch. The locking pawl 14' has accordingly, on its end surface, a central recess 18' into which the projection 13' can enter in closed position. This form lock provides assurance that both a transverse force in direction X of the bracket 2 and a transverse force acting in the opposite direction Y can be taken up. | A lock for doors, hinged covers or the like, particularly on motor vehicles, having a rotary fork latch which captures a closure member and engages in closed position with a locking pawl. In order that the lock remain in a dependable closed position even in the event of the action of transverse forces, the rotary fork latch (8) and the locking pawl (14) are in a form-locked engagement which is active in the direction of the support pin of the rotary fork latch (8). | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a divisional of U.S. patent application Ser. No. 08/956,738, filed Oct. 23, 1997, now U.S. Pat. No. 5,881,564.
FIELD OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a compressor for use in a refrigerator, which is provided with a rotary shaft rotatably supported by a bearing that is lubricated by liquid refrigerant.
FIG. 8 shows a bearing of a compressor relating to the present invention, which is intended for use in a refrigerator.
Rotary shaft 01 of the compressor is supported by the bearing 02. Liquid refrigerant is supplied into a recess portion 07 dug (or counterbored) in a bearing surface portion 06 of this bearing 02 through passages 04 and 05 which are bored in a housing 03 and the bearing 02, respectively. Then, the liquid refrigerant, which having lubricated the bearing surface 06 of the aforesaid bearing 02 and the outer peripheral surface of the rotary shaft 01 streams out of both of the left and right sides of the bearing 02. Incidentally, reference numeral 09 designates a retainer.
The aforementioned compressor for use in a refrigerator has a problem in that, when the temperature rising of the rotary shaft 01 and the bearing 02 occurs owing to an operation of the compressor, there is a fear that the lubrication failure or the seizure of the bearing 02 is caused by the vaporization of the liquid refrigerant supplied to the aforesaid bearing 02.
Further, in the case that the liquid refrigerant pump for supplying liquid refrigerant stops owing to a power failure or to a breakdown of the compressor, the supply of the liquid refrigerant is ceased in a short time. In contrast, the rotary shaft 01 keeps rotating for some time owing to the inertia thereof, while gradually reducing the rotational speed thereof. Thus, the aforementioned compressor has another problem in that the aforesaid bearing 02 is damaged during the rotary shaft 01 keeps rotating in such a case.
OBJECT AND SUMMARY OF THE INVENTION
The present invention is accomplished to solve the aforementioned problems of the aforesaid compressor for use in a refrigerator.
Accordingly, an object of the present invention is to provide a compressor for use in a refrigerator, which solves the aforementioned problems.
The gist of the present invention for achieving the foregoing object, lies in that, in a compressor (hereunder sometimes referred to as a first compressor of the present invention) for use in a refrigerator, which has a rotary shaft supported by a bearing lubricated by a liquid refrigerant, a header (assembly) for storing a predetermined amount of a high-pressure liquid refrigerant to be supplied to the aforesaid bearing, and means for maintaining an internal pressure of this header at a high pressure for a predetermined time period after a power failure by means of a check (or non-return) valve are provided.
Another characteristic aspect of an embodiment of the first compressor of the present invention resides in that a saturated liquid refrigerant stored in a reservoir of an evaporator is supplied to the aforesaid header by being pressurized by means of a liquid refrigerant pump.
Still another characteristic aspect of an embodiment of the first compressor of the present invention resides in that means for supplying a liquid refrigerant, which is stored in a reservoir of a condenser, to the aforesaid header at a power failure is provided in the first compressor.
Yet another characteristic aspect of an embodiment of the first compressor of the present invention resides in that a tank for storing a liquid refrigerant therein, a heater for heating the liquid refrigerant stored in this tank, a controller for regulating a heating value of this heater, and means for causing a solenoid (controlled or operated) valve to make the aforesaid tank communicate with the aforesaid header when stopping the aforesaid liquid refrigerant pump are provided in the first compressor.
Another compressor (hereunder sometimes referred to as a second compressor of the present invention) for use in a refrigerator according to the present invention, which has a rotary shaft supported by a bearing lubricated by a liquid refrigerant, characterized in that a piston thrust forward by a spring is liquid-tightly and slidably fitted into a cylinder, that a head side chamber is formed from the aforesaid piston and an end portion of the aforesaid cylinder and that a high-pressure liquid refrigerant is supplied to the aforesaid bearing through this head side chamber.
Another compressor (hereunder sometimes referred to as a third compressor of the present invention) for use in a refrigerator according to the present invention, which has a rotary shaft supported by a bearing lubricated by a liquid refrigerant, characterized by comprising a reservoir liquid tank for storing a predetermined amount of a high-pressure liquid refrigerator to be supplied to the aforesaid bearing, a storage gas tank for storing a predetermined quantity of a high-pressure gaseous refrigerant, and means for introducing a high-pressure gaseous refrigerant, which is stored in the aforesaid storage gas tank, to the reservoir liquid tank at a power failure.
Another compressor (hereunder sometimes referred to as a fourth compressor of the present invention) for use in a refrigerator according to the present invention, which has a rotary shaft supported by a bearing lubricated by a liquid refrigerant, characterized by comprising a reservoir liquid tank for storing a predetermined amount of a high-pressure liquid refrigerator to be supplied to the aforesaid bearing, a gas cylinder (or bottle) for storing high-pressure gas, and means for introducing a high-pressure gaseous refrigerant, which is stored in the aforesaid gas cylinder, to the reservoir liquid tank at a power failure.
Another compressor (hereunder sometimes referred to as a fifth compressor of the present invention) for use in a refrigerator according to the present invention, which has a rotary shaft supported by a bearing lubricated by a liquid refrigerant, characterized in that a refrigerant jacket for vaporizing a liquid refrigerant is provided on the outer peripheral surface of the aforesaid bearing.
Another characteristics aspect of an embodiment of the fifth compressor of the present invention resides in that means for introducing the liquid refrigerant to the aforesaid refrigerant jacket after lubricating the aforesaid bearing is provided in the fifth compressor.
The aforementioned compressors of the present invention have the following advantageous effects.
In the case of the first compressor of the present invention, the internal pressure of the header for storing a predetermined amount of a high-pressure liquid refrigerant to be supplied to the bearing is maintained at a high pressure for a predetermined time after a power failure by means of a check valve. Thus, even when the rotary shaft keeps rotating for a while after the power failure, the liquid refrigerant contained in the header can be supplied to the bearing during that. Consequently, the bearing can be prevented from being damaged.
When supplying a saturated liquid refrigerant, which is stored in the reservoir, to the aforesaid header by pressurizing such a liquid refrigerant by means of the liquid refrigerant pump, the liquid refrigerant can be easily brought into a supercooled state. Thus, the liquid refrigerant can be restrained from evaporating in the bearing. Consequently, the bearing can be securely lubricated.
In the case where the first compressor of the present invention is further provided with means for supplying the aforesaid header with the liquid refrigerant stored in the reservoir of the condenser at a power failure, the liquid refrigerant can be supplied to the bearing for a long time period. Thus, the bearing can be securely prevented from being damaged.
In the case where the first compressor of the present invention is further provided with a tank for storing a liquid refrigerant, a heater for heating the liquid refrigerant stored in this tank, a controller for regulating a heating value of the heater and means for causing the aforesaid tank to communicate with the aforesaid header when the aforesaid liquid refrigerant pump is stopped, a high-pressure gaseous refrigerant contained in the aforesaid tank is applied to the header when the aforesaid liquid refrigerant pump is stopped. Thus, the liquid refrigerant contained in the aforesaid header can be securely supplied to the bearing.
In the case of the second compressor of the present invention, the liquid refrigerant is supplied to the bearing through the head side chamber formed by liquid-tightly and slidably fitting the piston, which is thrust forward by the spring, in the cylinder. Thus, even if the rotary shaft continues rotating for a while after a power failure occurs, the liquid refrigerant contained in the aforesaid head side chamber can be supplied to the bearing during that. Consequently, the bearing can be prevented from being damaged.
In the case of the third compressor of the present invention, the liquid refrigerant stored in the reservoir tank is supplied to the bearing by introducing a high-pressure gaseous refrigerant, which is stored in the storage tank, to this reservoir tank at a power failure. Thus, even if the rotary shaft continues rotating for a while after a power failure occurs, the bearing can be prevented from being damaged during that.
In the case of the fourth compressor of the present invention, the liquid refrigerant stored in the reservoir tank is supplied to the bearing by introducing a high-pressure gaseous refrigerant, which is stored in the gas cylinder, to the reservoir tank at a power failure. Consequently, even if the rotary shaft continues rotating for a while after a power failure occurs, the bearing can be prevented from being damaged during that.
In the case of the fifth compressor of the present invention, the liquid refrigerant evaporates in the refrigerant jacket provided on the outer peripheral side of the bearing, so that the bearing is cooled by the latent heat of vaporization of this liquid refrigerant. Thus, the liquid refrigerant can be prevented from evaporating in the bearing surface portion of the bearing. Consequently, the bearing can be securely cooled by the liquid refrigerant.
Additionally, in the case that the liquid refrigerant is introduced to the refrigerant jacket after lubricating the bearing and is evaporated, the configuration of the compressor can be simplified.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram showing a first embodiment of the present invention;
FIG. 2 is a system diagram showing a second embodiment of the present invention;
FIG. 3 is a partially sectional view showing a third embodiment of the present invention;
FIG. 4 is a partially sectional view showing a fourth embodiment of the present invention;
FIG. 5 is a partially sectional view showing a fifth embodiment of the present invention;
FIG. 6 is a partially sectional view showing a sixth embodiment of the present invention;
FIG. 7 is a partially sectional view showing a seventh embodiment of the present invention; and
FIG. 8 is a sectional diagram showing a bearing of a compressor relating to the present invention, which is intended for use in a refrigerator.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a first embodiment of the present invention. Centrifugal impeller 31 of a turbocompressor 30 is fixedly mounted on an end portion of a rotary shaft 33 of an inverter motor 32.
Suction vane 37 is provided in the aforesaid turbocompressor 30. Quantity of refrigerant gas sucked into the turbocompressor 30 is regulated by opening and closing this suction vane 37 by means of a motor 38.
Rotary shaft 33 of the inverter motor 32 is supported by radial bearings 39 and 40 and thrust bearings 41 and 42.
Thus, when operating a turborefrigerator, a gaseous refrigerant discharged from the turbocompressor 30 enters a housing 46 of a condenser 2 through a check valve 54 and is condensed and liquefied therein by dissipating heat to a cooling medium, such as cooling water, flowing and passing through a heat transfer tube 3.
This liquid refrigerant then enters a throttling mechanism 4 wherein an adiabatic expansion of the refrigerant is caused by being throttled. Simultaneously with this, the flow rate thereof is regulated, so that a gas-liquid two-phase flow thereof is obtained.
Subsequently, this refrigerant enters a housing 45 of an evaporator 5, wherein this refrigerant evaporates and vaporizes by cooling a medium to be cooled, such as cooling water and brine. Thereafter, this cooled medium is sucked again into the turbocompressor 30 and is further compressed therein again.
Saturated liquid refrigerant contained in a reservoir 43, which is formed under the evaporator 5, is extracted by a liquid refrigerant pump 36 which is driven by a motor 35. After pressurized by this liquid refrigerant pump 36 in such a manner as to have a predetermined pressure, namely, in such a way as to be put into a supercooled state, the saturated liquid refrigerator enters the heater 52 through the check valve 51. Then, the refrigerant is supplied therefrom to and lubricates the bearings 39 to 42.
Further, after lubricating the bearings 39 to 42, the liquid refrigerant is collected in the reservoir 53. Subsequently, the liquid refrigerant returns to the housing 45 of the evaporator 5 owing to the self-weight thereof and a differential pressure.
When the solenoid valve 55 is opened at a power failure, a high-pressure liquid refrigerant having been collected in a reservoir 57 of the condenser 2 flows into the header 52 through the solenoid valve 55 and the check valve 56.
Incidentally, the solenoid valve 55 may be adapted to open when a discharge pressure of the liquid refrigerant pump 36 becomes lower than a predetermined value.
Thus, when a power failure occurs, the liquid refrigerant pump 36 stops in a short time. In contrast, the rotary shaft 33 of the turbocompressor 30 continues rotating for a while owing to the inertia thereof.
However, the internal pressure of the header 52 is maintained by the check valves 51, 54 and 56 at a high pressure for a while. Thus, the high-pressure liquid refrigerant stored in the header 52 is supplied to the bearings 39 to 42. Consequently, the bearings 39 to 42 are prevented from being damaged.
Further, when a power failure occurs, a high-pressure liquid refrigerant is supplied from the reservoir 57 of the condenser 2 to the header 52 by the solenoid valve 55 and the check valve 56. Thus, during the turbocompressor 30 continues rotating owing to the inertia thereof, a sufficient amount of liquid refrigerant can be supplied to the bearings 39 to 42.
Turning to FIG. 2, there is illustrated a second embodiment of the present invention.
This second embodiment is provided with a tank 80 for storing a high-pressure liquid refrigerant. Top part of this tank 80 is connected with the top part of the header 52 through a gas pipe 82 into which the solenoid valve 81 is inserted.
Heater 84 is dipped into the liquid refrigerant stored in the tank 80. By regulating the heating value of this heater 84 by means of a controller 85, the internal pressure of the tank 80 is maintained in such a manner as not to be lower than the discharge pressure of the liquid refrigerant pump 36.
The remaining portion of the configuration of this embodiment is similar to the corresponding portion of the first embodiment of the present invention, which is illustrated in FIG. 1. Thus, in FIG. 2, same reference character designate corresponding members of the first embodiment. Further, the description of such members is omitted.
Thus, when the liquid refrigerant pump 36 stops owing to a power failure or to a breakdown of the compressor, the solenoid valve 81 opens. Then, a high-pressure liquid refrigerant contained in the tank 80 is applied to the header 52 through the gas pipe 82. Thus, the liquid refrigerant contained in the header 52 can be securely supplied to the bearings 39 to 42.
Referring now to FIG. 3, there is illustrated a third embodiment of the present invention.
In the case of this third embodiment, a piston 12 is liquid-tightly and slidably fitted into a cylinder 11 which is formed in a housing 10 of a compressor. In addition, a coil spring 13 for pushing this piston 12 toward a head side chamber 23 is provided therein.
Thus, during an operation of the compressor, a liquid refrigerant is pressurized by a liquid refrigerant pump 14 and is then supplied to the head side chamber 23 through the check valve 15. Subsequently, the liquid refrigerant flows therefrom into a recess portion 18 dug in a bearing surface portion 21 of a bearing 20 through a passage 16 and thus lubricates a bearing surface 21 of the bearing 20 and the outer peripheral surface of the rotary shaft 22.
During that, the piston 12 is pressed by the pressure of the liquid refrigerant contained in the head side chamber 21. Thus, the piston 12 causes a coil spring 13 to contract, and is placed to the left, as viewed in this figure.
When the liquid refrigerant pump 14 stops at a power failure, the supply of the liquid refrigerant to the head side chamber 23 is stopped. However, the piston 12 is pushed by the coil spring 13, and gradually moves to the right, as viewed in this figure. Thus, the liquid refrigerant contained in the head side chamber 23 is supplied to the bearing 20. Consequently, the bearing 20 can be prevented from being damaged while the rotary shaft 22 reduces the rotational speed thereof until stops.
Referring to FIG. 4, there is illustrated a fourth embodiment of the present invention.
This fourth embodiment is provided with a reservoir tank 24 for storing a liquid refrigerant. Further, a solenoid valve 27 and a check valve 28 are inserted into a gas pipe 26 which connects this reservoir liquid tank 24 with a storage gas tank 25 for storing a high-pressure gaseous refrigerant.
Thus, during an operation of a refrigerator, the solenoid valve 27 is closed. Further, a high-pressure gaseous refrigerant discharged from a compressor flows into the storage gas tank 25 through the gas pipe 7 and the check valve 8, and is then stored in the storage gas tank 25.
Moreover, the liquid refrigerant is pressurized by a liquid refrigerant pump 14, and thus enters the reservoir liquid tank 24 through the check valve 15. Subsequently, the liquid refrigerant flows therefrom into a recess portion 18 dug in a bearing surface portion 21 of a bearing 20 through a passage 16 and thus lubricates a bearing surface 21 of the bearing 20 and the outer peripheral surface of the rotary shaft 22.
When a power failure occurs, the solenoid valve 27 opens. Further, the high-pressure gaseous refrigerant contained in the storage gas tank 25 flows into the reservoir liquid tank 24 through the gas pipe 26, the solenoid valve 27 and the check valve 28, and pressurizes the liquid refrigerant contained the tank 24. Thus, the liquid refrigerant stored in the reservoir liquid tank 24 is supplied to the bearing 20 while the rotary shaft 22 reduces the rotational speed thereof until stops.
Turning next to FIG. 5, there is illustrated a fifth embodiment of the present invention.
In the case of this fifth embodiment, a gas cylinder 9 is connected to a reservoir liquid tank 24 through a gas pipe 26 provided with a solenoid valve 27. The rest of the configuration of the fifth embodiment is similar to the corresponding portion of the fourth embodiment, which is illustrated in FIG. 4.
Thus, when a power failure occurs, the solenoid valve 27 opens, high-pressure inactive (or inert) gas, such as nitrogen gas, stored in a gas cylinder 9 enters the reservoir tank 24 through the gas pipe 26 and the solenoid valve 27. Then, this gas pressurizes the liquid refrigerant in the tank 24.
Incidentally, when the pressure of the liquid refrigerant being present downstream from the check valve 15 is lowered to a value which is lower than a predetermined pressure, the solenoid valve 27 may be adapted to open in response to a command signal sent from a pressure sensor 70 detecting such a pressure drop.
Referring next to FIG. 6, there is shown a sixth embodiment of the present invention.
In the case of this sixth embodiment, ring-shaped refrigerant jackets 61 and 62 are formed on the inner peripheral surface of a housing 10 of a compressor in such a way as to be placed on the outer peripheral surface side of the bearing 20.
Further, this embodiment is adapted so that the liquid refrigerant is supplied to these jackets 61 and 62 through a passage 63 and a throttle 64.
Thus, during the operation of the compressor, the liquid refrigerant enters the recess portion 18 through the passage 16 and lubricates the bearing surface 21 of the bearing 29 and the outer peripheral surface of the rotary shaft 22.
Simultaneously with this, the liquid refrigerant is throttled by the throttle 64 through the passage 63. Thereafter, the liquid refrigerant enters the refrigerant jackets 61 and 62 and further evaporates in these jackets. Thus, the liquid refrigerant cools the bearing 20 by latent heat of vaporization thereof.
The evaporated gaseous refrigerant is discharged through passages 65 and 66.
Thus, the temperature rising of the bearing 2 can be prevented. Consequently, the liquid refrigerant supplied onto the bearing surface 21 of the bearing 20 can be prevented evaporating thereof.
Turning to FIG. 7, there is illustrated a seventh embodiment of the present invention.
In the case of this seventh embodiment, ring-like grooves 72 and 73 are bored in the bearing surface portion 21 of the bearing 20 outside both sides of the recess portion 18, which are arranged in the direction of the rotary shaft. These grooves 72 and 73 communicate with refrigerant jackets 61 and 62 through passages 74 and 75, respectively.
Thus, during an operation of a refrigerator, a liquid refrigerant enters the recess portion 18 through a passage 16, and lubricates the bearing surface 21 of the bearing 20 and the outer peripheral surface of the rotary shaft 22.
Upon completion of the lubrication, the liquid refrigerant enters the grooves 72 and 73 and then flows into through the passages 74 and 75 into the refrigerant jackets 61 and 62, respectively, wherein the refrigerant evaporates. Thereafter, the refrigerant flows out of the jackets 61 and 62 through passages 65 and 66, respectively.
Although preferred embodiments of the present invention have been described above, it should be understood that the present invention is not limited thereto and that other modifications will be apparent to those skilled in the art without departing from the spirit of the invention.
The scope of the present invention, therefore, should be determined solely by the appended claims. | A compressor for use in a refrigerator, which has a rotary shaft supported by bearings to be lubricated by a liquid refrigerant and is adapted to permit the rotary shaft to continue rotating for a while after a liquid refrigerant pump is stopped at, for example, a power failure, thereby preventing the bearings from being damaged. To that end the compressor has a reservoir liquid tank for storing high pressure liquid refrigerant to be supplied to the bearing and a gas storage tank for storing high pressure gas. There is a valve system connected between the gas storage tank and the reservoir liquid tank which is operable upon a power failure to supply high pressure gas to the liquid storage tank. | 5 |
Claim priority of Provisional Application Ser. No. 60/037,086 filed Jan. 14, 1997.
FIELD OF THE INVENTION
The present invention relates to cosmetics and more particularly, to a system for organizing an inventory of cosmetics.
BACKGROUND OF THE INVENTION
A person's supply of cosmetics tends to accumulate over time, particularly in the case of lipstick, for example. As the number of acquired lipstick tubes increases, storage can become a problem, and finding the desired shade can become a hassle. Thus, a need exists for an inventory organizer which facilitates location of a desired lipstick color from among a large inventory of lipstick tubes.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for organizing an inventory of lipstick or any other sort of cosmetic made available in a range of colors. In the preferred embodiment, a sample of each lipstick color and an appropriate written description are placed on a discrete card and stored in a common holder. A person may then simply scan all of the cards in the container to locate a desired shade of lipstick from among those on hand. The associated written description then facilitates location of the appropriate lipstick tube within the collection.
The present invention may be seen to be useful in assisting a person (a) to organize and maintain a customized portfolio of the lipsticks within a collection; and/or (b) to view and assess all of the available colors without handling all of the lipstick tubes within the collection. Some of the advantages of the present invention may be seen to include: (a) it is cost effective to manufacture; (b) it is simple to use; (c) it occupies relatively little space; (d) it allows comparison of lipsticks to clothes without exposing the latter to the former; and/or (d) it tends to eliminate waste which might otherwise result due to unintentional purchases of essentially identical shades of lipstick.
BRIEF DESCRIPTION OF THE DRAWING
With reference to the Figures of the Drawing, wherein like numerals represent like parts and assemblies throughout the several views,
FIG. 1a is a top plan view of a preferred embodiment cosmetics organizer constructed according to the principles of the present invention, opened to a first type of page;
FIG. 1b is a top plan view of the organizer of FIG. 1, opened to a second type of page;
FIG. 1c is a top plan view of the organizer of FIG. 1, opened to a third type of page; and
FIG. 2 is a front view of an alternative embodiment cosmetics organizer constructed according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment cosmetics inventory system constructed according to the principles of the present invention is designated as 100 in FIGS. 1a-1c. The system or kit 100 is designed to organize cosmetic samples in a manner that is neat and user friendly, eliminating the need to handle the cosmetics themselves in order to assess the inventory and/or locate a desired shade. The system 100 generally includes a binder or holder 120, pages or sheets 140, cards or plates 160, and covers or laminates 180.
The binder 120 is a type known in the art as a 3-ring binder. Although the specific binder 120 is well suited for this application, those skilled in the art will recognize that the present invention is not necessarily limited in this regard. For example, as shown in FIG. 2, a box 220 could be used instead of the binder 120 to hold the cosmetic samples.
The pages 140 are similar in some respects to those present in a certain type of known photo album. As shown in FIG. 1a, each of the pages 140 includes a white backing 142 and a plurality of clear, transparent covers or patches 144. Peripheral portions of the patches 144 are adhered to the backing 142 to define an array of pockets 146. Each of the pockets 146 is oriented to open in the same direction--upward. In the preferred embodiment, both the backing 142 and the patches 144 are made of plastic. Along a side of each page 140, holes 148 are formed through a reinforced strip to facilitate storage of each page 140 in the binder 120. Although the pages 140 are well suited for this application, those skilled in the art will recognize that the present invention is not necessarily limited in this regard. For example, as shown in FIG. 2, index cards 240 could be used instead of the pages 140 to hold the samples.
The cards 160 are preferably made from white card stock and are sized and configured to slide into the pockets 146. As shown in FIG. 1b, the cards 160 provide a first area 162 suitable for receiving a color sample (of lipstick, for example), and a second area 164 suitable for receiving an appropriate written description of the color sample (Chanel Coco Burgundy, for example). Blank cards 160 are stored in sheet form within the binder 120 until needed for insertion into the inventory list. Along a side of each sheet 166, holes 168 are formed through a reinforced strip to receive the rings of the binder 120. Perforations 169 extend between the cards 160 to facilitate separation of each individual card 160 from the sheet 166.
The covers 180 are preferably made from clear plastic and sized and configure to overlie the cards 160. A clear adhesive on one side of the covers 180 temporarily secures them to backing material and subsequently secures them to respective cards 160. As shown in FIG. 1c, the covers 180 are stored in sheet form within the binder 120 until needed for covering a newly added card 160. Along a side of each sheet 186, holes 188 are formed through a reinforced strip to receive the rings of the binder 120. Perforations 189 extend between the covers 180 to facilitate separation of each individual cover 180 from the sheet 186.
Once a color sample and a written description have been applied to the face of an individual card 160, a cover 180 is secured over the face of the card 160 to protect same. The interconnected card 160 and cover 180 are then placed into one of the pockets 146 for future reference. Although the cards 160 and the covers 180 are well suited for this application, those skilled in the art will recognize that the present invention is not necessarily limited in this regard. For example, as shown in FIG. 2, an overlying transparency 280 could be used together with the index card 240 in lieu of both.
Those skilled in the art will also recognize that the present invention may lead cosmetics manufacturers to offer pre-printed cards together with their lipstick to facilitate use of the present invention. In such an event, the pre-printed card would simply be inserted into one of the pockets 146 upon acquisition of the lipstick associated therewith.
The present invention may also be seen to provide methods of organizing a cosmetics inventory. For example, a person can organize a lipstick inventory by depositing a sample of each available lipstick on a separate card together with an appropriate written description; and placing each sample card in a common holder. In a preferred method, each card is sealed and then disposed within one of several pockets on any of several pages disposed within a binder.
Although the present invention has been described with reference to particular embodiments and applications, those skilled in the art will recognize additional embodiments and/or applications which fall within the scope of the present invention. Accordingly, the scope of the present invention is to be limited only to the extent of the claims that follow. | An organizer includes sample cards which are mounted on pages which, in turn, are stored within a binder. Each of the sample cards bears a color sample and an associated written description for a particular cosmetic product. | 6 |
TECHNICAL FIELD The invention is concerned with a roller shade that can be lowered upon tensioning of an un-wrap spring and raised upon releasing of the un-wrap spring.
BACKGROUND
[0001] Roller shades also called roller blinds are characterized by a lifting mechanism, with which the curtain part of the shade can be raised in an upper position and be lowered to a lower position. The most common type of lifting mechanism is a chain mechanism on one side of the shade. The chain mechanism includes a chain loop by means of which the roller shade can be wound up around a roll and be unwound again.
[0002] Such chain loops as well as different ropes and strings can, however, cause a risk of choking for children that might place their head through the loop.
[0003] Different accessories can be used to keep the ropes and strings unavailable for children or the minimizing of the risk can otherwise be taken into consideration in the product design.
[0004] Such “safe by design” products are roller shades that are equipped with an electric motor or a spring mechanism for the winding.
[0005] Winding mechanisms of the latter type are well known and frequently used. A spring is tensioned when the shade is pulled down and a latching device blocks the roller shade at desired adjustments. The force of the spring is at its maximum when the tube around which the shade is rolled up has to carry the largest length of hanging shade. When the latching device is freed by means of a sharp pull in the shade, the roller shade is wound around the tube during a strong acceleration.
[0006] A problem in connection with roller shades having a spring mechanism is that the shade is raised up without any control with a high speed when the spring is released and could damage the shade and its support members as well as other parts of the roller shade. The shade could also be jammed between the wall and the shaft roll or be wound around the roll until complete release of the spring. In all these cases the release caused a hard collision and sound.
[0007] Different attempts have been made to facilitate the use of the spring rollers by connecting a brake there to that slows down the speed of the shade when the spring force is released in the lower position of the shade.
[0008] Such decelerating brake mechanisms are usually realized either with a mechanical friction brake or with hydraulic means. Both these solution, however, involve some problems.
[0009] In friction brakes, the problem is the abrasion of the brake shoes that usually are made of plastic and the sound of the braking.
[0010] Hydraulic brakes in turn have problems with the oil used inside and its properties in changing temperatures, i.e. the oil should stay inside the enclosed brake also in high temperature but should not brake too much or solidify in cold conditions.
[0011] European patent 1 893 841 is mentioned as prior art for a mechanical solution for fine adjustment of roller blinds by using a manually rotatable control element that engages an un-wrap spring in order to loosen it, whereby the roller blind becomes un-coupled from the drive shaft. The rotation of the control element also turns for fine adjustment in the same movement.
[0012] European patent 1 009 904 also discloses a solution for a controlled raising and stopping of a roller blind being an example of the above mentioned friction brake use.
[0013] The Canadian patent application 2 660 914, in turn, discloses an improved roller blind clutch assembly for controlling the raising and lowering of a roller blind.
[0014] US patent application US2014/0196857 is an example of a friction brake solution for a roller shade control system.
[0015] The object of the invention is a new alternative for a brake mechanism for retarding the raising speed of a roller shade, which works in all conditions and does not contain abrasive brake parts.
SUMMARY OF THE INVENTION
[0016] The roller shade of the invention is wrapped around a shaft tube, which has a supporting member through which the roller shade can be fastened to the wall or the like. The roller shade also includes a lifting mechanism, with which the roller shade can be lowered upon tensioning of an un-wrap spring fitted around the shaft that rotates in a first direction at the lowering and be raised upon releasing of the un-wrap spring when the shaft rotates in the opposite direction. The roller shade is mainly characterized by an eddy current brake fastened to the shaft for a controlled release of the tensioning of the spring.
[0017] Thus, the invention is a based on a roller shade that can be raised and lowered by spring force with a lifting mechanism. It has a support member that can be fastened with fastening means to the window frame, wall or the like. The lifting mechanism of the roller shade is a spring mechanism in which a spring becomes tensioned when the roller shade is lowered. The spring force is higher the lower the shade is drawn down. The spring mechanism is locked when the down drawing (the lowering) is stopped but the tension developed in the spring remains. The roller shade includes latching devices with which the roller shade can be locked in a desired lowered position. The locking is mechanically realized by means of small balls in such a way that the ball stays in the outer periphery of the spring mechanism when the shade is drawn downwards and when the drawing is stopped the ball falls down into a cavity in an end piece of the spring mechanism and locks the mechanism. By drawing the further downwards a little, the spring can be released again and the shade is raising by means of the accumulated force. If the roller shade is allowed to raise freely like in some prior art solutions, the speed is accelerated and the shade raises too strongly by colliding with the support members of the shade or by jamming between the wall and the shaft tube or by rolling around the shaft until the spring is completely released. In all these cases, the raising results in a hard collision and a loud sound and the shade can be damaged.
[0018] By using a brake mechanism that is based on magnetism as in the solution of the invention, the shade can be raised evenly, quiet and soundless to the upper position. An eddy current brake is a preferred solution to be used in the roller shade of the invention.
[0019] An eddy current brake, like a conventional friction brake, is a device used to slow or stop a moving object by dissipating its kinetic energy as heat. However, unlike electro-mechanical brakes, in which the drag force used to stop the moving object is provided by friction between two surfaces pressed together, the drag force in an eddy current brake, is an electromagnetic force between a magnet and a nearby conductive object in relative motion, due to eddy currents induced in the conductor through electromagnetic induction.
[0020] A conductive surface moving past a stationary magnet will have circular electric currents called eddy currents induced in it by the magnetic field, due to Faraday's law of induction. By Lenz's law, the circulating currents will create their own magnetic field which opposes the field of the magnet. Thus the moving conductor will experience a drag force from the magnet that opposes its motion, proportional to its velocity. The electrical energy of the eddy currents is dissipated as heat due to the electrical resistance of the conductor.
[0021] In an electromagnetic brake the magnetic field may be created by a permanent magnet, or an electromagnet so the braking force can be turned on and off or varied by varying the electric current in the electromagnet's windings. Another advantage is that since the brake does not work by friction, there are no brake shoe surfaces to wear out, necessitating replacement, as with friction brakes.
[0022] The specific feature of an eddy current brake lies in the fact that the braking power increases with gaining relative speeds. This type of brake shows a very low torque at low speeds. Its maximum braking torque is only reached at high speeds. The eddy current brake is successfully used when the braking action is supposed to depend on the speed, respectively when a moveable mass without heat development is rapidly damped to a stop or accelerated and when a contact-free and free of wear operation and supply of energy is required. The brake is therefore very suitable for unwinding continuous material.
[0023] The eddy current brake used in the invention, that is equipped with permanent magnets, is based on magnetism created by a rotating motion, whereby the braking magnetic force increases in relation with the rotary motion. This property makes it possible to raise the shade with an even slower speed. There is an air space between the magnetic core and the copper and steel tubes around it and therefore there is no abrasive contact or friction between components. The roller shade of the invention therefore has an excellent resistance and durability.
[0024] The outer periphery of the magnetic circuit in the eddy current brake of the invention is closed with an iron and copper tube, and therefore the material of the tube that works as a shaft for the shade is not critical. In addition, it is easy to design the magnetic brake for shade tubes of different sizes by calculating the magnetic field needed by means of the peripheral speed and torque and thereby the necessary number and size of the magnets.
[0025] The invention successfully uses an eddy current brake that calculationally corresponds to the spring force of the spring mechanism so that the movement of the raising curtain is even and the created eddy currents brakes mote the more the spring strive to rotate the shade and lift it up. No electricity is needed in the invention.
[0026] In the following, the invention is described by means of some preferable embodiments to which the invention is not restricted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a general presentation of a first embodiment of the roller shade of the invention, wherein there is a spring mechanism in one end of the shaft of the roller shade and an eddy current brake in other end
[0028] FIG. 2 is a general presentation of a second embodiment of the roller shade of the invention, wherein the spring mechanism and the eddy current brake are at the same end of the shaft of the roller shade
[0029] FIG. 3 is a detailed assembly illustration of the eddy current brake used in the invention in parts
[0030] FIG. 4 is a cross-section of the brake connected to the shaft of the roller shade
[0031] FIG. 5 is a detailed view of a part of FIG. 1 showing the brake and the end of the shaft of the roller shade separate from eachother
DETAILED DESCRIPTION
[0032] FIG. 1 presents generally a first embodiment of the roller shade of the invention. The roller shade of the invention comprises at least such components as a shade 2 , a tube-like shaft 4 , a spring mechanism 1 and a brake 3 .
[0033] The shade 2 , which term here is used to describe the fabric part of the roller shade of e.g. cotton or polyester, can be wound or rolled around the shaft 4 in an upper position and be lowered in a lowered position. In FIG. 1 , the shade 2 is partly wound up. The lower edge of the shade part 2 often has a bottom bar or some handle attached directly to the bar or a cord with a tassel to facilitate the lowering (not shown).
[0034] The spring mechanism 1 , which in FIG. 1 is shown separately from the roller shade, is in reality inside the shaft 4 of the shade and it includes a rod 5 around which is fitted a spiral torsion spring (cannot be seen in FIG. 1 ). The spring is fixed with fastening means 6 that rotates with the shaft 4 and work as a bearing. The end of the rod 5 is available at the outside of the shaft 4 in the form of a flat bar 8 , which is held against rotation by means of a fixture, which is not shown.
[0035] The rotation of the shaft 4 causes a tensioning of the spring when the roller shade is pulled down. In order to lock the roller shade in a desired lower position, latching devices are fitted in the bearing part 6 , which are released by pulling down the roller shade a little bit.
[0036] When the spring mechanism 1 is released by pulling down from the lower edge of the shade 2 , the tension of the spring pulls up the curtain 2 . The more force there is in the spring, the faster the shade 2 is lifted up. However, a brake 3 is used in the roller shade of the invention that brakes the shade 2 with increasing power along with increasing speed of the shade 2 .
[0037] Thanks to the brake 3 that is used in the roller shade of the invention, which is preferably an eddy current brake and fastened to the shaft 4 , a controlled release of the tensioning of the spring can be obtained. In the embodiment of FIG. 1 , the spring mechanism 1 is at one end of the shaft 4 of the roller shade and the eddy current brake 3 at the other end of the shaft 4 of the roller shade.
[0038] FIG. 2 presents generally a second embodiment of the roller shade of the invention, wherein the spring mechanism 1 and the eddy current brake 3 are at the same end of the shaft 4 of the roller shade.
[0039] FIG. 3 is a detailed assembly illustration of the eddy current brake 3 used in the invention in parts. The eddy current brake 3 comprises a magnetic core 9 that consists of narrow perpendicularly magnetized discs 10 of permanent magnets glued around a first steel tube 11 being alternately placed with respect to their polarity (+up and down). The brake force can be adjusted by means of the length of the discs 10 . The brake is more powerful the longer the discs 10 are. The magnetic force needed and the size of the magnets can be mathematically calculated when the force of the spring mechanism 1 , the diameter of the shaft 4 and the desired raising speed of the shade is known.
[0040] There are slots 12 in both end of the first steel tube 11 to which round-shaped end plates 13 , 14 of hard and slippery plastic can be locked. The outer periphery of these end plates 13 , 14 work as bearings against the inner edge of the outer end pieces 15 , 16 on both sides of the brake 3 . The outer end pieces 15 , 16 are also made of hard and very slippery plastic.
[0041] In the embodiment of FIG. 1 , one of the end pieces 15 is bigger than the other end piece 16 because the small one 16 has to fit inside the shaft 4 of the roller shade and the other one be big enough not to go completely inside but to fit tightly against the end of the shaft to facilitate keeping the brake 3 in place. In this embodiment, a flange of the bigger end piece 15 is outside the shade 4 .
[0042] In the embodiment of FIG. 2 , both end pieces 15 , 16 have to be small enough to fit inside the shaft 4 of the roller shade and can be similar, .i.e. they can e.g. both be like the smaller one 16 .
[0043] The eddy current brake 3 further comprises a plate-like axle 17 inside the magnetic core 9 from which axle 17 one end of the eddy current brake 3 can be fastened to the wall or to the supporting member of the roller shade in the embodiment of FIG. 1 . In the embodiment of FIG. 2 , the axle 17 is fastened to the rod 5 of the spring mechanism 1 .
[0044] The plate-like axle 17 is pushed into the magnetic core 9 through openings 18 in the end plates 13 , 14 .
[0045] Next, the combination of the magnetic core 9 and the end plates 13 , 14 and the plate-like axle 17 is pushed inside a copper tube 19 , on which copper tube 19 there is an outer second steel tube 20 .
[0046] In the embodiment of FIG. 2 , the diameter of the outer end pieces 15 , 16 is only slightly larger than that of the outer second steel tube 20 but smaller than the shaft 4 of the roller shade so that the assembled brake 3 easily could be pushed inside the shaft 4 .
[0047] In the embodiment of FIG. 1 , the bigger end piece 15 has to be dimensioned so that it is very tightly and securely locked to the shaft 4 of the roller shade so that a flange of the end piece 15 is outside the shaft 4 .
[0048] In practice, the magnetic core 9 itself does not rotate, since the axle 17 is locked to a supporting member of the roller shade like in FIG. 1 or to the rod 5 of the spring mechanism 1 like in FIG. 2 . However, the combination of the copper tube 19 and the outer steel tube 20 around the magnetic core do rotate together with the end pieces 15 and 16 by creating eddy currents between the magnetic core 9 and the tubes 19 , 20 . The tubes 19 and 20 hinder the eddy currents to exit when they are correctly dimensioned.
[0049] Thus, the outer end pieces 15 and 16 forms a bearing together with the end plates 13 , 14 by keeping the magnetic core 9 free from the copper tube 19 so that there is a little air space therebetween.
[0050] FIG. 4 is a cross-section of the brake 3 fastened to the shaft 4 of the roller shade in accordance with the embodiment of FIG. 1 .
[0051] It can be seen that the brake 3 is almost completely inside the shaft 4 so that only the flange of the bigger end piece 15 stays outside. In this bigger end piece 15 , there are small flexible ribs on the outer surface of the brake 3 that goes inside the tube shaft 4 . The brake 3 is wedged tightly inside the shaft 4 by means of these ribs.
[0052] FIG. 5 is a detailed view of a part of FIG. 1 showing the brake and the end of the shaft 4 of the roller shade separate from eachother. Ribs 21 inside the shaft 4 enables a fastening between the brake 3 and the shaft 4 also in embodiments when the brake 3 is completely inside the shaft 4 . In the embodiment of FIG. 5 , however, one of the end pieces 16 is small and the other end piece 15 is big enough so that a flange of it stays outside the shaft 4 and tightly keeps the brake 3 in place inside the shaft 4 and having slots that corresponds to the ribs 21 inside the shaft 4 . The ribs 21 cause the tubes 19 and 20 on the outer periphery of the brake 3 to rotate. Here, one end of the eddy current brake 3 is fastened to the wall or to the supporting member of the roller shade and the other end to the shaft 4 by means of a connection between the slots and the ribs.
[0053] In this embodiment, the rotation movement of the shaft 4 is transferred to the end pieces 15 and 16 of the brake 3 causing the end pieces 15 and 16 to rotate. The copper tube 19 and the outer steel tube 20 around the magnetic core 9 do rotate together with the end pieces 15 and 16 by creating eddy currents between the magnetic core 9 and the tubes 19 , 20 but the magnetic core 9 itself dos not rotate, since the axle 17 is locked to a supporting member of the roller shade.
[0054] Another fastening of the brake 3 is used for the embodiment of FIG. 2 . No detailed figure for this embodiment is shown. One end of the axle 17 will be attached to the end of the rod 5 of the spring mechanism 1 . The brake 3 and the spring mechanism are on the same end of the shaft tube 4 and the whole brake is going inside the shaft tube 4 of the roller shade. One end of the axle 17 of the brake 3 is connected to the rod 5 of the spring mechanism 1 . In this case, the outer end pieces 15 are 16 can be similar and both are small enough to fit inside the shaft tube 4 . Both end pieces 15 and 16 are connected to the shaft tube 4 by a similar fastening mechanism as described above, wherein there are ribs inside the shaft tube 4 that fit into slots in the end pieces 15 and 16 .
[0055] Instead of a fastening mechanism, wherein ribs and slots are used, the inside of the shaft 4 can be smooth. In such an embodiment suitable for the embodiment of FIG. 1 , the inner end piece 16 inside the shaft 4 has to be so tightly fitted inside the shaft tube that it rotates with the shaft 4 .
[0056] While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims. | The roller shade is wrapped around a shaft tube which has a supporting member through which the roller shade can be fastened to the wall or the like. The roller shade also includes a spring mechanism, with which the roller shade can be lowered upon tensioning of an un-wrap spring fitted around the shaft that rotates in a first direction at the lowering and be raised upon releasing of the un-wrap spring when the shaft rotates in the opposite direction. The roller shade is mainly characterized by an eddy current brake fastened to the shaft for a controlled release of the tensioning of the spring. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. application Ser. No. 10/827,440, filed Apr. 20, 2004, which is a continuation of U.S. application Ser. No. 10/437,306, filed May 14, 2003, which is a continuation of U.S. application Ser. No. 10/075,259, filed Feb. 15, 2002, now U.S. Pat. No. 6,580,686, which is a continuation of U.S. application Ser. No. 09/761,571, filed Jan. 18, 2001, which is related to and co-pending with U.S. application Ser. No. 09/761,570, filed Jan. 18, 2001, which are continuations of U.S. application Ser. No. 09/350,107, filed Jul. 9, 1999, now U.S. Pat. No. 6,219,331, which is a continuation application of U.S. application Ser. No. 09/090,310, filed Jun. 4, 1998, now U.S. Pat. No. 5,930,228, which is a continuation application of U.S. application Ser. No. 08/900,294, filed on Jul. 25, 1997, now U.S. Pat. No. 5,936,933, which application relates to U.S. application Ser. No. 08/863,126, filed on May 27, 1997, now U.S. Pat. No. 5,953,299, entitled “INFORMATION RECORDING METHOD AND APPARATUS” by H. Miyamoto et al, and assigned to the present assignee, based on Japanese Patent Application Nos. 08-136189 filed on May 30, 1996 and 09-079587 filed on Mar. 31, 1997, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to information recording media, and particularly to a high-density information recording medium and a high-density optical recording medium of which the track width is smaller than a beam spot or a detecting means such as a magnetic head.
[0003] Japanese laid-open patent publication No. 6-176404, for example, describes an example of a high-density (narrow track) recording medium. This example uses as a recording medium an optical recording medium in which groove portions and land portions are formed on a substrate and information recording areas are formed on both of the groove portions and the land portions. Prepits are formed on a virtual prolonged line of a boundary portion between the groove portion and the land portion as identification information of a recording unit (sector), whereby recording information is recorded on both of the groove portions and the land portions and identification (address) information indicative of a recording area is handled by the prepits. Also, one prepit commonly uses address information for a pair of groove portion and land portion. According to this system, when the recording medium of this system is applied to a phase change type recording medium and a magneto-optical recording medium, information from the adjacent land portion or groove portion can be prevented from being mixed into the groove portion and the land portion owing to an interference effect caused within the beam spot (i.e. crosstalk can be cancelled out), and hence the tracks of the recording medium can be narrowed, thereby making a high-density recording become possible.
[0004] However, in the example according to the related art, inasmuch as information indicative of the position on the information recording medium is concentrated in the prepit portions and the prepit portions located in a discrete fashion, position information cannot be obtained from portions other than the prepit portions. As a consequence, it is difficult to control a rotational speed of a disk precisely with a high reliability. There is then presented the problem from a reliability standpoint that the recording medium according to the relate art is not persistent to, in particular, defects or the like.
SUMMARY OF THE INVENTION
[0005] A first object of the present invention is to provide an information recording medium in which the aforementioned problems can be solved and which can be made high in recording density and highly reliable by assigning position information to other portions than prepit portions.
[0006] A second object of the present invention is to provide an information recording and/or reproducing method in which the aforementioned problems can be solved and in which information can be recorded and/or reproduced with a high recording density and with a high reliability by using an information recording medium in which position information is assigned to other portions than prepits.
[0007] In order to attain the above-mentioned first object, the present invention used the means which follow:
[0008] (1) In an information recording medium having almost spiral-like or concentric tracks comprising both of groove portions and a land portion between the groove portions, the recording medium is divided into groups of a plurality of areas in the radius direction, each track is divided at circular arc recording units having the same central angle arranged to be radial in the radius direction within each group, identification information indicative of the recording unit is provided in the track at every recording unit, the each track is divided into groups such that a length of a circular arc-shaped recording unit becomes almost constant between the groups, and the groove portion and the land portion are wobbled in the radius direction of the information recording medium.
[0009] Thus, position information can be reliably obtained in the recording portions because the identification information is provided at every recording unit, and the groove portions and the land portions, which are the recording portions, are wobbled. In other words, recorded information can be accessed reliably and recording information can be positioned with a high accuracy. Further, since the recording units are arranged to be positioned in the radius direction of the information recording medium, the tracks can be accessed with ease, and a crosstalk caused between position information of each recording unit can be suppressed to the minimum. Since the tracks are disposed in such a manner that the lengths of the circular arc-shaped portions which are the recording units become almost the same, the recording density becomes approximately uniform. Thus, it becomes possible to efficiently use the whole surface of the disk. Furthermore, it is possible to correct the displacement of tracking with a high accuracy.
[0010] Japanese laid-open patent publication No. 6-243468 describes a technology in which grooves are wobbled and a linear velocity of a disk is calculated by a wobble cycle detecting circuit, thereby rotating the disk at a constant linear velocity (CLV).
[0011] (2) Wobble cycles and phases of the groove portion and the land portion are uniformly arranged to be radial with respect to the adjacent tracks within each group, whereby the wobbling between the adjacent tracks can be reliably reproduced without interference. Also, since the widths of the respective tracks become constant, the recording characteristics can be prevented from being affected.
[0012] (3) A constant integral multiple of the cycle at which the groove portion and the land portion are wobbled is made coincident with the length of the circular arc-shaped recording unit. Thus, the starting point and the ending point of the recording unit can be detected reliably, and it becomes possible to detect an accurate position in the recording unit. Moreover, since the length of the recording unit and the wobble cycle in which the groove portion and the land portion are wobbled are synchronized with each other, it is possible to automatically and constantly keep the relative speed of the recording medium constant by making the frequency of the wobbling become constant.
[0013] (4) The maximum values of the amplitudes of wobbling in which the groove portion and the land portion are wobbled were selected to be smaller than one-tenth of the track width. Thus, the influence that is exerted upon the recording and reproducing characteristics by the above-mentioned wobbling could be suppressed to be less than 1−cos (180/10)=−26 dB, and the influence which affects an S/N (signal-to-noise ratio) (˜20 dB) necessary for the normal recording and/or reproduction can be suppressed to be negligibly small.
[0014] (5) Identification information was formed by prepits which were very small concave portions and convex portions disposed in the spacing between the groove portion and the land portion. Thus, it becomes easy to mass-produce an information recording medium with identification information Previously provided therein by a simple manufacturing process such as an injection molding. Therefore, a productivity with which an information recording medium is mass-produced can be raised.
[0015] (6) Identification information was disposed in an intermediate portion formed between a track and a track adjoining to the former track. Thus, since one identification information can be used by both of the two tracks, identification information assigned to one information area is doubled, and hence a reliability of the identification information can be improved. The information tracks in which identification information is disposed can be discriminated from each other by effectively utilizing a difference between the positions of the directions along the track. Moreover, since a relationship between the identification information of the adjacent track and the identification information of the track falls within a constant range, it becomes possible to discriminate the track from the identification information of the adjacent track.
[0016] (7) The track of the groove portion and the track of the land portion were disposed at least at one portion of the one circumference of the information recording medium in such a way as to be connected from the groove portion to the land portion or from the land portion to the groove portion. Thus, since it becomes possible to continuously access the tracks from the recording track of the groove portion to the recording track of the land portion, an effective transfer rate of information can be raised. Therefore, it becomes easy to record and/or reproduce successive information such as moving picture information on and/or from the information recording medium. The present invention used the following means in order to attain the above-mentioned second object:
[0017] (8) The above-mentioned information recording medium was used, and light was irradiated on the track. Then, a wobbling signal was detected by detecting reflected light with at least two split photo detectors, and information was recorded in the information recording medium and/or reproduced from the information recording medium by controlling a rotational speed of the information recording medium in such a manner that the cycle of the detected wobbling signal becomes constant. Thus, a rotational speed of the disk-like information recording medium can be controlled with ease and with a high accuracy in such a manner that a scanning velocity of light on-the information recording medium becomes almost constant.
[0018] (9) The above-mentioned information recording medium was used, and light was irradiated on the track. Then, a wobbling signal was detected by detecting reflected light with at least two split photo detectors, and information was recorded on the information recording medium by using a clock which was generated in synchronism with the phase of the detected wobbling signal. Thus, since it becomes easy to make the length of each recording unit on the information recording medium become constant, the lengths of extra gaps on the information recording medium can be minimized.
[0019] (10) The above-mentioned information recording medium was used, and light was irradiated on the track. Then, a wobbling signal was detected by detecting reflected light with at least two split photo detectors, and a displacement of the track was detected by comparing the amplitudes of the wobbling signals obtained from the two photo detectors of the split photo detector. Thus, since information can be recorded on the information recording medium and/or reproduced from the information recording medium while the displacement amount of the track is being monitored constantly, a reliability in the positioning servo can be improved greatly.
[0020] (11) The recording medium is an optical disk of a concentric-shaped or spiral-like groove configuration arranged along the tracks. This groove structure is wobbled in the radius direction of the optical disk. The track of the optical disk is divided into a plurality of recording units by radial boundary lines in the track direction. Of the recording units thus divided by the radial boundary lines, at least two recording units adjoining in the radius direction of the optical disk constitute one zone, and the groove structures included in the respective recording units within one zone have almost the same number of the wobbling.
[0021] Thus, since the position information can be highly reliably obtained even from the recording portions owing to the wobbling, recorded information can be accessed reliably. Hence, it becomes possible to accurately position recorded information on the optical disk. Further, since the recording units are arranged to be radial in the radius direction within the group (zone), recorded information among the tracks can be accessed with ease, and a crosstalk between the position information of the respective recording units can be suppressed to the minimum.
[0022] The recording unit need not always agree with the length of the sector, and a plurality of sectors of more than two sectors may be collected as the recording unit. Furthermore, a plurality of recording units may be collected as a logical sector or a logical block used to correct an error. At any rate, the recording unit herein will be referred to as an area of almost constant length provided within the optical disk.
[0023] (12) The recording medium is an optical disk of a concentric-shaped or spiral-like groove configuration arranged along the tracks. This groove structure is wobbled in the radius direction of the optical disk. The track of the optical disk is divided into a plurality of recording units by radial boundary lines in the track direction. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction of the optical disk constitute one zone. The optical disk includes a plurality of zones, and the groove structures included in one recording units within any zone have almost the same number of the wobbling.
[0024] Thus, since the relationship between the information recording unit and the duration of the wobbling becomes equal on the whole surface of the optical disk, it becomes possible to control the rotational speed of the optical disk and to generate the recording clock by using the wobble signal without switching the wobble signal in the zone. Therefore, a density within the optical disk can be made almost uniform by the apparatus of the simple configuration, and hence it becomes easy to utilize the whole surface of the optical disk efficiently.
[0025] (13) The recording medium is an optical disk having a concentric-shaped or a spiral-like groove configuration, and the groove structure is wobbled in the radius direction of the optical disk. The groove structure of the optical disk is divided into a plurality of recording units in the circumference direction of the optical disk by the radial boundary lines. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction constitute one zone, and the groove structures which are adjoining to each other in the radius direction of the optical disk have substantially the same wobbling cycle.
[0026] Alternatively, there might be used the following means:
[0027] (14) The recording medium is an optical disk having a concentric-shaped or a spiral-like groove structure, and the groove structure is wobbled in the radius direction of the optical disk. The groove structure of the optical disk is divided into a plurality of recording units in the circumference direction of the optical disk by the radial boundary lines. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction of the optical disk constitute one zone. The groove structures of the adjacent recording unit areas in the radius direction of the optical disk within one zone have almost the same wobbling cycle and the same number of the wobbling.
[0028] Thus, since the position information can be reliably obtained even from the recording portion, recorded information on the optical disk can be accessed highly reliably, and the recorded information can be positioned with a high accuracy. Furthermore, since the wobbling is arranged to be radial in the radius direction within the group (zone) and the phases of the wobbling are the same in the grooves, it becomes easy to access the tracks of the optical disk. Also, it becomes easy to detect the wobbling signal at a high quality of a signal. Strictly speaking from a theory standpoint, although this wobbling signal has a cycle proportional to the position at which the groove is located in the radius direction within one zone, the grooves which are close to each other like the grooves within one zone have almost the same wobbling cycle. Incidentally, the number of the wobbling need not always be limited to an integral number within the recording unit area.
[0029] (15) The recording medium is an optical disk having a concentric-shaped or a spiral-like groove structure. The groove structure is wobbled in the radius direction of the optical disk, and the groove structure of the optical disk is divided into a plurality of recording units in the circumference direction of the optical disk by the radial boundary lines. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction constitute one zone. The optical disk includes a plurality of zones, and the groove structure has almost the same wobbling cycle in the unit areas which are adjoining to each other in the radius direction of the optical disk within every zone, and also has the same number of the wobbling.
[0030] Thus, since the relationship between the information recording unit and the duration of the wobbling cycle becomes equal on the whole surface of the optical disk, it becomes possible to control the rotational speed of the optical disk and to generate a recording clock by using the wobbling signal without switching the wobbling signal in the zone. Thus, since a density within the optical disk can be made almost uniform by the apparatus of the simple configuration, it becomes easy to utilize the whole surface of the optical disk efficiently.
[0031] (16) The recording medium is an optical disk having a concentric-shaped or a spiral-like groove structure. The groove structure is wobbled in the radius direction of the optical disk, and the track of the optical disk is divided into a plurality of recording units in the track direction by the radial boundary lines. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction of the optical disk constitute one zone. Central angles corresponding to one period of the wobbling of the groove structure included in the respective recording units within one zone are the same, and the starting positions of the wobbling are arranged to be radial in the radius direction of the optical disk at each recording unit.
[0032] Thus, since the wobbling signal between the adjacent tracks can be reliably reproduced without interference and the width of each track becomes constant, the recording characteristics can be protected from being affected.
[0033] (17) The recording medium is an optical disk having a concentric-shaped or a spiral-like groove structure. The groove structure is wobbled in the radius direction of the optical disk. The track of the optical disk is divided into a plurality of recording units in the circumference direction of the optical disk by the radial boundary lines. Of the recording units thus divided by the radial boundary lines, at least two recording units which are adjoining to each other in the radius direction constitute one zone. Assuming that N is one integral number that is made common to all of the recording units on the optical disk, then the optical disk includes a plurality of zones, and all wobble cycles included in one recording unit of each zone is set to approximately 1/N times the length of the recording unit.
[0034] Thus, since the relationship between the information recording unit and the duration of the wobbling cycle becomes equal on the whole surface of the optical disk, it becomes possible to control the rotational speed of the optical disk and to generate the recording clock by using the wobble signal without switching the wobble signal depending on the zone, and hence a density within the optical disk can be made almost uniform by the apparatus of the simple configuration. As a consequence, it becomes easy to make effective use of the whole surface of the optical disk efficiently. Moreover, since the integral multiple of the wobbling cycle agrees with the length of the recording unit, the phases of the wobbling signal can be perfectly connected between the adjacent recording units without fractions. Hence, it becomes easy to generate a timing signal such as a clock over a consecutive recording unit by using the wobbling signal. The fact that the wobbling signal is connected without fractions as described above means that the phases of the wobbling signals are continuous between the adjacent recording units, and the wobbling signals need not always be continuously connected physically. Specifically, although it is possible to use such a wobble structure that the wobbling signal is dropped out over several cycles at the boundary portion of the recording units, if such dropout portion is interpolated (compensated for), then the phase of the wobble signal is continuously connected in the adjacent recording unit areas.
[0035] (18) Identification information was provided at every recording unit. Thus, it becomes easy to access the recording unit on the optical disk. Also, it becomes possible to fix the position of the beam spot at all positions on the optical disk by combining a signal detected from the wobbling and the identification information. Therefore, a reliability with which information is recorded on the optical disk and/or reproduced from the optical disk can be improved. Moreover, an accuracy with which recorded information is positioned on the recording medium can be improved. Thus, a buffer area required when information is recorded on the recording medium can be reduced. As a consequence, it becomes possible to enlarge a recording capacity of the recording medium. Moreover, even when a part of identification information on the optical disk cannot be detected due to a defect or the like, the position of the beam spot can be identified based on beam spot position information obtained from the wobbling so that a reliability with which information is recorded on the optical disk and/or reproduced from the optical disk can be improved greatly. If the above-mentioned advantage is used, even though recording media are not inspected when they are shipped, a reliability with which information is recorded on the optical disk and/or reproduced from the optical disk can be maintained so that a cost of the recording medium can be reduced considerably. Moreover, since the recording medium is very resistant to smudges, and need not be protected by some suitable means such as a case. Thus, it becomes possible to provide an inexpensive recording medium.
[0036] (19) The above-mentioned identification information was formed by prepits comprising optical concave or convex portions.
[0037] Thus, optical disks can be mass-produced with ease by a replica method, and it becomes possible to provide stable and highly-reliable identification information which can be prevented from being deteriorated.
[0038] (20) The recording medium includes information recording areas provided along the central line of the groove structure and the central line of the land structure.
[0039] Thus, according to the above-mentioned information recording areas, it becomes possible to dispose recorded information with a high density, i.e. it is possible to realize a medium of a high density (large capacity).
[0040] (21) Light is irradiated on the recording medium, a wobble signal is detected by detecting reflected light of the irradiated light by a photo detector, and a recording or reproducing timing signal is obtained by using the wobble signal.
[0041] Thus, since position information is reliably obtained even from the recording portions by the wobbling of the groove portions and the land portions which are served as the recording portions, recorded information can be accessed highly reliably, and recorded information can be positioned on the recording medium with a high accuracy, i.e. information can be recorded and/or reproduced on and/or from the recording medium highly reliably, and an accuracy with which information is recorded on the recording medium can be raised.
[0042] (22) Light is irradiated on the recording medium, and the wobble signal is detected by detecting reflected light of the irradiated light with a photo detector. By using the wobble signal, it is possible to obtain a starting or ending timing at which at least any of recorded information and identification information is recorded on and/or reproduced from the recording medium.
[0043] Thus, since timing information can be obtained highly reliably even when a timing at which the recording unit and the identification signal are generated is fluctuated because a revolution rate of the optical disk, for example, is not stable due to the wobbling of the groove portions and the land portions which are served as the recording portions, the recorded information on the optical disk can be accessed highly reliably. As a consequence, a speed at which recorded information is accessed can be raised, and it becomes possible to use an inexpensive motor so that an information recording and/or reproducing apparatus can be produced inexpensively.
[0044] (23) At least one identification information is detected by irradiating the recording medium with light. When at least one succeeding identification information which succeeds the identification information is detected, the recording area that should be identified by the succeeding identification information is recorded on or reproduced from the recording medium by using either an identification information detecting signal indicating that the succeeding identification information is detected or a pseudo-succeeding identification information detecting signal which is generated from a recording or reproducing timing signal obtained from the above-mentioned wobbling of the groove portions and the land portions.
[0045] Thus, even when the succeeding identification information cannot be detected due to some causes such as defects or smudges, the recording area that should be identified by the succeeding identification information can be accessed by using the signal obtained from the wobbling so that a reliability with which information is recorded on the recording medium and/or reproduced from the recording medium can be increased greatly.
[0046] (24) There is provided a method of recording and/or reproducing information in which information is recorded on and/or reproduced from a recording medium by using a timing signal obtained from the wobbling instead of identification information if the identification information cannot be detected when the identification information is detected by irradiating light on the recording medium.
[0047] Thus, even when the succeeding identification information cannot be detected due to some causes such as defects or smudges, the recording area can be accessed highly reliably by using the wobble signal, and hence a reliability with which information is recorded on and/or reproduced from the recording medium can be improved greatly. Therefore, since the reliability in recording and/or reproducing information on and/or from the recording medium can be maintained high without inspecting the recording medium when the recording medium is shipped, it becomes possible to reduce the cost of the recording medium considerably. Furthermore, since the recording medium becomes very resistant to the smudges, the recording medium need not be protected by some suitable means such as a case. Therefore, it becomes possible to provide a more inexpensive recording medium.
[0048] (25) Light is irradiated on the recording medium, and a wobble signal is detected by detecting reflected light of the irradiated light with a photo detector. When a recording or reproducing timing signal is generated from the wobble signal, at least the portion in which the above-mentioned identification information is provided can be interpolated by a signal synchronized with a series of immediately-preceding wobble signals.
[0049] Thus, the recording and/or reproducing timing signal obtained from the wobble signal is prevented from being deteriorated due to the identification signal of the identification information portion, and hence the position information from the wobble information can be highly reliably obtained even at the position located immediately after the identification information. Specifically, since the area located immediately after the identification Information that cannot be detected can be accessed highly reliably, it is possible to maintain a reliability with which information can be recorded on and/or reproduced from the recording medium. Therefore, it becomes possible to carry out a real time recording and/or reproduction and a highly-reliable recording without the dropout of the information at all.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is a plan view illustrating the manner in which the tracks are disposed in an information recording medium according to an embodiment of the present invention;
[0051] FIG. 2 is a plan view illustrating the manner in which identification information is disposed in the information recording medium according to the embodiment of the present invention;
[0052] FIG. 3 is a plan view illustrating the manner in which identification information is disposed at a track connected portion in the information recording medium according to the embodiment of the present invention;
[0053] FIG. 4 is a fragmentary perspective view illustrating the information recording medium according to the present invention in an enlarged scale;
[0054] FIG. 5 is a plan view illustrating the manner in which the divided groups are disposed in the information recording medium according to the embodiment of the present invention;
[0055] FIG. 6 is a plan view illustrating the manner in which identification information is numbered in the information recording medium according to the embodiment of the present invention;
[0056] FIG. 7 is a block diagram showing an example of a recording and/or reproducing apparatus using the information recording medium according to the present invention;
[0057] FIG. 8 is a diagram of a waveform of a reproduced signal obtained from the information recording medium according to the present invention;
[0058] FIG. 9 is a diagram of a waveform of a signal that is used to record and/or reproduce the information recording medium according to the present invention; and
[0059] FIGS. 10A through 10D are respectively diagrams used to explain a recording and/or reproducing method using the information recording medium according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] Embodiments of the present invention will hereinafter be described with reference to the accompanying drawings. Reference numerals in the sheets of drawings should identify the following elements and parts.
[0061] Reference numeral 1 denotes a recording unit, reference numeral 2 denotes identification information, reference numeral 3 denotes a groove portion, reference numeral 4 denotes a land portion, reference numeral 5 denotes a track switching portion, reference numeral 6 denotes a non-switching portion, reference numeral 7 denotes a beam spot, reference numeral 15 denotes a wobbling, reference numeral 16 denotes a one cycle of wobbling, reference numeral 21 denotes identification information disposed at a first position, reference numeral 22 denotes identification information disposed at a second position, reference numeral 23 denotes a prepit, reference numerals 11 and 12 denote recording units, reference numerals 91 , 92 , 93 denote grooves, and reference numerals 81 , 82 denote information recording portions, respectively.
[0000] Embodiment 1: Information Recording Medium
[0062] FIG. 5 shows the manner in which tracks and sectors of the information recording medium according to the present invention are disposed. As shown in FIG. 5 , a plurality of groups 91 , 92 and 93 are disposed in the radius direction of a disk-like recording medium 8 . The track 3 is wobbled by a very 20 small amount in the radius direction of the disk-like recording medium 8 . Each track 3 is divided into a plurality of circular arc-like sectors (recording units) 1 arrayed in the radius direction of the disk-like recording medium 8 . The length of the circular arc-like sector 1 is selected in such a manner that the number of the divided sectors per circumference of the disk-like recording medium 8 increases in the groups located at the position of the larger radius so as to make the length of the circular arc-like sector 1 become almost constant independently of the groups.
[0063] FIG. 1 shows an example of the manner in which tracks are disposed within one group of the information recording medium according to the present invention. As shown in FIG. 1 , within one group, there are alternately located groove portion information tracks 3 having a width of 0.7 μm and a depth of 60 nm and a land portion information track 4 having a width of 0.7 μm. The groove portion information track 3 and the land portion information track 4 are connected to each other by a switching portion 5 . Specifically, the groove portion information track 3 is arranged such that it is connected to the adjacent land portion information track 4 after one circumference of the track, and the land portion information track 4 is arranged such that it is connected to the adjacent groove portion information track 3 after one circumference of the track. Each track is divided into a plurality of circular arc-like recording units such as sectors, and identification information 2 is disposed at the head of each of the information recording units 1 . In this example, the length of the sector is about 8 mm, which corresponds to a user capacity of 2048 bytes. The groove portion information track 3 and the land portion information track 4 are wobbled with an amplitude of about 20 nm in the radius direction of the disk-like recording medium 8 . A wobble cycle during which the groove portion information 3 and the land portion information track 4 are wobbled in the radius direction was set to 1/145 of the sector length, i.e. about 55 μm. The ratio of 1:145 was selected in such a manner that the wobbling cycle becomes an integral multiple of the length (channel bit length) of recorded data. According to this arrangement, it becomes easy to generate a recording clock from the wobbling.
[0064] FIGS. 2 and 3 are respectively fragmentary plan views illustrating information identification information portions in an enlarged scale.
[0065] FIG. 2 schematically shows a portion 6 in which preceding and succeeding tracks of identification information are connected by the groove portion information tracks 3 and the land portion information tracks 4 . Also, FIG. 3 schematically shows a portion in which preceding and succeeding tracks are connected at the groove portion information tracks 3 and the land portion information tracks 4 , i.e. a portion in which identification information is disposed such that the positions of the directions extended along the information tracks are different in the adjacent tracks but agree with the track advanced or delayed by two tracks. As shown in FIG. 2 , identification information is disposed to be radial in the radius direction at the two places of the first position 21 and the second position 22 . The preceding and succeeding tracks are connected by the groove portion information tracks 3 and the land portion information tracks 4 . In this illustrated example of FIG. 2 , each identification information corresponds to the recording area of the right-hand side information track. Further, identification information corresponding to the right-hand side groove portion information track 3 is disposed at the first position 21 , and identification information corresponding to the land portion information track 4 is disposed at the second position 22 . Specifically, the positions of the identification information along the information tracks are different from each other in the adjacent tracks but agree with each other in the tracks advanced or delayed by the two tracks.
[0066] In the switching portion 5 of FIG. 3 , the preceding and succeeding tracks of identification information are connected to each other in the groove portion information track 3 and the land portion information track 4 . Also in this case, each identification information corresponds to the recording area of the right-hand side information track. As shown in FIG. 3 , Identification information corresponding to the right-hand side groove portion information track 3 is disposed at the first position 21 , and identification information corresponding to the land portion information track 4 is disposed at the second position 22 .
[0067] As a consequence, when the beam spot 7 scans the land portion information track 4 , only pits of the one side are constantly reproduced. There is then no risk that a crosstalk occurs from the adjacent track. Therefore, it becomes possible to satisfactorily reproduce address information from the prepits without crosstalk. The address information at the prepit is recorded by an 8/16 (eight-to-sixteen) modulation code (channel bit length is 0.2 μm).
[0068] FIG. 4 is a perspective view illustrating the manner in which tracks and identification information are configured according to the embodiment of the present invention, highlighting the manner in which identification information is formed by small concave portions (pits) 23 .
[0069] According to this embodiment, since the pits 23 are equally disposed on both sides of the track (land portion or the groove portion), a bad influence exerted by the pits 23 upon a tracking servo signal can be cancelled out. Accordingly, it is possible to suppress a track offset to be sufficiently small. Further, when the land portion information track 4 , for example, is reproduced, address information of the first prepit portion 21 and address information of the second prepit portion 22 are reproduced continuously. Therefore, if information is disposed in such a fashion that both of the address information of the first prepit portion 21 and the address information of the second prepit portion 22 may be integrated as one address information, then address (track No.), i.e. identification information can be set independently of the land portion information track 4 and the groove portion information track 3 . Specifically, it becomes possible to discriminate the land portion information track 4 and the groove portion information track 3 from each other by continuously reproducing the address information of the first prepit portion 21 and the address information of the second prepit portion 22 .
[0070] FIG. 6 shows concretely an example of the manner in which identification information is numbered. In FIG. 6 , there are illustrated the identification information of the recording area 11 and the identification information of the recording area 12 . In this example, identification information is recorded on and/or reproduced from the recording medium by relatively scanning detection spots from left to right of FIG. 6 . A groove portion information track K of the left-hand side, for example, is connected to a land portion information track K+1 of the right-hand side of the switching portion 5 . A land portion information track K+1 of the left-hand side is connected to the land portion information track K+1 after one circumference. In this example, identification information of an information recording area 81 of the groove portion information track K, for example, is N−1+S where S denotes a sum of optical recording information units per circumference of the track. When the identification information portion 6 of this track is reproduced by the beam spot or the like, N−1+2S is reproduced as identification information located at the first position 21 ; and N−1+S is reproduced as identification information located as the second position 22 . In this case, if a smaller number is constantly used as a recording area No. in advance, then N−1+S is used as identification information of the information recording area 81 of this groove portion information track K. When the land portion information track K−1 is scanned by the beam spot or the like, N−1 is similarly used as identification information located at the first position 21 . At the same time, it is possible to discriminate the groove portion information track and the land portion information track from each other by detecting whether the identification information located at the first position 21 or the identification information located at the second position 22 is used.
[0071] When the information track located at the track switching portion 5 is reproduced, a correspondence of identification information and recorded information can be judged in exactly the same manner, and also the groove portion information track and the land portion information track can be discriminated from each other in exactly the same way. Accordingly, it is possible to switch the track polarity between the groove portion information track and the land portion information track by making effective use of the above-mentioned relationship.
[0072] While there are two sets of the first and second identification information portions as described above, the present invention is not limited thereto, and there may be provided a plurality of sets of identification information portions. If there are provided four sets of identification information portions, for example, then first and third prepit portions are located under the groove portions and second and fourth prepit portions are located above the groove portions. If the number of the prepit portions increases, then the information recording medium according to the present invention becomes resistant to defects or the like, and therefore becomes highly-reliable.
[0073] Here, a phase change type recording film (GeSbTe) was used as a recording film of this information recording medium. Accordingly, a recording mark is produced in the form of amorphous area.
[0000] Embodiment 2: Information Recording and/or Reproducing Method
[0074] An example of an information recording and/or reproducing method using the recording medium according to the embodiment 1 will be described with reference to FIG. 7 .
[0075] As shown in FIG. 7 , the information recording medium 8 according to the embodiment 1 is rotated by a motor 162 . A light intensity control circuit 171 controls a light generating circuit 131 so that the light generating circuit 131 generates light 122 having a light intensity instructed by a central control circuit 151 . A converging circuit 132 converges the light 122 generated from the light generating circuit 131 to form a beam spot 7 on the information recording medium 8 . Reflected light 123 of the light 122 is detected by a photo detecting circuit 133 . The photo detecting circuit 133 comprises a plurality of split photo detectors. A wobble detecting circuit 191 reproduces information from the information recording medium 8 by using a reproduced signal 130 from the split photo detectors of the photo detecting circuit 133 . When a wobbling of the track on the information recording medium 8 is detected, there is used a differential output among the outputs from the split photo detectors of the photo detecting circuit 133 . The reason that the differential output is utilized is based on such a fact that an intensity distribution of diffracted light from the beam spot is changed depending on a positional relationship between the beam spot and the track. On the basis of the wobble signal detected by the wobble detecting circuit 191 , information indicative of the positional relationship between the beam spot and the track and further prepit identification information, a position control circuit 161 controls the position of the converging circuit 132 and a rotation frequency of the motor 162 . When the position control circuit 161 controls the rotation frequency of the motor 162 , the rotation frequency is controlled in such a manner that a reproduced wobble-signal may have a previously-determine constant value. If the rotational frequency of the motor 162 is controlled by the position control circuit 161 as described above, then the rotational speed of the motor 162 can be automatically and properly controlled independently of the groups on the information recording medium 8 . Also, since this rotation information of the motor 162 has one cycle of about 55 μm, the rotation information is very high in density, and it becomes possible to control the rotation of the motor 162 with a high accuracy. Furthermore, since this rotation information is disposed all over one revolution of the disk, even when a part of the rotation information is dropped out by some causes such as smudges or defects, the rotation information can be reproduced from the information recording medium 8 with a high accuracy satisfactorily.
[0000] Embodiment 3: Information Recording and/or Reproducing Method
[0076] A description will now be given on a method of recording and/or reproducing information on and/or from an information recording medium by generating a clock synchronized with a phase of a wobble signal when information is recorded and/or reproduced. In order to generate the above-mentioned clock synchronized with the phase of the wobble signal, there is used a PLL (Phase-Locked Loop) circuit. Since this clock is accurately synchronized with the wobble information of the information recording medium, if information is recorded on and/or reproduced from the information recording medium by using this clock, then information can be recorded on and/or reproduced from the information recording medium at a timing perfectly synchronized with the position on the information recording medium. Therefore, information can be recorded on and/or reproduced from the information recording medium without providing unnecessary buffer areas on the information recording medium, and it is possible to obtain an information recording medium which is high in format efficiency. As a consequence, there can be raised a recording capacity of the information recording medium. Furthermore, since the wobble information (rotation information) is disposed all over one revolution of the disk, even when a part of the wobble information is dropped out, information can be reproduced from the information recording medium with a high reliability satisfactorily.
[0000] Embodiment 4: Information Recording Medium
[0077] FIG. 5 shows the manner in which the tracks and the sectors of the recording medium according to the embodiment of the present invention are disposed. As shown in FIG. 5 , there are disposed a plurality of zones (groups) 91 , 92 , and 93 in the radius direction of the disk-like recording medium 8 having a diameter of 120 mm. In this example of FIG. 5 , there are divided 24 zones of which the radiuses are ranging from about 24 mm to 58 mm. Accordingly, one zone has a band width of about 1.4 mm. The groove portion information track 3 is wobbled by a very small amount in the radius direction of the disk-like recording medium 8 . Each of the groove portion information track 3 is divided into a plurality of circular arc-like sectors (recording units) 1 arrayed in the radius direction of the disk-like recording medium 8 . The length of the circular arc-like sector 1 is made almost constant independently of the zones (groups) so that the number of the divided sectors per circumference increases in the zone located at the position of the larger radius. In this embodiment, each track 3 is divided in such a manner that there are provided 17 recording units 1 per circumference in the zone (inner-most peripheral zone) of the radius of about 25 mm. The number of the divided zones increases one by one in the outer peripheral zone. By using the information recording medium having the groups divided in such a manner that the number of the divided groups increases in the outer peripheral zone as described above, the lengths of the recording units 1 in the inner and outer peripheries of the information recording medium 8 can be made almost constant. In other words, the density of the rotation information can be made substantially constant, and the surface area (i.e. whole surface) of the information recording medium 8 can be used effectively. Moreover, since information can be recorded on and/or reproduced from the information recording medium at the same rotational speed and with the same recording frequency within each group, an information recording and/or reproducing apparatus using the information recording medium can be simplified in configuration. It is needless to say that the lengths of the recording units are slightly different in the inside and the outside of each zone.
[0078] FIG. 1 shows an example of the manner in which tracks within one group are disposed in the information recording medium according to the present invention. As shown in FIG. 1 , there are alternately disposed the groove portion information tracks 3 having a width of 0.74 μm and a depth of 60 nm and the land portion information tracks 4 having a width of 0.74 μm. In each zone, there are disposed about 950 groove portion information tracks 3 and the land portion information tracks 4 of the same number as that of the groove portion information track 3 . The groove portion information track 3 and the land portion information track 4 are connected to each other by the track switching portion 5 which is located at one place on one circumference of the disk. Specifically, the groove portion information track 3 is connected to the adjacent land portion information track 4 after one circumference of the track, and the land portion information track 4 is connected to the adjacent groove portion information track 3 after one circumference of the track. Each track is divided into a plurality of circular arc-like information recording units 1 , and the identification information 2 is disposed at the starting portion of each information recording unit 1 . In this example, the length of the information recording unit 1 is about 8.5 mm, which corresponds to a user capacity of 2048 bytes.
[0079] The groove portion and the land portion are wobbled in the radius direction of the information recording medium by a half width amplitude of about 20 nm. The wobble cycle was set to 1/232 of the sector length or about 37 μm. The ratio of 1:232 is set not only within one group (zone) but also in all the recording units 1 on the disk. The ratio of 1:232 was selected in such a fashion that the wobble cycle becomes an integral multiple (in this example, 186 times) of the unit length (channel bit length) of the recorded data. Accordingly, the length of the recording unit is equivalent to 232×186=43152 channel bits when it is expressed by the channel bit number. Since the wobble cycle is equal to the integral multiples of the recording channel bit as described above, it is possible to easily generate a recording clock by multiplying the wobble frequency with an integral number. Moreover, since the relationship between the information recording unit 1 and the duration of the wobbling cycle becomes equal over the whole surface of the disk, it becomes possible to generate the recording clock by using the signal obtained from the wobbling without switching the signal at the zone. Thus, a density within the disk can be made almost uniform by the apparatus of the simple configuration, and the whole surface of the disk can be used efficiently. Furthermore, if the rotational speed of the disk is controlled in such a manner that the wobbling frequency becomes constant, then it becomes possible to make a relative linear velocity between the beam spot and the information recording medium almost constant independently of the position of the information recording medium. If the linear velocity is made substantially constant as described above, then information can be recorded on and/or reproduced from the recording medium under the same recording conditions independently of the position of the information recording medium. Thus, the recording and reproducing characteristics of the information recording medium can be controlled with ease, and hence the recording apparatus and the information recording medium can be configured with ease. Here, since the lengths of the recording areas 1 are slightly different in the inside and the outside of the zone, the duration of the wobble cycle of a reciprocal of an integral number of the recording unit also is different in the inner and outer peripheries of the zone. Thus, it is needless to say that a linear velocity also is different slightly. However, because central angles formed by the recording units are constant within the zone, the revolution rate (angular velocity) within the zone become constants so that it becomes possible to access the information recording medium within the zone at a high speed.
[0080] Moreover, since the integral multiple (232 times) of the wobbling cycle agrees with the length of the recording unit 1 , the phases of the wobbling signals can be perfectly connected to each other without fractions between the adjacent recording units 1 . Thus, it is easy to generate a timing signal such as a clock over the consecutive recording units 1 by using the wobbling signal. The fact that the phases of the wobbling signals are perfectly connected to each other without fractions means that the phases of the wobbling signals are made continuous between the adjacent recording units 1 but the wobbling signals need not always be continuous from a physical standpoint. Specifically, there might be used such an information recording medium in which a wobbling signal is dropped out at the boundary portion of the recording units 1 over several cycles. In that case, if such dropped-out portions are interpolated, then the phases of the wobbling signals may be connected between the adjacent recording units 1 . In actual practice, according to this embodiment, the identification information composed of prepits is provided at the starting portion of the recording unit and neither the groove portion information track 3 nor the land portion information track 4 exists with the result that the wobble signal is not formed at all. That is, the wobble signal is dropped out during about 11.2 cycles due to this identification information 2 . Accordingly, while there exist about 220.8 wobble signals in actual practice, the length of the recording information unit becomes exactly 232 times the cycle of the wobble signal.
[0081] Here, the recording unit in this embodiment need not always agree with the length of the sector. For example, more than two sectors may be integrated as one recording unit, and identification information may be disposed within such integrated recording unit. Moreover, a plurality of recording units may be integrated as a logical sector or a logical block necessary for correcting errors. At any rate, the recording unit in this embodiment is referred to as an area of substantially a constant length in which identification information is disposed at the starting portion thereof.
[0082] FIGS. 2 and 3 are respectively plan views illustrating identification information portions of the information recording medium in an enlarged scale.
[0083] FIG. 2 shows a portion 6 in which preceding and succeeding tracks of identification information are connected at the groove portions and the land portions. FIG. 3 shows a portion 5 in which preceding and succeeding tracks are connected at the groove portions and the land portions, i.e. a portion in which the positions at which identification information is arrayed along the information tracks are different between the adjacent tracks but agree with the track advanced or delayed by two tracks. As shown in FIG. 2 , identification information is disposed to be radial at a first position 21 and a second position 22 in the radius direction of the information recording medium. The preceding and succeeding tracks are connected to each other by the groove portion information tracks 3 and the land portion information tracks 4 . In this illustrated example, each identification information corresponds to the recording area of the groove portion information track 3 on the right-hand side of FIG. 2 . Further, identification information corresponding to the groove portion information track 3 on the right-hand side of FIG. 2 is placed at the first position 21 , and identification information corresponding to the land portion information track 4 is placed at the second position 22 . Specifically, the positions at which identification information is arrayed along the information tracks are different between the adjacent tracks but agree with the track which is advanced or delayed by two tracks.
[0084] The wobble signal is of a sine wave shape which begins with the same phase relative to all information tracks. The wobble signal starts immediately after the identification information portion or starts via a few buffer areas. With this arrangement, if points at which phases of the sine-wave wobble signal become zero degree are connected to each other by the adjacent tracks, then these points are arrayed to be radial so that the track width is never changed by the wobble signal. There is then presented no risk that the wobble signal will exert a bad influence upon the recording and reproducing characteristics. If the phases of the wobble signals are not made uniform in each track, then there is produced a portion in which the track width is modulated by the wobble signal, thereby resulting in the recording and reproducing characteristics being affected considerably. Therefore, as is evident from the above description of the present invention, in order to realize the present invention, it is very important to make the phases (including polarities) of the wobble signals uniform between the adjacent tracks.
[0085] In the track switching portion 5 shown in FIG. 3 , the preceding and succeeding tracks of the identification information are connected to each other at the groove portion and the land portion. Also in this case, each identification information corresponds to the recording area of the information track on the right-hand side of FIG. 3 . Identification information corresponding to the groove portion information track 3 on the right-hand side, of FIG. 3 is placed at the first position 21 , and identification information corresponding to the land portion information track 4 on the right-hand side of FIG. 3 is placed at the second position 22 .
[0086] Therefore, when the beam spot 21 scans the land portion information track 4 , for example, only one pit is constantly reproduced. There is then no risk that a crosstalk from the adjacent track will occur. Accordingly, it becomes possible to satisfactorily reproduce address information provided at the prepits without crosstalk. In this example, the address information provided at the prepits is recorded on the information recording medium by an 8/16 (eight-to-sixteen) modulation code (channel bit length is 0.2 μm). Accordingly, a shortest pit length is about 0.6 μm. From a standpoint of simplifying the configuration of the information recording and/or reproducing apparatus, the modulation code of the prepit portion and the modulation code of the user information recording portion should preferably be made the same. In this embodiment, the modulation code and the recording linear density are both made the same with the result that most of the circuit portions of the information recording and/or reproducing apparatus can be made common.
[0087] FIG. 4 is a perspective view illustrating the manner in which tracks and identification information according to this embodiment are configured, highlighting the manner in which identification information is formed by small concave portions (pits) 23 .
[0088] In this embodiment, since the pits 23 are equally disposed on both sides of the track (the land portion or the groove portion), an influence exerted upon a tracking servo signal by the pits 23 is cancelled out so that a track offset can be suppressed to be sufficiently small. Further, when the land portion information track 4 is reproduced, the address information of the first prepit portion 21 and that of the second prepit portion 22 are reproduced continuously. Therefore, if information is disposed in such a fashion that both of address information are integrated as one address information, then it is possible to separately set address (track No.), i.e. identification information independently of the land portion information track 4 and the groove portion information track 3 . Specifically, if the address information of the first prepit portion 21 and the address information of the second prepit portion 22 are reproduced continuously, then it becomes possible to discriminate the land portion information track 3 and the groove portion information track 4 from each other.
[0089] FIG. 6 concretely illustrates the example of the manner in which identification information is numbered, showing identification information of the recording area 11 and identification information of the recording area 12 . In this example, information is recorded and/or reproduced while detection spots are relatively scanned from left to right of the information recording medium. As shown in FIG. 6 , a groove portion information track k on the left-hand side is connected to a right-hand side land portion information track K+1. The left-hand side land portion information track K+1 is connected to this track after one circumference of the information recording medium. In this example, identification information of an information recording area 81 of the groove portion information track K is N−1+S where reference letter S denotes a sum of optical recording information units per circumference of the track. If the identification information portion 6 of this track is reproduced by the beam spot or the like, then N−1+2S is reproduced as identification information existing at the first position 21 , and N−1+S is reproduced as identification information existing at the second position 22 . In this case, if a smaller number is constantly used as a recording area No. in advance, then N−1+S is adopted a identification information of the information recording area 81 of this groove portion information track K. When the land portion information track K−1 is scanned, N−1 is adopted as the identification information existing at the first position 21 similarly. At the same time, by the identification information existing at the first position 21 or the identification information existing, at the second position 22 , it is possible to discriminate the groove portion information track 3 and the land portion information track 4 from each other.
[0090] When the information track placed at the track switching portion 5 is reproduced, the correspondence between the identification information and the recording area can be detected, and the groove portion information track 3 and the land portion information track 4 can be discriminated from each other in exactly the same manner as that described above. Therefore, by using this relationship, it is possible to switch the track polarities of the groove portion information track and the land portion information track.
[0091] While there are provided two sets of the first and second identification information portions as described above in this example, there may be provided a plurality of sets of identification information portions. If there are provided four sets of identification information portions, then the first and second prepit portions may be located on the lower side of the groove portion (inside of the radius direction), and the third and fourth prepit portions may be located on the upper side of the groove portion (outside of the radius direction). Alternatively, the first and third prepit portions may be located on the lower side of the groove portion, and the second and fourth prepit portions may be located on the upper side of the groove portion. The information recording medium can be made more resistant to the defects or the like and become highly-reliable by increasing the number of the prepit portions.
[0092] Here, a phase change type recording film (GeSbTe) was used as a recording film. Accordingly, a recording mark is produced in the form of an amorphous area.
[0000] Embodiment 5: Information Recording and/or Reproducing Method
[0093] The manner in which information is recorded on and/or reproduced from the information recording medium of the embodiment 4 by the information recording and/or reproducing apparatus shown in FIG. 7 will be described below. As shown in FIG. 7 , the information recording medium 8 according to the embodiment 4 is rotated by the motor 162 . The light intensity control means 171 controls the light generating circuit 131 to generate the light 122 in such a way as to obtain a light intensity instructed by the central control circuit 151 . The converging circuit 132 converges the light 122 to form the beam spot 7 on the information recording medium 8 . The light 12 is detected by using the reflected light 123 from the beam spot 7 with the photo detecting circuit 133 . The photo detecting circuit 133 comprises a plurality of split photo detectors. The wobble detecting circuit 191 reproduces information from the information recording medium 8 by using the reproduced signal 130 from the split photo detectors of the photo detecting circuit 133 . When the wobble signal of the track on the information recording medium 8 is detected, there is used a differential output between the outputs from the split photo detectors of the photo detecting circuit 133 . This utilizes the fact that an intensity distribution of diffracted light from the beam spot is changed depending upon a positional relationship between the beam spot and the track. On the basis of the wobble signal detected by the reproducing means 191 , information indicative of the positional relationship between the beam spot and the track and prepit identification information, the position control circuit 161 controls the position of the converging circuit 132 , and also controls the rotation frequency of the motor 162 . In this case, the position control circuit 161 controls the rotation frequency of the motor 162 in such a manner that the frequency of the reproduced wobble signal becomes a previously-determined constant value. If the rotation frequency of the motor 162 is controlled by the position control circuit 161 as described above, then it is possible to automatically control the motor 162 independently of the zones on the information recording medium 8 so that the motor 162 can be rotated at a proper rotational speed. Also, since this rotation information has one cycle of about 37 μm, the rotation information is considerably high in density, and it becomes possible to control the rotation of the motor 162 with a high accuracy. Furthermore, since this rotation information is disposed all over one revolution of the disk, even when one portion of the rotation information is dropped out due to some causes such as smudges or defects, information can be satisfactorily reproduced from the information recording medium 8 highly reliably.
[0094] FIG. 8 shows examples of a reproduced signal 41 of wobble information and a reproduced signal 42 of identification information portion. In this example, photo detectors which are split at least by a half in the radius direction are used as a detector, and there is obtained a differential signal between the outputs from the two split photo detectors. Specifically, there was used a detection system that is similar to a detection system of a push-pull signal used in an ordinary tracking control or the like. However, since the frequency of the wobble signal and the frequency of the identification information signal are higher than the band necessary for the tracking servo, there were prepared an amplifying apparatus and a differential circuit, both of which should be in accordance with the high frequency specification. There were obtained reproduced signals 421 , 422 , 423 and 424 in correspondence with the first, second, third and fourth identification information signals 21 , 22 , 23 and 24 . When the beam spot 7 is not overlapping the prepit 23 of the identification information portion 2 , reflected light is equally introduced into the above-mentioned split photo detectors so that a reproduced signal (differential signal) output is almost zero. Whereas, under the condition that the beam spot 7 partly overlaps the prepit 23 (see FIG. 2 ), a distribution of reflected light from the beam spot 7 is largely deviated due to a diffraction effect, and the outputs from the split photo detectors are unbalanced. As a consequence, there is obtained a large differential signal output. Inasmuch as the direction in which the distribution of reflected light is deviated at that time is different depending on the positional relationship between the beam spot and the pit, the differential output corresponding to the identification information portions 21 , 22 and the differential output corresponding to the identification information portions 23 , 24 are inverted in polarity. Accordingly, if this polarity of the differential outputs is used, then it is possible to determine any one of the groove portion information track and the land portion information track in which the beam spot is positioned. Identification information can be obtained when the resulting signal is converted into a binary signal and then decoded by a follow-up slice circuit (not shown). At that time, since error detection information is added to the identification information, it is possible to judge whether or not identification information is detected correctly. Hence, there can be used only correct identification information in a plurality of identification information.
[0095] The wobble signal is detected in a similar manner. Specifically, since the positional relationship between the beam spot and the groove is modulated by the wobbling signal, there is obtained a signal output 41 shown in FIG. 8 . However, since an amplitude (track displacement amount: 20 nm) of a wobble signal is small relative to the displacement amount (about 0.3 μm) of identification information, the amplitude of the wobble signal becomes smaller in proportion thereto.
[0096] An example of the manner in which a timing signal (clock signal) is obtained from the wobble signal thus detected will be described with reference to FIGS. 10A through 10D .
[0097] Initially, the reproduced signal 41 shown in FIG. 8 is supplied to a limiter circuit shown in FIG. 10A , in which an identification information is limited in amplitude. Then, by using the bandpass filter shown in FIG. 10B , only a signal having a component synchronized with the wobble signal is extracted from the reproduced signal. Then, the resulting signal is converted into a binary signal by a comparator shown in FIG. 10C , and eventually, there is obtained the clock signal by using a phase-locked loop (PLL) comprising a phase comparator, a filter circuit, a VCO (voltage-controlled oscillator) and a divide-by-186 circuit as shown in FIG. 10D . At that time, a filter characteristic used in the PLL is set to be sufficiently lower than the frequency corresponding to 11.2 wobble cycles in this example in such a manner that the clock signal may be prevented from being affected by a dropped-out portion (identification information portion) of the wobble signal. In this embodiment, since the frequency of the wobble signal becomes 160 kHz, the frequency band of the PLL is set to about 2 kHz. This frequency should preferably be set to be larger than a frequency (about 700 Hz) corresponding to the length of the recording unit from a standpoint of a high-speed accessing.
[0098] In this way, there was obtained the clock signal that was synchronized with the wobble signal. A method of recording and/or reproducing information on and/or from the information recording medium by using this clock signal and identification information will be described below.
[0099] FIG. 9 is a timing chart used to explain the manner in which information is recorded on and/or reproduced from the information recording medium. In FIG. 9 , reference letters (a), (b), (c), and (d) denote an identification information detecting signal, a wobble signal, a clock signal, and a recording and reproducing timing signal, respectively. The identification information detecting signal is a signal indicating that identification information is detected normally. It is customary that the recording unit areas that should be recorded and/or reproduced are discriminated from each other based on this identification information detecting signal and that the recording and/or reproducing timing can be controlled. According to the present invention, when the identification information could not be normally detected as shown in FIG. 9 (crosses on (a) in FIG. 9 show that identification information could not be detected normally), it is possible to obtain the recording and reproducing timing signal instead of the identification information detecting signal by counting the clock signal obtained from the wobble signal based on the final identification information that was detected normally. According to this arrangement, even when identification information cannot be detected normally, there can be obtained the recording and reproducing timing signal. Also; since this recording and reproducing timing signal is generated from the wobble signal synchronized with the information recording medium, even if there is an error such as a rotational speed of the information recording medium, the recording and reproducing timing signal can be obtained accurately. Furthermore, even when a plurality of identification information cannot be detected continuously, there is no risk that errors will be accumulated. Therefore, it becomes possible to configure an information recording and/or reproducing apparatus which can greatly allow errors of identification information itself.
[0100] If the signal detected from the above-mentioned wobble signal and the identification information are combined as described above, then it becomes possible to identify the position of the beam spot at all positions on the disk. Thus, information can be recorded on and/or reproduced from the information recording medium highly reliably. With the above-mentioned advantage, even if the information recording medium is not inspected at al when the information recording medium is shipped, it becomes possible to maintain the recording and/or reproduction highly reliable, thereby making it possible to reduce the cost of the information recording medium considerably. Furthermore, since the information recording medium becomes very resistant to smudges, the information recording medium need not be protected from the smudges by some suitable means such as a case. Therefore, it becomes possible to provide an inexpensive information recording medium.
[0101] According to the aforementioned first to fifth embodiments of the present invention, since information can be recorded on and/or reproduced from the information recording medium highly reliably, even if the information recording medium is not inspected at all when the information recording media are shipped, a high reliability with which information is recorded on and/or reproduced from the information recording medium can be maintained, thereby making it possible to reduce the cost of the information recording medium considerably. Moreover, since the information recording medium according to the present invention becomes very resistant to smudges, the information recording medium need not be protected from the smudges by some suitable means such as a case. Therefore, it becomes possible to provide an inexpensive information recording medium.
[0102] Further, since the recording units are arrayed to be radial in the radius direction of the information recording medium, the tracks can be accessed with ease, and a crosstalk between position information of respective recording units can be suppressed to the minimum.
[0103] Moreover, since the recording units are disposed in such a manner that the lengths of the circular arc-shaped portions which are the recording units are made almost the same, a recording density becomes substantially uniform within the disk, and hence it becomes possible to use the whole surface of the disk efficiently.
[0104] Moreover, the starting point and the ending point of the recording unit can be reliably detected by using the wobble cycle, and it becomes possible to detect the accurate position in the recording unit. Also, since the length of the recording unit and the wobble cycle are perfectly synchronized with each other, by making the wobble frequency become constant, it is possible to automatically control the rotational speed of the information recording medium in such a fashion that the relative velocity of the information recording medium becomes almost constant.
[0105] Further, since it becomes easy to make the length of each recording unit on the information recording medium become constant, the length of the extra gaps on the information recording medium can be minimized.
[0106] Furthermore, since it is possible to record and/or reproduce information on and/or from the information recording medium while monitoring the displacement amount of the track, a reliability with which the positioning servo is effected can be improved greatly.
[0107] According to the present invention, since the identification information is provided at every recording unit and the position information can be reliably obtained from the recording portion owing to the wobbles of the groove portion and the land portion, the recorded information can be accessed reliably and the recording information can be positioned on the information recording medium with a high accuracy.
[0108] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various changes and modifications can be effected therein by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims. | An apparatus for reproducing information recorded on an optical recording medium, including a disk-like substrate, a spiral or concentric-shaped groove structure along tracks formed on the substrate, each of the tracks being divided into a plurality of recording units. Each of the recording units includes a dropout portion in a circumferential direction of the groove structure with the dropout portion being a non-groove portion. The groove structure is formed with a wobble in a fixed cycle in a radial direction which continues in the circumferential direction along the track. Each length of the recording units is an integer multiple of the cycle of the wobble. The apparatus includes an irradiation source for irradiating a light spot on the medium, an optical detector for detecting a reflected light from the medium, and a reproducer for reproducing information by using a signal from the optical detector. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
Benefit is herein claimed of the filing date under 35 U.S.C. §§ 119 and/or 120, and 37 CFR § 1.78 to U.S. Provisional Application Serial No. 60/083.931, filed on May 1, 1998, entitled “Shaped-Charge Liner”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to shaped explosive charges, and in particular to a liner material used in shaped charges, such as those used in oil and gas wells.
2. Description of the Prior Art
Shaped charges for use in oil and gas well perforation and retrieval operations typically will consist of a casing which houses a quantity of explosive and a liner formed from a compressed-powder metal mixture. Materials used for such liners are well known and include copper, graphite, tungsten, lead, nickel and tin. The purpose of these metals is to allow a reasonably homogeneous mixture with specific properties. When formed under load into a liner, the density and symmetry of the liner can be controlled. By varying the material components, i.e. the material percentages in the matrix, the performance can be controlled.
Over the last few years, the tendency has been to use increasing amounts of tungsten (W) in the mixture to achieve higher density jets that penetrate deeper. One of the problems, however, with these denser powdered metal mixes, is the tendency to cause “slugging” or blockage of the perforation tunnel. This slugging limits the flow of hydrocarbons through the perforation tunnel and into the well bore for recovery. Slugging is attributed to a re-agglomeration of some of the liner materials during the formation of the jet. This can be from the jet itself or the after-jet, known as a “slug” or “carrot.” The higher the density of the liner the more the likelihood of this phenomenon occurring. Therefore those mixtures with highest amounts of wolfram and other high density metals tend to produce the most slugging.
What is therefore needed is a liner material for a shaped charge with a high density to achieve maximum formation penetration, yet which reduces or eliminates those problems associated with prior art liner materials, such as slugging.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide a means of making a high density charge lining without the disadvantages of slug formation.
Another object of the present invention is to provided a charge liner material comprising at least molybdenum (Mo) and other materials of higher density such as tungsten (W).
Yet another object of the present invention is to provide an improved shaped-charge for forming perforations in a wellbore.
These objects are achieved by providing a liner material for use in a shaped explosive charge, such as those used in oil and gas wells for perforating formations surrounding the borehole of the well. The liner material is formed from a powdered metal mixture that contains molybdenum. The metal mixture may further contain tungsten and other powdered metals. In one embodiment the liner material contains an amount of molybdenum of between about 0.5% to 25% by weight of the metal mixture, with tungsten making up between about 40% to 85% by weight of the metal mixture. The mixture may also contain graphite.
The liner may be formed in a shaped charge having a casing. The casing has a casing wall and a hollow interior. The liner is positioned within the interior of the casing, and an explosive material is disposed within the interior of the casing between the casing wall and the liner. The liner may be formed in a generally conical configuration.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a shaped charge within a well perforating gun assembly and showing a liner of the shaped charge; and
FIG. 2 is a cross-sectional side view of the perforating gun assembly from which the cross-sectional view is of FIG. 1 is taken along the lines I—I.
DETAILED DESCRIPTION OF THE INVENTION
When the explosive in a perforating gun is detonated, the force of the detonation collapses the liner material and ejects it from one end of the charge. The ejected material is a “jet”, which penetrates the casing, the cement around the casing, and a quantity of the formation. It is desirable to penetrate as much of the formation as possible to obtain the highest yield of oil or gas. Thus, the jet formation is critical to the operation of the shaped charge. While a high density material such as tungsten gives deeper penetration into the formation, it also creates slugs that block the perforation. This is due to a re-agglomeration of the molten material instead of dispersal. By changing the constituents that make up the liner, the dynamics of the jet and slug formation can be controlled.
The present invention improves the jet dynamics and slug formation of shaped-charges. Referring to FIG. 1, a transverse cross section of a perforating gun assembly 10 is shown. FIG. 2 shows a longitudinal cross section of the perforating gun assembly 10 . The perforating gun 10 has a tubular carrier 12 having an interior cylinder wall 14 and an exterior cylindrical surface or wall 16 . A cylindrical charge tube 18 is disposed within the tubular carrier 12 and is concentric with the tubular carrier 12 . The outside diameter of the charge tube 18 is such that an annular space 20 is created between the outer surface of the charge tube 18 and the inner wall 14 of the carrier 12 .
An explosive shaped charge 22 has a frusto-conical charge case 24 . The charge case 24 is typically formed from steel, die cast aluminum, or zinc alloys and has an interior surface or wall 26 that defines a hollow interior of the charge case 24 . The charge case 24 is open at the outer end and tapers inward. Disposed within the interior of the case 24 is a liner 28 having a generally conical or frusto-conical configuration. The liner 28 tapers inward from a base 30 , located at the outer end, to a nose portion 32 . The liner 28 is open at the base 30 and has a hollow interior. As discussed infra, the liner 28 is formed from a powdered metal matrix that is compressed under high pressure to the desired configuration and density.
Disposed between the liner 28 and interior wall 26 of the casing 24 is an explosive material 34 . The explosive material 34 extends from the interior of the case 24 through channel 36 formed in the innermost end of the case 24 . A pair of ears 38 extend from the channel 36 of the case 24 and receive a detonating cord 40 for detonating the explosive 34 of the shaped charge 22 .
As shown in FIG. 2, a plurality of shaped charges 22 are mounted in the charge tube 18 and the perforating gun assembly 10 is mounted within a wellbore (not shown) When the shaped charges 22 of the perforating gun assembly 10 are detonated, the liner 28 disintegrates forming a jet that penetrates through the casing (not shown) of the wellbore and into the surrounding formation to form a perforation.
As discussed previously, the liner 28 is formed from a powdered metal mixture that is compressed at high pressures to form a solid mass in the desired shape. A high density metal must be included in the mixture in order to achieve the desired effect from the explosive force. Common high density metals used include copper and tungsten, but other high density metals can also be used. The mixture of metals typically contains various other ductile metals being combined within the matrix to serve as a binder material. Other binder metals include nickel, lead, silver, gold, zinc, iron, tin, antimony, tantalum, cobalt, bronze and uranium. Powdered graphite is also commonly used and serves as lubricant during the formation of the liner.
It has been found that the inclusion of molybdenum in the metal matrix enhances both the jet formation and density of the jet formed and retards re-agglomeration of the liner materials that form slugging or blockage of the perforation tunnel. Molybdenum has been found to have higher shock velocities than conventional constituents of the liner matrix, such as lead, copper or tungsten. With the addition of molybdenum to the mixture, the reduction or elimination of the slugging phenomenon results and a cleaner perforation is formed. Further, the higher shock velocity imparted to the charge by the addition of the molybdenum increases the overall depth of penetration of the jet.
In the present invention, molybdenum is added to the matrix and may be used to replace, in whole or in part, one of the other ductile metals otherwise used in the metal matrix. The molybdenum also allows higher amounts of tungsten to be used to achieve a higher density mixture, thus increased penetration into the formation. Another benefit of the molybdenum is that it provides lubricating effects so that the graphite lubricant typically used can be reduced or eliminated.
The liner mixture may consist of between 0.5% to 25% molybdenum, 60% to 85% tungsten, with other ductile malleable metals comprising 10% to 35%, and from 0% to 1% graphite. All percentages given are based upon the total weight of the powdered mixture. Table 1 shows the ranges percent composition of metals that may be used for the liner based on percentage by weight of the total powdered mixture.
TABLE 1
Percentage Range of Component Metals in
Charge of the Invention.
COMPONENT
PERCENTAGE
Molybdenum (Mo)
0.5-25%
Copper (Cu)
0-10%
Tungsten (W)
60-85%
Lead (Pb)
10-19%
Graphite (C)
0-1%
Table 2 shows representative data from tests performed on the charge of the invention as compared to other commonly used charges. These data show that the depth of penetration into the wellbore (TTP) is greatest when molybdenum is present in the metal mixture. Thus, the shaped charge of the invention (NTX liner) give the best results. As discussed above, an increase in tungsten tends to increase slugging, which is born out in the data of Table 2. The “Western Atlas” (WA) liner having 80% tungsten had a TTP value of 18.13 inches, but a slug length of 3.38, the longest of the three example tests. Using the higher density tungsten is desirable to obtain high penetration, but results in the negative effect of forming slugs in the perforation. Further, the “NT” shaped-charges which contain only 55% tungsten had a relatively low TTP, and also a high slug length, both values being undesirable. By adding molybdenum to the metal mixture to a 15% (by weight) level, the amount of added tungsten can be increased, thus increasing the TTP, while decreasing the slug length. These data show the increased depth of bore penetration and lower slug length by using the mixture of molybdenum and tungsten of the present invention.
The data in Table 2 also indicate that using molybdenum may also improve the shock velocity of the liner. This is indicated by the 19.57 TTP value, being larger than even the WA value which contains more tungsten. An increase in the shock velocity of the liner will improve the depth of penetration of the jet into the surrounding formation, thus improving the performance of the shaped-charge.
TABLE 2
Comparison of Liner Performance of Present
Invention with Other Shaped-Charges.
Percent
TTP
Slug Length
Liner Type
Tungsten
(inches)
(inches)
NT
55%
17.60
2.75
NT
55%
15.20
4.70
NT
55%
17.60
2.60
NT
55%
18.20
3.75
NT
55%
15.80
2.20
NT
55%
16.90
2.80
Averages
16.88
3.13
NTX(15% Mo)
70%
20.00
2.75
NTX(15% Mo)
70%
19.25
2.25
NTX(15% Mo)
70%
19.50
0.00
NTX(15% Mo)
70%
19.00
3.00
NTX(15% Mo)
70%
19.38
2.00
NTX(15% Mo)
70%
20.30
2.20
Averages
19.57
2.03
WA
80%
17.50
4.50
WA
80%
20.50
3.25
WA
80%
18.00
4.25
WA
80%
17.25
3.50
WA
80%
16.75
1.25
WA
80%
18.80
3.50
Averages
18.13
3.38
The shaped charge liner has several advantages over the prior art. The inclusion of molybdenum in the liner matrix allows materials to be used that create a higher density liner to achieve deeper penetration yet reduces slugging and re-agglomeration effects that are undesirable in many applications.
The present invention allows for deeper penetration of the jet of a shaped charge into the formation due to the higher shock velocity imparted to the charge by the molybdenum, thus improving the oil or gas yield in an operation.
The molybdenum containing lining of the invention also provides lubricating effects during the formation of the liner, thus decreasing the need for graphite in the metal mixture.
Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiment as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A liner for a explosive shaped charge, such as those used in perforating operations in oil and gas wells, is formed from a powdered metal mixture that includes molybdenum. The molybdenum allows a higher density liner to be formed to create denser jets for achieving deeper penetration, but without the negative effects that often accompany the use of higher density materials. The molybdenum may be used in the amount of 0.5% to 25% by weight of the metal mixture, with tungsten and other constituents forming the remainder of the mixture. | 5 |
REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/832,958, filed Jul. 25, 2006, whose disclosure is hereby incorporated by reference in its entirety into the present disclosure.
FIELD OF THE INVENTION
[0002] The invention is directed to a system and method for predicting tumor spread and migration in the brain and thereby improving clinical outcomes by changing the planning approach to radiotherapy and radiosurgery of brain cancer.
DESCRIPTION OF RELATED ART
[0003] Several common types of primary and secondary brain cancer have a historical and physiological basis for aggressive tumor spread in the brain that thwarts curative treatment using our most sophisticated technology and all existing pharmacologic agents. Aggressive primary brain cancers are usually associated with oligodendrogliomas, low-grade astrocytomas, anaplastic astrocytomas, and glioblastomas. At present, the 5-year survival rate for patients of age 45+ ranges from 16% for those with anaplastic astrocytomas to 2% or less for those with glioblastomas. A recent RTOG study found that stereotactic radiotherapy (SRT) currently achieves a low 9% local control rate for glioblastomas.
[0004] Stereotactic radiotherapy (SRT) is used to deliver a large, lethal dose of radiation to a brain lesion with rapid dose falloff into the surrounding normal tissue. SRT is the treatment method of choice for lesions that cannot be readily accessed with conventional surgery. Typically, an SRT treatment plan of high-grade astrocytoma includes a margin of up to 2 cm surrounding the lesion to account for any unobserved, microscopic spread of the primary tumor. This margin size is selected based on histological analysis of tumor spread dating from the 1980's and in consideration of the critical need to minimize margin size to avoid potentially life-threatening complications resulting from radiation damage to surrounding healthy brain tissue. If the margin is inadequate then distant recurrences will occur.
[0005] Despite the symmetric 2 cm margin to account for unobserved, microscopic dispersal of cancer cells, recurrent tumors often occur. Current methods for predicting patterns of cancer spread are simply inadequate. A 2 cm margin is clearly too large in some directions leading to complication and loss of cognitive function. It is too small in others leading to recurrences, usually with a catastrophic result.
[0006] Diffusion weighting is a magnetic resonance imaging technique in which the image contrast is altered based on the diffusivity of water molecules within each pixel of the image. In any one experiment one can quantify the local diffusion coefficient along a predefined direction, where the direction is governed by the applied magnetic field gradients—the diffusion encoding gradients. By applying the diffusion encoding gradients along multiple directions, one unique direction for each scan, a diffusion coefficient unique for each direction is measured. By combining the information from multiple diffusion scans, one can reconstruct for each pixel in the image the three-dimensional (3D) diffusion coefficient tensor (a symmetric 3×3 matrix that is unique for each image pixel). This procedure is called diffusion tensor imaging—DTI. The tensor is diagonalized to obtain the three diffusion coefficient Eigenvalues and Eigen vectors. The direction of maximal diffusion is given by the Eigen vector corresponding to the maximal Eigen diffusion coefficient and is associated with the orientation of the most prominent fiber bundle. No injected contrast media nor any other invasive procedure nor any particularly special MR hardware is needed to obtain the DWI (diffusion weighted imaging) data, as it requires only a special sequence of commands to run the MR scanner to obtain the correct diffusion encoding steps. Post-acquisition analysis of the diffusion image data can be performed off-line to compute the unique diffusion tensor for each pixel in the series of brain slices.
[0007] The classic diffusion tensor approach has a significant limitation in that it accounts for only a single fiber orientation within any volumetric image element (voxel). The model fails therefore in voxels that have fiber crossing, branching or severe bending. High Angular Resolution Diffusion Imaging (HARDI) methods have been developed in recent years to overcome this limitation. HARDI involves sampling the diffusion function along a high number of directions (usually >60) and with high b values (achieved with strong applied magnetic field gradients and long inter-pulse delay times to accentuate the alterations in the MR signal due to water diffusion). The underlying multi-fiber diffusion environment can then be reconstructed as either a superposition of multiple non-coplanar diffusion tensors or using model-free approaches.
[0008] As early as 1961, post-mortem histological analyses in humans have suggested that glioma cells migrate preferentially along white matter tracts. More recently, human glioma cells implanted in the rat brain have been observed to move actively along the myelinated fibers of corpus callosum. En masse invasion occurs through both gray and white matter while migration of individual cells occurs preferentially through nerve fiber bundles. During embryogenesis neonatal astrocytes show a preferential movement along developing axon tracts. Thus there is existing evidence that migration of both healthy and cancerous astrocytes is influenced by the underlying fiber architecture.
[0009] The possible role of diffusive cell migration in human brain tissue has been simulated by previous researchers through retrospective analysis of diseased brains with massive tumor growth. The role of diffusion anisotropy in cell migration in the brain has been simulated by previous researchers by superposing a DWI dataset from a healthy human subject to brains of diseased subjects to estimate nonuniform growth patterns and compared the results to growth of real tumors. Other previous research has investigated the utility of DWI for: 1) assessing an index of relative diffusion anisotropy to discern white matter disruption due to the presence tumor infiltration, 2) differentiating tumor recurrence and radiation injury after radiotherapy, and 3) predicting cell density and proliferation activity of glioblastomas. These prior studies are distinct from the current proposal in that the infiltration models considered merely expansive growth of the primary tumor rather than isolated cell migration to distant sitesand the technology at the time did not afford the investigators the ability to acquire MR DWI and anatomical data in the same patient subjects.
SUMMARY OF THE INVENTION
[0010] In treating aggressive brain tumors with radiation we find that treatment often fails because cancer cells have migrated undetected great distances beyond the treatment area. There is therefore a need in the art for an improved prediction and treatment for brain cancer spread. It is therefore an object of the invention to provide such improvements.
[0011] The invention is based on the realization that brain cancer cells spread preferentially along paths of elevated water diffusion, such as along nerve fiber bundles, that can be measured by magnetic resonance (MR) diffusion-weighted imaging (DWI) and the migration of cancer cells away from the primary tumor can be predicted using computational models that incorporate DWI information. The invention therefore applies DWI to develop appropriate non-symmetric margins for radiation treatment of malignant brain tumors. The invention can additionally apply a computational model of cell migration to better predict directions of microscopic tumor dispersal at the time of the initial treatment of the primary tumor and thereby enable us to tailor treatment margins to encompass the high-risk regions (thereby improving cancer control) while diminishing the margin in low-risk regions (thereby reducing harmful side-effects). The invention provides the first prospective analysis of tumor recurrence and DWI in brain cancer patients, and also involves the first combined analysis of tumor dispersal, DWI and histology in an animal model. Achievement of these aims marks a significant contribution to the treatment of brain cancer using SRS and allow for an innovative integration of novel MRI methodologies with state-of-the-art radiation delivery technology for cancer treatment.
[0012] Evidence in the literature links tumor dispersion in the brain to the underlying nerve fiber bundles, and recent advances in MR diffusion-weighting imaging enables us to discern this fiber architecture non-invasively in both the clinical and research settings. We have observed clinically a key link between patterns of tumor recurrence following high-dose stereotactic radiation therapy (SRS) and analysis of MR DWI.
[0013] In one aspect of the invention, a computational model of cell migration is used in which the model is constrained by the MR DWI (diffusion tensor imaging) information. Thus, this is an extension, and specific example for implementation, of the use of MR DWI data for treatment planning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A preferred embodiment of the invention will be set forth in detail with reference to the drawings, in which:
[0015] FIGS. 1A-1D show experimental results from one patient;
[0016] FIGS. 2A-2D show experimental results from another patient; and
[0017] FIG. 3 is a block diagram of a system on which the present invention can be implemented.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] A preferred embodiment of the invention will be set forth in detail with reference to the drawings, in which like reference numerals refer to like elements throughout.
[0019] FIGS. 1 A-D and 2 A-D demonstrate our key preliminary results merging DWI tractography with repeated clinical follow-up of tumor spread and recurrence in high-risk subjects.
[0020] FIGS. 1A-1D show the following: FIG. 1A : Primary glioblastoma multiforme (GBM) in splenum of corpus callosum (green arrow) 6 months post-SRS treatment. Also seen at this time point is a small hyper-intense region in the anterior horn of the left lateral ventricle (white arrow), which proved to be a secondary tumor. FIG. 1B : T2 weighted image at the same time point with a depiction of all fibers emanating from the secondary tumor site. We employed a simple streamline approach (DTIstudio15]) to compute all fiber tracks passing through the secondary tumor site, showing several prominent fiber tracks coursing laterally and anteriorly from the secondary tumor site. FIG. 1C : An on-edge view of the slice plane gives a better appreciation of the 3D extent of the fiber tracks. In image B all the 3D fiber tracks are projected onto the plane of the slice. In C we see that the tracks directed posteriorly have also a significant out-of-plane component. FIG. 1D : Same subject 3 months later showing the spread of the secondary tumor, with substantial growth both laterally and anteriorly (yellow arrows). Thus the pattern of tumor expansion followed the dominate fiber tracts measured previously.
[0021] FIGS. 2A-2D show the following. FIG. 2A : and MR T1 weighted brain image of a patient with a glioblastoma in the right hemisphere. FIG. 2B : A CT image of the patient's brain depicting the radiation treatment plan used to treat this patient, where the contour lines represent different radiation dose exposure, with the highest doses toward the center of the tumor. FIG. 2C : The same MR T1 weighted image as in FIG. 2A but overlaid with 3 items. The wide contour represents the boundary of the lethal radiation dose exposure, taken from the radiation exposure data shown in FIG. 2B . Tissue within the wide contour line experience a lethal radiation dose. The white to red color rendering (shown in grayscale) represents the results of the computation model of cell migration, wherein the white (lightest) areas present the predicted highest concentration of cells after migration from the primary tumor. The yellow to red (darker) areas indicate predicted lesser concentration of cells. The narrow contour represents the results of a modified radiation treatment plan designed to encompass within the lethal radiation dose the areas of high predicted cell concentration that are also located within 15 mm of the originally planned lethal zone (wide contour). FIG. 2D : A follow-up MR image showing the presence of a recurrent tumor (just below the original tumor). The contours are the same as those of FIG. 2C . Of note, the recurrent tumor is located just outside the originally planned lethal zone (pink) but within the lethal zone that would have been used were the MR DWI data incorporated into the treatment planning process. Previous groups have modeled the local metastatic and glioma spread as a random mechanical walk with larger step size along paths of elevated water diffusion relative to the step sizes in the other directions. One realization of the present invention uses a constrained random walk of cells as a probabilistic model of local metastatic and glioma spread and supports the use of DWI and computational modeling as a means to predict and thereby ablate microscopic islands of migrating cells at the edge of the conventional planning target volume.
[0022] In the example of one realization of the present invention, the ratio of the rates of migration of cancer cells along white matter tracts versus gray matter is more dramatic than that observed for the diffusion of water molecules. Our objective in this realization of the invention is to model the relationship between the diffusivity of water molecules and migratory behavior of cancer cells in the brain. We use the single tensor transformation given by:
D =a 1 ( r )λ 1 e 1 e 1 T +a 2 ( r )λ 2 e 2 e 2 T +a 3 (r)λ 3 e 3 e 3 T (1)
[0023] where a i is defined by
[ a 1 a 2 a 3 ] = [ r r 1 1 r 1 1 1 1 ] [ c 1 c p c s ]
c 1 = λ 1 - λ 2 λ 1 + λ 2 + λ 3 ; c s = 2 ( λ 2 - λ 3 ) λ 1 + λ 2 + λ 3 ; c p = 3 λ 3 λ 1 + λ 2 + λ 3 ( 2 )
[0024] The relationship between water diffusion and cell migration is controlled by the factor r. In voxels that have two crossing fibers the principal directions will be weighted by the volume fraction of each fiber bundle. The resulting cell migration probability map is compared to the measured cell migration indices obtained from the mouse histological studies, and the r and a i parameters is optimized accordingly for the mouse model.
[0025] Our initial realization of the computational model of cancer cell migration is a modified random walk, starting with multiple seed locations within the tumor of interest in the human subjects. The model takes into account the two major biological phenomena underlying the spread of glioma and cells: growth and migration. Migration is considered to be anisotropic with cells migrating preferentially along a direction favored by direction of maximal diffusivity—along the white matter fibers. Prior studies have shown that the logistic model may be inadequate to model tumor growth; therefore, we use Gompertz law to model tumor growth. Tumor growth due to cell division will be represented by a differential equation in time.
∂ c / ∂ t = pc ln ( C m C ) ( 3 )
[0026] where c is the tumor cell concentration, ƒ is a function representing the temporal evolution pattern of growth, ρ is the relative increase of cell concentration per unit time and c m is the initial cell concentration (10 5 cells/mm 3 ). The second part of the model takes into account the migration of tumor cells in space. The overall partial differential equation combines cell proliferation (time component) and cell infiltration (space component).
∂ c / ∂ t = ∇ · ( D ( x ) ∇ c ) + pc ln ( C m C ) ( 4 )
[0027] where ∇ is the gradient operator and D is the 3×3 diffusion tensor. The initial condition will be defined as c(0,x)=c 0 (x). Boundary conditions are imposed based on the anatomic MR images to inhibit migration of cells through the dura covering the brain: D(x)∇c·n=0 for x on the sulcal and ventricular boundary of the brain, where n is the normal to the surface. Initial conditions will be represented by tumor cell concentration c 0 in each pixel, as selected manually on the anatomical images that represent in humans the primary site of GBM or metastases; and in mice the site of xenotransplantation. The computational model is constructed in Matlab.
[0028] The above model is customized to model tumor growth and cell migration via a Monte-Carlo approach incorporating fiber probability. Briefly, rather than considering the diffusivity within a pixel with a single Eigenvector, the surrounding diffusion environment is incorporated into a probability model of the distribution of fiber tracts contained within each pixel. Assuming that the distribution of fiber tract directions within each pixel can be considered as single or bi-Gaussian, then a combined Monte-Carlo and random-walk simulation can be used to estimate the probability of a given cell migrating to a predetermined location distal to the starting pixel location. The Monte-Carlo feature is to simulate 1000-5000 unique trajectories, using for each run a random number generator confined to obey the DWI-determined bi-Gaussian probability distribution for fiber direction. The simulated cell then steps a small increment along that direction, and then the local fiber trajectory is recomputed—the random-walk component. Standard statistical analyses using subgroups are used to assess the appropriateness of the step size and of the number of Monte-Carlo runs needed to achieve a meaningful result.
[0029] The distance metrics are used to identify the appropriate correspondence between the coefficients of water diffusion and the migration rates of cancer cells (the r parameter in Equation 2). The Monte-Carlo simulation is run using this parameter to generate between 1000-5000 model cell migratory pathways. A stopping time for the runs is matched to the 21-day interval between the injection of the U87 cells and the time of brain fixation. For a representative collection of U87 cells in the mouse brain, identified by histology and categorized by final location, each cell is matched to the nearest simulated cell trajectory. The migratory distances (preserving sign) between the two sets of matched cells are compiled and recorded for each real cell and the data analyzed using standard statistical means to determine the presence of a consistent bias (overshoot or undershoot) of the simulation (by consideration of the mean miss distance), and the accuracy of the model (by consideration of the standard deviations around the mean miss distance). If the bias is nonnegligible, then the r parameter in Equation 2 can be adjusted and the simulation repeated until a zero, or nearly zero, bias is obtained. A value for the standard deviation that is less than 25% of the mean distance traveled for each cell is used to indicate the success or failure of the computational model. Failure of the computational model necessitates the incorporation of additional complexity to the fiber reconstruction approach and to the cell infiltration model (Equation 4).
[0030] FIG. 3 shows a block diagram of a system 300 on which the preferred embodiment can be implemented. MRI coils 302 image a region of interest in the brain of a patient P. A computer 304 , which can be any suitable computing device, receives raw data signals from the coils and performs the calculations described above to control a radiosurgery device 306 .
[0031] While a preferred embodiment of the present invention has been set forth above, those skilled in the art who have reviewed the present disclosure will readily appreciate that other embodiments can be realized within the scope of the invention. For example, numerical values are illustrative rather than limiting, as are specific computational techniques. Therefore, the present invention should be construed as limited only by the appended claims. | The invention is based on the realization that brain cancer cells spread preferentially along paths of elevated water diffusion, such as along nerve fiber bundles, that can be measured by magnetic resonance (MR) diffusion-weighted imaging (DWI) and the migration of cancer cells away from the primary tumor can be predicted using computational models that incorporate DWI information. The invention therefore applies DWI and models cell migration to develop appropriate non-symmetric margins for radiation treatment of malignant brain tumors. | 0 |
BACKGROUND
[0001] There are few if any treatments for radiation exposure that have quantitative dose modifying benefits when given hours a day after exposure. Similarly, even those drugs that have benefits when given before radiation, typically are ethicacious only for a few hours and have transient side effects that prevent the subject from full function, for example, hypotension and peripheral neuropathy.
[0002] Radiation-induced soft tissue fibrosis is a consequence of acute and chronic inflammatory responses. While modern radiation techniques have improved therapeutic gain and reduced the incidence of severe radiation-induced fibrosis, radiation-related side effects still occur when aiming for optimal tumor control. It has been shown that radiation-induced soft tissue damage is expected in about 10% of patients when radiation is optimized to achieve 90% tumor control.
[0003] Soft tissue fibrosis occurs in the late stage of radiation-induced tissue damage. It is caused by multiple factors and is poorly understood. However, the early stage of radiation-induced soft tissue damage is characterized by infiltration of various inflammatory cells and overproduction of cytokines. The late stage is pathologically characterized by active fibroblast proliferation with atypical fibroblasts, and excessive extracellular matrix production. Radiation injury is similar in some ways to normal tissue injury. Surgical injury, for example, is a process that features a relatively short period of brisk cytokine production, angiogenesis, fibroblast, and epithelial cell proliferation. The atypical proliferation results in granulation, which abruptly stops, allowing mature scar to develop. IL-1 is an important signal controlling this process. Radiation-induced soft tissue fibrosis has many of the same features of normal tissue repair, but is less brisk and may remain active for years at subclinical levels. The continuous inflammation results in continuously active deposition of collagen.
[0004] Radiation pneumonitis is a distinct clinical entity that differs from other pulmonary symptoms such as allergic pneumonitis, chemical pneumonitis, or pneumonia by various infectious agents. Recent research has supported the mechanism of cellular interaction between lung parenchymal cells and circulating immune cells mediated through a variety of cytokines including pro-inflammatory cytokines, chemokines, adhesion molecules, and pro-fibrotic cytokines. Identifying reliable biomarkers for radiation pneumonitis will allow identifying individuals at risk for pneumonitis before or during the early stage of therapy.
[0005] Radiation pulmonary injury manifested as subacute pneumonitis and late fibrosis has long been recognized in patients receiving radiotherapy to the chest region. Lung injury by radiation is a major obstacle prohibiting the high dose radiation required for eradicating cancer of the thoracic region. Radiation pneumonitis is a distinct clinical entity and there has been increasing awareness and recognition of its impact on the treatment of thoracic malignancy. It manifests unique clinical and radiographic characteristics that separate it from other pulmonary symptoms such as allergic pneumonitis, chemical pneumonitis, or pneumonia by various infectious agents of viral, bacterial, fungal, or parasitical origins.
[0006] Radiation pneumonitis is a type of inflammatory response of the lung tissue in response to radiation insult. Indeed, at the cellular level, radiation pneumonitis is characterized by lymphocytic alveolitis, a result of inflammatory infiltrates of mononuclear cells from the vascular compartment into the alveolar spaces. As expected at sites of inflammation, an active interaction between cellular and humoral factors are involved including immune cells, parenchymal cells, macrophages, chemokines, adhesion molecules, lymphocytes, inflammatory cytokines and fibrotic cytokines. Research in radiation pulmonary injury has supported involvement of inflammatory cytokines, chemokines, and fibrotic cytokines. Although investigation of adhesion molecules in radiation lung injury is still underway, these molecules are expected to be involved to serve as prerequisites for leukocyte adhesion to endothelial cells of blood vessels and consequently for transmigration to tissues at sites of inflammation. At the time of clinical symptoms, radiographic infiltrates are often observed in lung volumes, which generally conform to the radiation treatment ports on chest radiographs. The alveolar spaces are filled with patchy infiltrates on chest CT scans and the patients often experience worsening dyspnea. These mononuclear infiltrates may be cleared from alveolar spaces rapidly in response to steroids, likely due to rapid apoptosis of lymphocytes by steroids, and patients often experience marked improvement of dyspnea. With longer follow-up, almost all patients develop radiographic evidences of lung fibrosis.
[0007] While current fast-developing new techniques have significantly improved radiotherapeutic gains, radiation-related normal tissue damage still remains unavoidable especially when aiming for optimal tumor control. Normal tissue tolerance, in particular, soft tissue fibrosis, is one of the major dose-limiting factors influencing radiation therapy. It has been reported that radiation-induced soft tissue damage is expected in ten percent of patients when radiation dose is optimized to maximum tumor control. Therefore, a better understanding of the molecular basis of radiation-induced normal damage could provide an effective means for the prevention, or even reversal of radiation-related complications in the clinical radiotherapy. Furthermore, due to the unsatisfactory outcomes of present combination of radiotherapy and chemotherapy, especially with multiple-areas and prolong schedule procedure, much emphasis also are needed to placed on developing better and less side-effects treatment procedure for normal tissue protection.
SUMMARY OF THE INVENTION
[0008] We have discovered that IL-1 is a major contributor to acute and late radiation complications to the bone marrow, bowel, and lungs and soft tissues. We have shown that humans that have high circulating levels of IL-1 before any radiation is delivered develop radiation pneumonitis. In addition, we have found that the absence of IL-1 alpha results in a low propensity for the development of fibrosis following radiation. However, we have also discovered that the elevation of IL-1 persists or rises at later times after radiation.
[0009] We have further found that blocking IL function with circulating proteins or drugs is a useful method for the prevention of toxicity to normal tissue and is ethicacious after radiation for the prevention of the progression of toxicity over time.
[0010] As a result, the present invention provides for the prevention of and therapy for radiation pneumonitis, dermatitis, soft tissue fibrosis and central nervous system toxicity in patients undergoing therapeutic radiation. In addition, it provides for pre-treatment of those responding to nuclear bio terrorism or other nuclear or radiological accidents. Thus, with the present invention, subjects may be treated in order to prevent toxicity from nuclear bio terrorism or other nuclear or radiological accidents. More particularly, we have discovered a method for profallactically treating radiation toxicity in normal tissue of a subject comprising administering an anti-radiation toxicity effective amount of a cytokine blocking agent through the subject.
[0011] More specifically, we have discovered a method for profallactically treating radiation pneumonitis, dermatitis, soft tissue fibrosis or central nervous system toxicity in a subject comprising administering an anti-radiation pneumonitis, dermatitis, soft tissue fibrosis or central nervous system toxicity effective amount of a cytokine blocking agent to the subject.
[0012] We have further discovered that the administration of an anti-radiation induced soft tissue effective amount of a COX-2 enzyme inhibitor significantly reduces the amount of tissue damage due to radiation.
[0013] We have investigated the role of specific COX-2 inhibitors (Celebrex) in radiation induced soft tissue damage, and explored the relationship between chemokine and its receptor mRNA expression and radiation-induced skin damage in mammary tumor-bearing mice. Here we report that 50 mg/kg Celebrex, given daily with gavage for 15 doses in three weeks, significantly reduced single dose of radiation (60 Gy) induced normal skin damage in MCa-35 mammary tumor-bearing mice. Decreased skin damages are associated with the reduction of the radiation-induced chemokines, Rantes, MCP1, and their related receptor mRNA expression in skin, but not in tumor tissues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a graph showing the time scale of the currents of pneumonitis at various time points after radiation;
[0015] FIG. 2 is a serious of graphs showing the absolute cytokine level and relative cytokine changes between groups with and without radiation pneumonitis.
[0016] FIG. 3 shows the results of circulatory cytokine changes of several cytokines;
[0017] FIG. 4 shows plasma levels of Monocyte Chemotactic Protein 1;
[0018] FIG. 5 depicts typical changes in gross appearance after radiation of skin;
[0019] FIG. 6 Shows a histological changes at various times after radiation;
[0020] FIG. 7 graphically depicts the basil levels of IL-B mRNA in mouse skin
[0021] FIG. 8 graphically depicts the basil levels of IL-B mRNA in mouse skin
[0022] FIG. 9 depicts the circulating IL-1β tissue mRNA expression;
[0023] FIG. 10 depicts IL-1α mRNA expression in muscle;
[0024] FIG. 11 depicts the effects of radiation on IL-1 Ra mRNA in muscle;
[0025] FIG. 12 depicts skin lesions in mice after 20 days of radiation
[0026] FIG. 13 depicts inflammation and cellular component infiltration in the dermis in Celebrex treated mice
[0027] FIG. 14 summarizes the effects of Celebrex on radiation-induced mRNA expression of chemokines
[0028] FIG. 15 depicts the infiltration of inflammatory cells in the derma of Celebrex-treated mice.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
[0029] Materials and Methods: Prospective blood sampling, scoring of respiratory symptoms, and chest imaging were conducted for patients receiving thoracic radiation for malignancy. Serial plasma specimens were analyzed for circulating cytokine changes before, during radiation, and up to 12 weeks post-radiation. Radiation pneumonitis was diagnosed using NCI common Toxicity Criteria. Cytokine analysis was assayed for interleukin a (IL-1α), interleukin 6 (IL-6), Monocyte Chemotactic Protein 1 (MCP-1), E-Selectin, L-Selectin, Transforming Growth Factor β1 (TGF-β1), and Basic Fibroblast Growth Factor (bFGF) using Enzyme Linked Immmunosorbant Assay (ELISA).
[0030] Methods
[0000] Patient Characteristics
[0031] Patients who were to receive thoracic radiation for malignancy were eligible. Blood, thoracic imaging, and respiratory symptom scoring were collected prospectively. Twenty-four patients had follow-up longer than 12 months and their characteristics are shown in Table 1.
TABLE 1 Patient Characteristics Pneumonitis (NCI CTC Grade) Grade 1 (Radio- Grade 2 graphic (Sympto- All No Infiltrates matic Patients Pneumonitis Only) Pneumonitis) No. of Patients 24 5 (20.8%) 6 (25%) 13 (54%) Age: 63 (40-80) Median (range) Sex (M:F) 11:13 2:3 3:3 6:7 Race (W:H) 23:01 5:0 6:0 12:1 Histology Squamous cell 5 (20.8%) 2 1 2 Andenocarcinoma 11 (45.8%) 1 3 7 Andenosquamous 1 (4.2%) 0 0 1 Non-small nos 3 (12.5%) 1 2 0 Small cell 3 (12.5%) 1 0 2 Thymoma 1 (4.2%) 0 0 1 Total 24 5 6 13 Tumor present Yes 21 (87.5%) 5 3 13 No 3 (12.5%) 0 3 0 Clinical stage I 3 (12.5%) 0 2 1 II 0 III 15 (62.5%) 2 4 9 IV 3 (12.5%) 2 0 1 Limited small cell 3 (12.5%) 1 0 2 Chemotherapy No 6 (25%) 1 2 3 Yes 3:15 (75%) 1:2 0:4 2:9 (ncocadjuvant: concurrent) Abbreviations: NCI CTC, National Cancer Institute common toxicity criteria; nos, not otherwise specified.
Clinical and Radiographic Evaluation
[0032] History and physical examinations emphasizing the respiratory symptoms were performed periodically. Clinical evaluation for pulmonary symptoms was evaluated and graded using the LENT/SOMA scoring system for the lung. This system includes the RTOG treatment side effect scoring of subjective clinical symptoms, and an objective assessment of serial chest X-rays and CT scan changes. Pneumonitis grading was also defined according to NCI Common Toxicity Criteria.
[0000] Circulating Cytokinie Analysis
[0033] Plasma samples were collected before therapy and weekly, during therapy. Specimens were collected in sodium heparin as well as EDTA up to 12 weeks post-therapy. Platelet-free plasma was produced by centrifugation at 1200 rpm at 0° C. for 10 minutes. The plasma was stored in aliquots at −20° C. Heparinized plasma was used for the analysis of most cytokines and EDTA plasma was used for the analysis of bFGF. Cytokines were analyzed using Enzyme-Linked Immunosorbent Assay (ELISA). The methodology of ELISA analysis was according to manufacturers' instructions as previously described.
[0034] Twenty-four patients had clinical follow-up longer than 12 months after radiation. Thirteen developed symptomatic pneumonitis (NCI grade 2). The peak incidence of symptoms was between 6- and 13 weeks post radiotherapy. Six patients had only radiographic infiltrates. (NCI grade 1). Five patients did not have clinical or radiographic pneumonitis. Both IL-1α and IL-6 levels were significantly higher before, during, and after radiation for those who developed pneumonitis. The pattern of changes of MCP-1, E-Selectin, L-Selectin, TGF-β1, and bFGF varied but none of these cytokines correlated with radiation pneumonitis.
[0035] Analysis of a panel of circulatory cytokines with different putative function in radiation pulmonary injury showed that pre-treatment IΛ-1α and IL-6, as well as mid and post-treatment levels were significantly higher for patients who subsequently developed radiation pneumonitis.
[0000] Radiation Pneumonitis
[0036] Symptomatic radiation pneumonitis is characterized by an annoying cough that is either non-productive or with clear sputum. This period is generally accompanied by markedly worsening dyspnea in an otherwise healthy appearing individual. Generally there are also radiographic infiltrates on chest x-ray and CT scan that usually conforms to radiation ports. The individual in general is afebrile or has a low-grade temperature, and is without an increase of blood neutrophil counts. Clinical symptoms are rapidly relieved with low dose steroid treatment. Of the 24 patients with follow-up longer than 12 months, 13 developed clinical symptoms consistent with radiation pneumonitis (NCI grade 2 pneumonitis). Six had radiographic infiltrates only, without clinical symptoms (NCI grade 1). Five did not have either radiographic infiltrates or clinical symptoms. The timescale of occurrence of pneumonitis is shown in FIG. 1 . As demonstrated in FIG. 1 , asymptomatic infiltrates occurred at random time points after radiation, while symptomatic pneumonitis occurred most commonly between 6 weeks and 13 weeks after completion of radiation. For all symptomatic pneumonitis, the first episodes all occurred within 6 months post-radiotherapy. The outliers beyond 6 months in FIG. 1 were those with recurrence of symptomatic pneumonitis. In all these cases, however, the first symptoms had occurred within 6 months after therapy.
[0000] Pro-inflammatory Cytokinies Markers: IL-1α and IL-6
[0037] We analyzed pro-inflammatory cytokine IL-1α, and IL-6 levels before radiation treatment, weekly during treatment, and up to 12 weeks following radiation. FIG. 2 shows the absolute cytokine level (in pg/ml) (A1 for IL-1α, and A2 for IL-6) and the relative cytokine changes normalized to individual pre-treatment value (B1 for IL-1α, and B2 for IL-6), as well as the comparison of absolute values between the groups with and without radiation pneumonitis (C1 for IL-1α, and C2 for IL-6). The data showed a very wide range of individual circulatory IL-1α levels (A1), but a relative lack of changes with radiation treatment (B1). In contrast to IL-1α, IL-6 levels were not as variable among individuals (A2), but they fluctuated somewhat with radiation. Of note, after completion of radiation treatments, there is a trend toward an increase of IL-6 in both absolute levels and relative changes (A2 and B2, p=0.065). Both IL-1α and IL-6 absolute levels were significantly higher before radiation, at multiple time points during radiation, and after radiation (C1, and C2, p<0.05) in patients who subsequently developed radiation pneumonitis.
[0000] Pro-fibrotic Cytokine Markers: bFGF and TGF-β1
[0038] FIG. 3 demonstrates results of circulatory cytokine changes of fibrotic cytokines bFGF and TGF-β1. Basic FGF levels fluctuated during treatments and showed no correlation with pneumonitis (A1, B1, and C1). In contrast, there were many individual variations of circulatory TGF-β1 (A1), but there was much lesser degree of relative changes during radiation and after radiation up to 12 weeks post-therapy. Similar to bFGF, circulating TGF-β1 did not show an appreciable difference between the group with and the group without pneumonitis (C2).
[0000] Chemokine and Adhesion Molecule Markers: MCP-1, L-Selectin, and E-Selectin
[0039] Plasma levels of MCP-1 (Monocyte Chemotactic Protein 1), L-Selectin, and S-Selectin ( FIG. 4 ) were also measured. FIG. 4A demonstrates the absolute levels of MCP-1 (A1), relative changes of MCP-1 (B1), and the comparison of the groups with and without pneumonitis (C1). Our data showed a decline of MCP-1 levels during the last week of radiation and up to 8 weeks after radiation (p<0.04). Data on L-Selectin demonstrated a marked and significant decline of the circulatory levels of L-Selectin (A2, p<0.01) and the relative changes (B2, p<0.01), and a lack of difference between the pneumonitis group and the non-pneumonitis group. There was some decline of circulatory MCP 1 near the end of radiation up to 8 weeks after treatments. Data on E-Selectin is similar to L-Selectin in that there was some decline of levels near the end of radiation and after radiation (p<0.03) as well as a decrease of relative changes through most time points of the period investigated (p<0.01). There also was not a significant difference between the pneumonitis group and the non-pneumonitis group.
[0040] Radiation pneumonitis and fibrosis can be regarded as the consequences of a wound-healing inflammatory reaction to radiation damage of lung tissues. Research in immunological regulation of inflammation has revealed the complex interaction between local tissues and immune cells mediated through chemokines, adhesion molecules, inflammatory cytokine, and fibrotic cytokines.
[0000] Inflammatory Cytokines and Radiation Pneumonitis
[0041] We have shown that lung radiation is associated with a temporal expression of IL-1α, TGF-β1, collagen I, collagen III, and collagen IV gene expression in fibrosis-prone mice (C57BL/6). Among the panel of cytokines potentially involved in the inflammatory response to radiation lung injury, IL-1α and IL-6 were the only two cytokines that correlated significantly with radiation pneumonitis ( FIG. 4 ). In addition, pre-treatment levels of both IL-1α and IL-6 were significantly higher in patients who subsequently developed pneumonitis, supporting their role as predictors of radiation pneumonitis. Our data showed some differences between IL-1α and IL-6, however, in that when normalized to individual pre-treatment levels, IL-1α remains relatively constant during treatment course, but there is a trend toward elevation of IL-6 at 8 to 12 weeks post-radiation.
[0042] The rise of IL-6 after completion of radiation was observed. It coincided with the period of clinical symptomatic pneumonitis and this deserves further investigation ( FIG. 1 ). Both IL-6 and IL-1α are important immunoregulatory moieties. Although both are inflammatory cytokines, they differ somewhat in origin of cells and in some functional aspects. Both cytokines mediate fever and regulate inflammation and fibrotic response through immune cells. The source of IL-1 is primarily from monocytes as well as alveolar macrophages. IL-6 is synthesized by a variety of cells in the lung parenchyma, including the alveolar macrophages, type IT pneumocytes, T lymphocytes, and lung fibroblasts. In the in vitro system, when alveolar macrophages were exposed to clinically relevant dose of radiation (2 Gy), it was found that both IL-1α and IL-1β were released in increased amounts. It has been shown that IL-1 stimulates human lung fibroblast in the production of IL-6 and stabilizes IL-6 messenger RNA production. In patients with higher pre-treatment levels of IL-1α, IL-1α may regulate a subsequent increase of IL-6 after radiation, was observed ( FIG. 2 ).
[0000] Pro-fibrotic Cytokines and Radiation Pneumonitis
[0043] Pro-fibrotic cytokines participate in radiation lung injury, especially during the development of lung fibrosis phase, which generally starts at 4 to 6 months after treatment and continues without a clear end point. Lung fibrosis is equivalent to the scar after the initial inflammatory phase of lung reaction to radiation injury. Although radiographic fibrosis in general is not observed until 4 to 6 months after completion of radiation, it has been reported that circulatory TGF-β1 changes may serve as an early predictor for radiation pneumonitis and its expression increases with radiation in animal research models. Two pro-fibrotic cytokines, bFGF and TGF-β1, and their changes in the association to radiation pneumonitis ( FIG. 3 ) was investigated. As the incidence of radiation pneumonitis peaks at 6 to 13 weeks in our cohort of patients, we analyzed our data up to 12 weeks and did not find an association in predicting radiation pneumonitis with either bFGF or TGF-β1. This finding may be attributed to the patient population and sample size differences. Since cytokines are relatively fragile molecules, technical differences in specimen collection, processing, and laboratory assays may also result in the differences in laboratory measurements.
[0044] We have discussed that circulatory measure of IL-1α and IL-6 turned are significantly associated with radiation pneumonitis. Thus, patients with higher baseline levels of inflammatory cytokines are more vulnerable to radiation lung injury.
[0000] Figure Legends:
[0045] FIG. 1 . Twenty-four patients were followed prospectively for clinical symptoms of radiation pneumonitis and radiographic changes. The scattered plot demonstrates the time of either symptomatic pneumonitis (top line) or only radiographic infiltrates without symptoms (bottom line). Data showed that symptomatic pneumonitis was diagnosed primarily between 6 weeks and 13 weeks after completion of radiation with rare outliers occurring prior to 6 weeks and between 6 months to 9 months.
[0046] FIG. 2 . IL-1α absolute levels (A1), relative changes normalized to individual pretreatment levels (B1), and the comparison of levels between patients with grade 1 to 3 pneumonitis (solid bar) and no pneumonitis (hatched bar) are presented for pre-treatment baseline level, weekly during radiation, and up to 12 weeks after radiation. FIG. 2 A 2, B2, and C2 demonstrate the IL-6 absolute levels, and relative changes and the comparison between the two groups of patients, respectively.
[0047] FIG. 3 . Basic FGF a absolute levels (A1), relative changes normalized to individual pretreatment levels (B1), and the comparison of levels between patients with grade 1 to 3 pneumonitis (solid bar) and no pneumonitis (hatched bar) are presented for pre-treatment baseline level, weekly during radiation and up to 12 weeks after radiation. FIG. 3 A 2, B2, and C2 demonstrate the TGF-β1 absolute levels, relative changes, and the comparison between the two groups of patients, respectively.
[0048] FIG. 4 . Basic MCP1 absolute levels (A1), relative changes normalized to individual pretreatment levels (B1), and the comparison of levels between patients with grade 1 to 3 pneumonitis (solid bar) and no pneumonitis (hatched bar) are presented for pre-treatment baseline level, weekly during radiation and up to 12 weeks after radiation. FIG. 4 A 2, B2, and C2 demonstrate the L-Selectin absolute levels, relative changes, and the comparison between the two groups of patients, respectively. In FIG. 4 , A3, B3, and C3 demonstrate the E-Selectin absolute levels, relative changes, and the comparison between the two groups of patients, respectively.
EXAMPLE 2
[0049] Materials and Methods
[0000] Mice Strains and Radiation Treatment
[0050] Six to 7 week-old female C3H/HeN, BALB/c and C57BL/6 mice were used (Jackson Laboratories, Bar Harbor, Me.). The right hind leg (10 mice per group) was given 10, 20, 30, 40, 60, or 80 Gy in a single radiation dose with a Shephered Irradiator, a 6000 Ci Cs source, together with collimating equipment. The left, non-irradiated hind leg was used as the non-irradiated control. Mice were sacrificed at different time points after radiation (0.5, 1, 2, 4, 8, 12hrs, day 1, day 7, and day 14). At least 10 mice were used at each time point. Tissues from 3 mice were used for histology, and the remaining animals were used for mRNA analysis. Skin and muscle tissues from control and irradiated legs were dissected, and total RNA was isolated. Guidelines for the humane treatment of animals were followed as approved by the University of Rochester Committee on Animal Resources.
[0000] Tumor Tissue RNA Isolation and RNase Protection Assays
[0051] Skin and muscle tissues from each treatment group (7-10 mice) were pooled and total RNA was isolated by pulverizing the frozen tissue and dissolving it in TRI Reagent (Molecular Research Center, Ohio) according to the manufacturer's specifications. To determine the integrity of isolated RNA, 2 μg of RNA from each sample was fractionated on a formaldehyde gel and visualized by staining in ethidium bromide. RNase protection was performed using established multi-probes template sets (PharMingen, SanDiago, Calif.) as described previously. The interleukin (IL) sets include: IL-1α:, IL-1β, IL-1Rα, IL-6, IL-10 and IL-12. Two internal controls, L32 and GAPDH, were used as loading controls. The cocktail constructs were used to prepare P-UTP labeled antisense cRNA probes using the PharMingen in vitro transcription kits (PharMingen, SanDiago, Calif.). Probes were hybridized with 30 μg of total RNA at 50° C. for 16 hr. RNase A (1 mg/ml) and RNase T1 (2000 U/ml) were then added to digest single-stranded RNA. After digestion, the RNA was precipitated and resuspended in gel loading buffer, heated at 95° C. for 5 min, and run in 7% denaturing polyacrylamide gel (National Diagnostics, Ga.). The gel was run for 2-3 hr at 60v, dried on Whatman filter paper, and placed on a phosphorimager screen for quantitative analysis using a Cyclone Phosphorimager device (HP Company, Conn.). Area integration of each mRNA-protected fragment was normalized against the protected internal control band (GAPDH) in the corresponding lane to calculate the ratio of targeted/GAPDH mRNA. In order to compare the basal levels with radiation-induced levels for each interleukine mRNA tested, relative mRNA levels (folds) were plotted. Some gels are shown with over-exposure of the control lanes to highlight differences in IL-1α/β expression.
[0000] Blood Cytokines Assays (ELISA)
[0052] Blood samples were collected from 3 mice strains at various time points after radiation. After centrifugation for 30 minutes at 4° C., plasmas were aliquated and stored at −70° C. until analysis. Immunoenzymetric assays for murine IL-1β (Endogen Inc, Cambridge, Mass.) were performed according to the manufacturer's instructions. A standard curve with cytokine-positive control was run in each assay and the lower limit of detection was determined to be 3.5 pg/ml. Most of non-irradiated mice had circulating IL-1β protein levels near the limit of detection.
[0000] In Situ Hybridization
[0053] Localization of the IL-1β gene in soft tissue was determined by in situ localization and was performed as previously published. Briefly, leg tissues were fixed in 10% formalin and 2% paraformadhyde by cutting the whole leg into 3-5 pieces. Tissue sections were then placed on specially prepared slides (acid washed and T3-aminopropyl trietlioxysilane coated) and were deparaffinized and rebydrated. Proteinase K-digested sections were hybridized with appropriate amounts of IL-1β riboprobe. Sections to be examined were hybridized with anti-sense RNA under conditions of probe excess, and, after washing, they were prepared for autoradiography using NBTII emulsion (Kodak, Rochester, N.Y.). After autoradiography and staining, the slides were analyzed by bright and dark field microscopy. Backgrounds for these studies were determined using the sense stand RNA probe. As positive controls for hybridization, some sections were hybridized with constitutively expressed mRNA (GAPDH) and were analyzed for cell specific expression of the molecule of interest. Cell types and locations of IL-1β over-expression were identified histologically.
[0000] Statistical Analysis
[0054] Cytokine mRNA expression levels from skin and muscle in non-irradiated versus irradiated tissues were compared using the unpaired Student's t-test, or Mann-Whitney Rank Sum test as appropriate. Differences were considered significant for p<0.05.
[0055] Results
[0000] Pathological Observation
[0056] At early time points after irradiation of the skin, the gross appearance was only mildly different from one strain of mice to another. FIG. 5 shows typical changes seen after 30 Gy. During this acute process, which occurs over the 14 days following limb irradiation, the C3H/HeN mice (least fibrosis sensitive strain) had some hair loss and leg swelling ( FIG. 5 b ). The BALB/c mice, which have intermediate fibrosis sensitivity, had the most edema and hair loss ( FIG. 5 f ), while the fibrosis sensitive C57BL/6 mice had only a thinning of the fur with minimal edema over the first 14 days ( FIG. 5 d ). Local hair loss was noted during the first 14 days in all 3 mice strains, in a dose dependent manner. Ulceration was seen only in the high dose groups (60 and 80 Gy) at 14 days, and it was less common in the C57BL/6 mice. However, the acute inflammation that occurred in these animals over the 2 week observation period did not correspond to the degree of fibrosis that is expected 2 months after therapy.
[0057] The histological changes mirrored the clinical examinations, with some qualitative differences. As an example, 30 Gy irradiated tissues at various times after treatment are shown in FIG. 6 . C3H/HeN and BALB/c mice had lower basal densities of hair follicles compared to C57BL/6 mice ( FIG. 6 a, d, and g ). Three days after 30 Gy irradiation, all 3 strains had similar follicle densities; however, the sub-epidermal matrix accumulation was more pronounced in BALB/c and C3H/HeN mice ( FIG. 6 c and f ). At 14 days, inflammatory cells and fibroblasts in the dermis were more pronounced in C57BL/6 mice ( FIG. 6 ).
[0000] Expression of IL-1β mRNA
[0058] In order to determine the molecular correlation of radiation-induced soft tissue damage, we examined mRNA expression of interleukins, IL-1α, IL-1β, and IL-1Ra by RNase protection assay in skin and muscle tissues from the 3 mice strains before and after different doses of radiation. As shown in FIG. 7 and FIG. 8 , and summarized in Table 2, all 3 mice strains had detectable basal levels of IL-β mRNA in their skin (C3H/HeN mice had the highest), but only very low levels of IL-1β mRNA in muscle. Skin IL-1β mRNA expression was substantially increased within a few hours following 30 Gy leg irradiation ( FIG. 3 ). There were two phases of IL-1β mRNA elevations: first from 0.5 to 4 hrs and then from 7-14 days following irradiation ( FIG. 7 a, b, and c ). C3H/HeN and BALB/c mice had similar patterns of IL-β mRNA expression after irradiation ( FIG. 7 ). In contrast, the fibrosis-sensitive C57BL/6 mice had little if any IL-1β mRNA induction. Neither of the bimodal peaks were seen in irradiated muscle of C57BL/6 mice. Elevation of skin and muscle IL-1β mRNA in C3H/HeN and BALB/c mice was radiation dose-dependent. Very high dose (80 Gy) radiation significantly increased mRNA expression of skin and muscle IL-β (6 and 9 fold, respectively) in C3H/HeN mice at 4 hrs ( FIG. 8 a, b, and c ). After 14 days, the 80 Gy dose significantly increased IL-1β mRNA levels in both C57BL/6 and C3H/HeN mice, which were over 15-fold higher than those of non-irradiated controls. Local leg radiation not only increased local tissue IL-1β mRNA expression, but it also increased circulating IL-1β measured by ELISA. Circulating IL-1β was associated with tissue mRNA expression with bimodal elevations at 4-8 hr and again at 7 to 14 days in both BALB/c and C3H/HeN mice ( FIG. 9 b ). There appeared to be a dose response, with higher local radiation doses leading to chronically higher circulating IL-1β levels. In order to define the cell types producing IL-1β mRNA, in situ hybridization was performed on irradiated soft tissues. Increased IL-1β mRNA was mainly localized in keratinocytes and stroma cells in the dermis of non-irradiated skin.
[0000] Expression of IL-1α mRNA
[0059] As shown in FIG. 7 and Table 2, undetectable or very low levels of IL-1α mRNA were measured in the skin of C3H/HeN mice. A 2 to 6 fold induction of skin IL-1α mRNA was detected in both C57BL/6 ( FIG. 7 a ) and BALB/c mice after high doses of radiation ( FIG. 10 a and 10 b ). This increased skin IL-1α mRNA expression was radiation dose-dependent, progressed with time, and was minimal at the sub-fibrogenic radiation doses (≦30Gy). Radiation did not appear to induce IL-1α mRNA expression in muscle of any of the 3 mice strains ( FIG. 10 c ).
[0000] Expression of IL-1Ra mRNA
[0060] Like IL-1β mRNA, IL-1Ra mRNA was highly expressed in skin tissue, and no substantial difference in the basal levels of IL-1Ra mRNA was seen among the three strains ( FIG. 11 ). Skin IL-1Ra, however, was dramatically induced by radiation in C57BL/6 mice, but not in C3H/HeN or BALB/c mice. Induction of IL-1Ra mRNA in C57BU6 mice was radiation dose dependent. The effects of radiation on IL-1Ra mRNA expression in muscle of any strain was minimal ( FIG. 11 d ).
[0061] Discusssion
[0062] Murine models were used to simulate the situation that occurs in human skin after irradiation. This enabled us to examine the molecular characteristics of soft tissue fibrosis. Doses that caused little or no fibrosis (<30Gy), as well as highly fibrogenic doses (60-80Gy) were used in the 3 mice strains. We expected that, if radiation-induced cytokine mRNA expression is a causal event, then high doses would induce higher levels of cytokine mRNA, explaining strain variation in fibrosis sensitivity. Two key questions were asked in this study: 1) Is there a difference in basal mRNA expression of certain cytokines in skin or muscle tissues among 3 mouse strains with different fibrosis sensitivities? 2) Does this difference in mRNA expression contribute to the various radiation-related fibrosis responses in the three mouse strains? We demonstrated that: 1) skin tissues express higher levels of several interleukins than muscle tissues, independent of mouse strain. This is consistent with prominent initial fibrosis occurring in the subepidermal regions, with less and later development of fibrosis in muscle tissue. 2) C3H/HeN mice have the lowest predisposition for developing fibrosis and did not express IL-1α mRNA in their skin. The most fibrosis sensitive strain, C57BL/6, had high basal and radiation-induced levels of this cytokine. Muscle, which is more fibrosis resistant than skin, also had lower or undetectable IL-1α expression compared to skin. 3) Radiation induced elevation of IL-1β mRNA was biphasic with an early peak (1 to 4 hr) and another at a later time (3 to 14 day). The first phase was absent in the fibrosis sensitive strain, and it was intermediate in the strain with intermediate fibrosis sensitivity. 4) Cytokine responses in muscle were more blunted, compared to those in skin, and required higher radiation doses. 5) Cytokine responses after local radiation could be large enough to be detected in the circulation. 6) The cells synthesizing the greatest quantities of IL-1β appear to be the keratinocytes and stromal cells of the epidermis and dermis. Taken together we propose that these patterns suggest that brisk IL-1α responses to radiation and high basal IL-1α mRNA levels are associated with a higher risk for late radiation fibrosis. An early pulse of IL-1β expression after irradiation appears to correlate with a lower risk for developing radiation soft tissue fibrosis. The data also provided evidence that circulating levels of cytokines might be a useful marker of local cytokine production following radiation.
[0063] It has been demonstrated both experimentally and clinically that high basal levels of fibrogenic cytokines and/or growth factors are related to a higher incidence of radiation- or chemotherapy-induced late tissue damage. Our recent animal studies also suggest that high blood TGF-β levels are associated with a high risk for radiation-induced tissue fibrosis. We measured local and circulating levels of interleukin mRNA in our 3 mice strains with different fibrosis sensitivities because higher basal mRNA levels of these cytokines may also be related to a higher risk of radiation-mediated normal tissue fibrosis. It is apparent from our data that C3H/HeN skin does not have detectable IL-1α mRNA. Low or undetectable skin IL-1α mRNA in C3H/HeN mice, a fibrosis resistance mouse strain, may be responsible for its resistant phenotype. In our radiation-induced lung fibrosis models, similar results were also observed. The correlation of low mRNA levels of skin and lung IL-1α with increased resistance of radiation-induced fibrosis warrants further investigation.
[0064] Radiation-induced expression of interleukin mRNA is organ-dependent. All interleukin responses were more pronounced in the skin than in muscle. Inducible levels of each cytokine, however, varied between skin and muscle tissues. For example, radiation induced an elevation of skin IL-1α mRNA, not muscle IL-1α mRNA, in C57BL/6 mice. Our previous data in cultured cell lines (keratinocytes, skin fibroblast, and squamous cell carcinoma cells) also demonstrated that different cell types not only express different levels of each cytokine, but also respond to radiation differently. Our data here may also provide some guidance for clinical radiation therapy. For example, avoidance of cutaneous radiation might prevent cytokine cascades that could result in late tissue fibrosis. This is because soft tissue fibrosis begins in the subepidermis, later extends through the dermis, and eventually involves the superficial and the deeper muscle layers. Clinically, the efficacy of megavoltage radiation is in large part due to the lower epidermal dosimetry. It is an intriguing notion that patients with elevated basal IL-1α mRNA might be treated prophylactically with anti-cytokine therapy to prevent fibrosis.
[0065] While radiation-induced alteration of interleukin mRNA in lung and other organs have been reported in several strains of mice, altered mRNA levels of cytokines in soft tissues from different strains of mice have not yet been reported. In this study, we collected and processed RNA samples of three strains in the same RNase protection gel, and we also compared the IL-1 mRNA expression difference between skin and muscle. We found that the patterns of cytokine mRNA expression were consistent with the degree of fibrotic response. In contrast, macroscopic and microscopic acute alterations were weak predictors of fibrosis sensitivity. The lack of correlation between acute reactions and late effects has been studied for decades, and the role that cytokines and growth factors play appears to finally help explain the phenomenon.
[0066] Radiation increased IL-1 mRNA expression in two waves, the first at approximately 4 hours after therapy and another 3 to 14 days post-radiation. Examination of corresponding skin tissue morphology at each time point suggested that acute tissue response in preexisting cellular components may be responsible for the first peak of cytokine production. In situ hybridization studies suggest that keratinocytes, endothelial cells, and skin fibroblasts are the source of the early IL-1β mRNA expression. Infiltrating inflammatory cells and activated fibroblasts are probably responsible for the second peak in cytokine mRNA production. Several studies have demonstrated that pulses of IL-1, given within 24 hours of radiation, are radioprotective. Endogenous pulsing of IL-1β in C3H/HeN mice after radiation may therefore partly explain this strain's higher resistance to fibrosis compared to C57BL/6 mice.
[0067] In conclusion, we have shown that skin tissues produce more interleukin mRNA compared with muscle tissues. Skin IL-1α and IL-1Ra mRNA are upregulated in C57BL/6 mice, while IL-1β mRNA is increased in C3H/HeN and BALB/c mice within a few hours of local leg radiation. These results show that radiation-induced differential mRNA expression for interleukin and varied basal levels of interleukin mRNA participate in radiation-induced normal tissue damage.
[0068] Legends
[0069] FIG. 5 . Typical gross observation of radiation changes seen in control (a, c and e) and 14 days following 30 Gy irradiation (b, d and f) of the right hind limb in 3 mice strains. Edema was similar in all three strains, and hair loss was similar in C3H/HeN and C57BL/6 mice, with slightly greater hair loss in BALB/c mice (f).
[0070] FIG. 6 . The characteristic histological observation of progressive pathological changes of radiation fibrosis are shown in panels a through i. Normal mouse skin for C3H/HeN (a), BALB/c (d), and C57BL/6 (g). Note the thin epidermis with underlying papillary dermis, hair follicles containing multiple hairs. Leg muscle is free of significant inflammation. Day 3 (b, e, and h) and day 14 (c, f, and i) after 30 Gy radiation are shown. Early soft tissue reaction includes progressive loss of dermal papilla, reduced hair follicle number, increased empty hair follicles, and a superficial filling of the dermis with matrix and inflammatory cells. There is little inflammation of muscle, and the dermal inflammatory cell infiltrates were grossly similar in all strains.
[0071] FIG. 7 . IL-1β mRNA expression in irradiated limbs in 3 mice strains by RNase protection assay (a). IL-1β mRNA expression was quantitatively determined using a Cyclone PhosphorImager (HP Co, MI). IL-1β mRNA values are pooled from seven mice per measurement for irradiated skin (b) and muscle (c). Lanes are shown over-exposed to demonstrate the absence of IL-1α in the skin of C3H/HeN mice, and the brisk IL-1β response to radiation in C3H/HeN and BALB/c but not in C57BL/6. The early phase of IL-1β mRNA expression was seen in muscle, while the later increase at 1 to 2 weeks was less evident in muscle. 30 Gray is sufficient to cause a high frequency of severe acute reactions in all strains, but, at 2 months following radiation, 30 Gy is sub-fibrogenic for most C3H/HeN and BALB/c mice.
[0072] FIG. 8 . Determination of IL-1β mRNA expression in high dose (80 Gy) irradiated limbs from C3H/HeN and C57BL/6 mice by RNase protection assay (a and b). mRNA from seven mice was pooled. 80 Gy radiation induced elevated IL-1β mRNA expression in both skin and muscle tissues. 80 Gy is sufficient to cause substantial fibrosis and acute reaction in all strains.
[0073] FIG. 9 . Plasma IL-1β levels in C3H/HeN and BALB/c mice after limb irradiation. Circulating levels of IL-1β in platelet depleted plasma were significantly increased after 30 Gy radiation in BALB/c mice (left). The difference from baseline was not significant at any time after 10 Gy, which is a sub-fibrogenic dose. In a separate experiment (right), 30 Gy radiation significantly increased blood IL-1β in both C3H/HeN and BALB/c mice. The results suggest that circulating IL-1β is a surrogate for protein locally produced in the hind limb.
[0000] elevation compared to baseline significant p<0.05.
[0074] FIG. 10 . Determination of IL-1α mRNA expression in 30, 40, or 60 Gy irradiated limbs from 3 mice strains by RNase protection assay. Each value was normalized to its internal control GAPDH and represents the pooled expression from seven mice per measurement. Radiation elevated IL-1α mRNA in skin (a and b) but not in muscle tissue (c). The effect was greater with increased radiation dose. C3H/HeN mice express no detectable IL-1α mRNA in their skin at any time after irradiation.
[0075] Elevation of IL-1α during the first day after radiation was most pronounced in the fibrosis sensitive strain.
[0076] FIG. 11 . Determination of IL-1Ra mRNA expression in 30, 40, or 60 Gy irradiated limbs from 3 mice strains by RNase protection assay. Each value was normalized to its internal control L32 and represents the pooled expression from seven mice per measurement. Radiation-dose and time dependant induction of IL-1Ra mRNA mainly occurred in skin, with no detectable induction in muscle tissue. The fibrosis sensitive strain had the greatest induction of IL-1Ra.
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EXAMPLE 3
[0132] Material and Methods
[0000] Tumor Models and Radiation Treatment
[0133] Isotransplantable murine MCa-35 mammary tumor cells was inoculated i.m. into right hind thighs of 6-7 week-old female C3H/HeN mice (NCI, Fredrick, Md.). Right hind thigh tumors were given 60 Gy (single dose using a Cs irradiator) when tumors reached 8-9 mm in diameter. Mice were sacrificed 20 days after radiation.
[0134] Tumors and the overlaying skin tissues were removed for histology and RNA preparation. Irradiated tissues (tumor and skin) were also collected for making paraffin blocks for immunohistochemical staining. Guidelines for the humane treatment of animals were followed as approved by the University of Rochester Committee on Animal Resources.
[0000] Celebrex Treatment
[0135] Celebrex (Pfizer Inc.) powder was dissolved in PBS. Due to partial dissolution, the agent was mixed very well every time before gavaging. 50 mg/kg (0.2 ml) Celebrex was given daily, and five days per week for constitutive three weeks. Four experiment groups were used. All mice were treated with single 60 Gy radiation in tumor-bearing leg. Group 1 was radiation alone; mice in group 2 were given 50 mg/kg Celebrex 2 hours before radiation (2 hr pre-radiation); mice in group 3 and 4 were received the same amount of Celebrex at day 2 or day 7 post-radiation. Mice in the group 4 were received total 10 doses, and rest treated mice were given total 15 doses. All mice were sacrificed 20 day after radiation.
[0000] Determination of Radiation Induced Skin Damage by 5-Scales Scoring System
[0136] Radiation induce skin damage was assessed using 5-scales Skin Scoring System. 20 days after single 60 Gy radiation, mice from each treatment group were determined blindly for the degree of skin damage by three investigators. Grade 1: normal skin; grade 2: slight hair loss in irradiated area; grade 3: radish and swollen tissue; grad 4: small area erosion; grade 5: small ulceration. Grades 2-3 is referred as mild, and grades 4-5 is considered as severe skin damage.
[0000] Tumor Tissue RNA Isolation and RNase Protection Assays
[0137] Total RNA was isolated from tumors and skin overlying tumors, respectively, with 9-10 mice in each treatment group by pulverizing the frozen tissue, and dissolved in TRI Reagent (Molecular Research Center, Ohio) according to the manufacturer's specifications. To determine the integrity of isolated RNA, 2 μg of RNA from each sample was fractionated on a formaldehyde gel and visualized by staining in ethidium bromide. RNase protection was performed using established multi-probe template sets (PharMingen, San Diego, Calif.) as described previously [Okunieff, 1998 #4388]. The chemokine multiple templet includes: MCP-1, MIP-1α, MIP-1β, MIP-2, Rantes, Eotaxin and IP-10. The C-C chemokine receptor multiple templete includes: CCR1, CCR2, CCR3, CCR4 and CCR5. The C-X-C chemokine receptor multiple templets includes: CXCR2 and CXCR4. Two internal standards, L32 and GAPDH, were used as loading controls. The cocktail constructs were used to prepare 32 P-UTP labeled antisense cDNA probes using PharMingen in vitro transcription kits (PharMingen, San Diego, Calif.). Probes were hybridized with 30 μg of total RNA at 50° C. for 16 hrs RNase A (1 mg/ml), and RNase T1 (2000 U/ml) was then added to digest single-stranded RNA. After digestion, the RNA was precipitated and resuspended in gel loading buffer, heated at 95° C. for 5 min, and run on a 6M urea, 7% denaturing polyacrylamide gel (National Diagnostics, Ga.). The gel was dried on filter paper and placed on a phosphorimager screen for quantitative analysis of mRNA expression levels for each cytokine/chemokine. Area integration of each mRNA-protected fragment probe was normalized against the protected band for GAPDH or L32 mRNA in each corresponding lane to calculate the ratio of targeted mRNA/GAPDH mRNA expression. In order to compare the basal levels of each gene tested, relative levels (ratios) were plotted.
[0000] Quantitative Measurement of Total Structural and Perfused Vessels
[0138] Immunohistochemistry methods have previously been described in detail. Immediately following cryostat sectioning, tissue slices (normal muscle and tumor) were stained with CD31 antibody (PharMingen Calif.) for determination of total vasculature. The stained sections were imaged using an epi-fluorescence equipped microscope, digitized (3-CCD camera), background-corrected, and image-analyzed using Image Pro software (Media Cybernetics, Mass.) and a 450 MHz Pentium computer. Color images from individual microscope fields were automatically acquired and digitally combined to form four montages of the tumor cross-section (total area=15.5 mm2) using a motorized stage and controller. The image montages were processed to enhance the contrast between background and CD31 staining. From the enhanced images, locations of CD31-stained vessels were recorded. The quantitative vascular information was analyzed using custom Fortran programs to perform a “closest individual” analysis as previously described. Briefly, the distances from computer-superimposed sampling points to the nearest blood vessel were determined. The cumulative frequency distribution of these distances provided the probability of encountering vessels within any specified distance from the tumor cells. Median distances (μm) to the nearest vessel were used for statistical comparisons.
[0000] Statistical Analysis
[0139] mRNA levels (ratios) of tumors and skin from irradiated or non-irradiated mice were evaluated using the unpaired Students t-test or Mann-Whitney Rank Sum test as appropriate. Differences were considered significant for p<0.05.
[0140] Results
[0141] 20 days after single 60 Gy irradiated MCa-35 tumor skin had varied lesions including edema, erosion and superficial necrosis in most of saline-treated control mice 20 days after radiation ( FIG. 12 a ). However, Celebrex-treated tumors had less radiation-induced skin damage compared with saline-treated controls ( FIG. 12 b - d ). The most of Celebrex treated mice, regardless pre- (2 hr before radiation) or post-radiation (day 2 or day 7 after radiation) had less inflammation and cellular component infiltration in the dermis ( FIG. 13 b, c and d ) compared with saline-treated controls ( FIG. 13 a ). 23.8% (5/21) of mice in 60 Gy alone treated group developed severe skin damage, but only 17.6% of mice in the pre-2hr Celebrex treated group, 5.3% of mice in the post-day 2 Celebrex treated group, and 11.1% of mice in post-day 7 Celebrex-treated group, appeared as the severe skin damage 20 days after radiation. Oral administration of Celebrex also caused the reduction of blood vessels in MCa-35 tumor ( FIG. 12 f ), focal necrosis ( FIG. 12 g ) and even massive tumor necrosis ( FIG. 12 h ) in some areas of tumors, compared with saline-treated controls ( FIG. 12 e ).
[0142] Because radiation inducing soft tissue damages has been reported to associate with the persistent overproduction of cytokine or chemokine in irradiated normal or tumor cells, we next examined the effects of Celebrex on the radiation-induced mRNA expression of chemokines including five C-C family members (Rantes, eotactin, MIP-1α, MIP-β and MCP-1), one C-X-C family (MIP-2) and one C family member (lymphotactin), as well as C-C receptors (CCR1, CCR2 and CCR5) and C-X-C receptors (CXCR2 and CXCR4) in tumor skin and tumor tissues by RNase protection assay. As shown in FIG. 14 and summarized in Table 3 and 4, Celebrex treatment caused the significant reduction of Rantes (2.3±1.1 vs 7.4±1.6, P<0.05) and MCP-1 (10.2±1.1 vs 18.8±3.2, p<0.05) mRNA expression in irradiated skin tissues, but not in tumor tissues (Table 3), Although radiation induced higher levels of skin MIP-2 mRNA expression in 37.5% (⅜) of mice, only 14.3%-28.6% of tumor skin had high MIP-2 mRNA expression after Celebrex treatment. Similarly, Celebrex-treatment did not significantly alter the tumor MIP-2 mRNA (Table 4). Celebrex not only reduced C-C chemokines, it also caused the decrease mRNA expression of both C-C and C-X-C chemokine receptors in tumor skin ( FIG. 14B and D), not in tumor tissues ( FIG. 14C ). All quantitative measurement are shown in Tables 3 and 4.
[0143] Due to each individual mouse variation, there was 15-30% of Celebrex-treated mice still developed the moderate or severe skin damage after radiation. Radiation-induced skin damage was quantitatively determined by the skin scores from each individual mouse. In order to find out the relationship between overexpression of chemokines or their receptors mRNA and radiation-induced skin damages, the correlation of skin scores and skin tissue chemokine and chemokine receptor mRNA expression levels from each individual mouse were plotted and shown in FIG. 15 . Significant positive correlation between skin damages (skin scores) and overexpression of chemokine and its receptor mRNA expression were observed in 60 Gy radiation-treated mice. However, the correlation of Celebrex-mediated the reduction of chemokine and chemokine receptor mRNA expression with skin damages only occurred in Rantes ( FIG. 15 a ) and it receptor CCR5 ( FIG. 15 d ), MCP-1 ( FIG. 15 b ) and its receptor CCR2 ( FIG. 15 d ). Although Celebrex-mediated reduction of MIP-2 mRNA expression did not correlate with less skin damage, related CXCR4 mRNA expression was significantly reduced in Celebrex-treated mice, which had less radiation-induced skin damage.
[0144] As shown in FIG. 16 , Celebrex-treated mice had less infiltration of inflammatory cells in the dermas ( FIG. 16 c ) compared with saline controls ( FIG. 16 a ). However, the infiltration of inflammatory cells in tumor tissue was not obviously altered by Celebrex treatment ( FIG. 16 b and d ).
[0145] Discussion
[0146] Thus we have discussed that: 1) Radiation induced Rantes/CCR5 and MCP-1/CCR2 mRNA expression was decreased by Celebrex; and 2) Celebrex-mediated reduction of chemokine and their receptor mRNA expression was correlated with ameliorated skin damage. 2 | A method for the prevention of and therapy for radiation pneumonitis, dermatitis, soft tissue fibrosis and central nervous system toxicity in patients undergoing therapeutic radiation. In addition, the invention provides for pre-treatment of those responding to nuclear bio terrorism or other nuclear or radiological accidents. Thus, with the present invention, subjects may be treated in order to prevent toxicity from nuclear bio terrorism or other nuclear or radiological accidents. More particularly, we have discovered a method for prophylactically treating radiation toxicity in normal tissue of subject comprising administering an anti-radiation toxicity effective amount of a cytokine blocking agent through the subject. More specifically, we have discovered a method for prophylactically treating radiation pneumonitis, dermatitis, soft tissue fibrosis or central nervous system toxicity in a subject comprising administering an anti-radiation pneumonitis, dermatitis, soft tissue fibrosis or central nervous system toxicity effective amount of a cytokine blocking agent to the subject. | 0 |
This patent application is claiming the benefit of U.S. Provisional Application No. 60/303,416, filed Jul. 9, 2001, the entire disclosure of which is hereby incorporated by reference herein.
U.S. Provisional Application No. 60/303,416 is based upon U.S. application Ser. No. 09/098,860, filed on Jun. 17, 1998, entitled Transaction Tracking And Assessment Data Processing System And Network, by Stephen D. Messer, which is a continuation-in-part of prior application Ser. No. 08/871,921, filed on Jun. 10, 1997, entitled Data Processing System For Integrated Tracking And Management Of Commerce Related Activities On A Public Access Network, by Stephen D. Messer, now issued as U.S. Pat. No. 5,991,740, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to a novel computer system for managing network-based communications. More particularly, the present invention is directed to a network-based promotional system and method that provides dynamically updated Rich Media centrally stored for selective presentations per pre-defined coding regimen.
BACKGROUND OF THE INVENTION
A sophisticated network promotion tracking and management system is disclosed in U.S. Pat. No. 5,991,740 to Stephen Dale Messer. This system includes a plurality of computers linked together to allow transfer of information and files in accordance with a select profile. Promotions at one computer are used to direct consumers to a Merchant computer where commerce can take place. The system tracks the referrals from the promotion to the commerce and permits proper allocation of commissions for the referral.
The foregoing U.S. Patent and pending patent application Ser. No. 09/098,860 filed on Jun. 17, 1998 are hereby incorporated by reference, forming the foundations for the improvements thereto discussed below as part of the present invention.
While a vast spectrum of variations exists in implementation, the above network promotion tracking includes a Clearinghouse Web Site, where Merchants and Affiliates interact and develop mutually acceptable promotional arrangements consistent with operational considerations. Often, the system includes at the Clearinghouse, select promotional links pre-packaged for ease in implementing by the Affiliate, simply by downloading the link code structure—usually expressed in HTML code. For example, the Clearinghouse server will include banner ads formed by pre-packaged links that include graphics for a select Merchant trademark, such as LL Bean or the like. This allows the Merchant to control the image quality of the banners and eases their implementation by the Affiliate.
In addition, promotional links take forms other than mere banner ads, and can include e-mail, text, search box, and select graphic/image configurations. All these link code packages have in common a static characteristic. That is, once placed on the Affiliate's Web page, the content and appearance remains constant until replaced or updated. Indeed, if the Merchant moves, or the product is discontinued, the link becomes obsolete and unproductive.
Other links are more sophisticated. These links include embedded code for local execution upon activation. For example, the promotional link can include a Java script that provides a short animation upon activation by a potential user, enhancing the overall promotional presentation to the USER. These short programmed applet-based presentations are known as Rich Media because the format allows a substantially richer presentation upon execution. However, even this more sophisticated presentation is static in the sense that once programmed with the Web page, it largely repeats as instantiated. Changing and/or updating the presentation involves the full removal and replacement of the page coding at the Affiliate site, an arduous and complex process particularly with the more sophisticated presentation materials.
These more sophisticated promotional links that include animation or other programmed capabilities are often created by professionals apart from and operating separately from the Affiliates and Merchants within the network. Indeed, these vendors are skilled in this select field of programming and offer their Rich Media applets to the industry pursuant to their individual fee structures. Vendor supply of these Rich Media offerings upon acceptance requires the transfer on select intervals of the Rich Media creative to the subscribing Affiliate from the producers. Problems can arise in this transfer particularly if the Affiliate is without meaningful programming support or lacks the experience to manage updating and modifying promotional applets on a continuous basis.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide a data processing system to enhance promotional activity across a wide area network.
It is another object of the present invention to provide a computer network-based Affiliate program that supports Rich Media applications having a common protocol for enhanced management.
It is still another object of the present invention to provide a computer-based server having programmed controlled functions to allow Rich Media serving to plural Affiliate Web Sites across a wide area network, such as the Internet.
It is yet another object of the present invention to provide a network-based programming protocol that provides a code wrap for remote stored promotional link commands.
It is yet another object of the present invention to provide a select API for Rich Media creatives that allows centralized storage and/or management of the distribution of the promotions associated with the Rich Media creatives.
It is still another object of the present invention to provide a programming protocol that provides a common interface for supporting Rich Media, Dynamic Text Links, third-party ad serving and select dynamic search box controls.
The above and other objects of the present invention are realized in the application of a selectively programmed group of interconnected servers, linked for network communications to support a plurality of Merchants and Content Providers or Affiliates. The network provides a sophisticated promotional mechanism that presents goods and services to potential customers creating a streamlined gateway for these customers to interact with sponsoring Merchants in placing orders or exploring product characteristics. The system places within this network, a Clearinghouse server that is selectively programmed to manage and implement the promotional activities of the participants. The Clearinghouse server is further configured to provide a coded application program interface (API) that allows for a common protocol for wrapping Rich Media promotions used in support of product and service marketing. In one construct, this involves wrapping a script tag around linking code to be provided to Affiliates. By placing this common protocol in place, the Clearinghouse server thereafter becomes a source for vendors to supply creative media for use by Merchants and Affiliates within the network. In addition, the common protocol permits simplified updating of promotional programs by Merchants across their Affiliate franchise.
The foregoing paradigm has several innovative extensions in use. In one aspect, this process supports a sophisticated applet known as a search box, used on an Affiliate Web Site to enhance product access by users. The search box link may be centrally stored on the Clearinghouse site for hosting directly and in conjunction with the Rich Media creatives in accord with the above protocol.
The foregoing features of the present invention may be better understood by review of the following description of an illustrative example thereof, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a block diagram depicting the operative environment of the present invention;
FIG. 2 is a logic flow chart for the Affiliate interface; and
FIG. 3 is a logic flow chart for the Merchant interface.
DETAILED DESCRIPTION OF THE INVENTION
In overview, the present invention is directed to an enhancement to an existing network-based Clearinghouse Centric Affiliate Program and the systems designed and implemented to support commerce within the network in accordance with the program dictates. The system, at its more fundamental level, provides tracking and reporting capabilities for a confluence of participating Merchants and Affiliates. In this way, select promotions are deployed at Web Sites throughout the Internet, and link back, first through the Clearinghouse, and then to the Merchant sites to permit commerce on the promoted products, with commissions credited to the appropriate sourcing Web Site.
The system operating characteristics are enhanced by creating a new module for managing creative content and its distribution as the focal of promotional activity. The new module, reference here as the “Rich Media” module, provides the programming support for Merchants to systematically control and update the promotions used on their respective syndicated Affiliate networks. This is made possible by selectively wrapping the promotion code within a select Java script—script tag, that calls a stored implementation program. This wrap provides a common API allowing seamless interchange of creative links for use in the network.
With the foregoing overview in mind, attention is first directed to FIG. 1 , comprising a block diagram of the participants in the present invention. At block 100 , a User has a computer or other communication portal device. This may include without limitation all forms of PDAs, cell phones, laptop and desktop processors, equipped with a browser type program capable of downloading and decoding selectively encoded Web pages. As shown in the figure, the User visits sites on the Web (shown graphically as Sites 200 - 240 ), where information of interest is available. Interaction with each site involves the downloading of site content—typically Web pages with information and commerce inducing promotions.
Continuing with FIG. 1 , the Clearinghouse 500 server resides at the center of activity. In addition to the links from the sites, the Clearinghouse server is linked to Vendors ( 310 - 330 ) as suppliers of creative content for use in the promotions, and the supporting Merchant base, (Merchants 610 - 630 ). Finally, operation is also supported by third-party Ad servers, 400 , i.e., Web servers that host ads to the Web Sites.
Operation requires a generic API to support the extension for promotion. Application of this process involves four discrete operations. Initially, and as the first of the operative steps, this requires the Merchant to upload its promotion template, typically HTML code (dynamic link—see below). This template can also comprise the Clearinghouse specific code for, e.g., Affiliate ID variables for placing the Affiliate ID when the Affiliate generates the linking code. The starting template resides in the following exemplary file on the Clearinghouse:
OTHER_HTML.html_clob
This process is demonstrated with the following example, where a simple promotional link is first wrapped and loaded for access, starting with the initial code uploaded as a template—either hosted by the Merchant or uploaded to the Clearinghouse for Clearinghouse hosting, as depicted in Table I:
TABLE I
<P>This product SKU01234 is great!
<A HREF=“<lsn click>&tmpid=1&RD_PARM1=SKU01234”>
click here to buy</A>
The foregoing is then converted or “wrapped” in a Java script tag and stored at the above file location, as follows:
TABLE II
<script language=“javascript”>
document.write(‘<P>This product SKU01234 is great!);
document.write(‘A HREF=“’ + lsn_click+&tmpid=1&RD_PARM1=
SKU01234”>);
document.write(‘click here to buy</A>’)
</script>
The above code wrap operation is for sourcing the promotion to the Affiliate network from the Clearinghouse server directly. An alternative approach is available and involves hosting the promotional content from the Merchant site. This requires the Clearinghouse server to store the URL of the Merchant server in the designated page:
OTHER_HTML.media_url:
http://www.merchant.com/linkshare/medial.js
In this example, LinkShare is the Clearinghouse, the content of medial.js is the same as OTHER_HTML.html_clob and is the same as depicted above for the Clearinghouse server example.
In either approach—Clearinghouse or Merchant hosting—the next operative step involves the generation of the Affiliate linking code. As depicted below, the Clearinghouse will generate Affiliate linking code within the “OTHER MEDIA” module, using the implementation program (“show” in this example), listed here as “14”:
TABLE III <script src=“http://ad.linksynergy.com/fs-bin/show?id= IMh2Xiq9xN0&bids=11111.1&type=14&subid=0”> </script>--
NOTE: The Affiliate may freely append u 1 parameters or wrap any other variables into the link, e.g., &u 1 =my_u 1 _number.
TABLE IV <script> var lsn_click=“http://click.linksynergy.com/fs-bin/click?1Mh2Xiq9x N0&offerid=11111&type=14&subid=0&ul=my_u1_number”; </script> <!--from OTHER_HTML.html_cob--> <script language=“JavaScript”> document.write(‘<P>This product SKU01234 is great!’); document.write(‘<A HREF=“’ + lsn click + &tmpid=1&RD_PARM1= SKU01234”>’); document.write(‘click here to buy </A>’) (/script>
For hosting on the Merchant site, the system creates the following instruction set:
TABLE V
<script>
var lsn_click=“http://click.linksynergy.com/fs-bin/click?1Mh2Xiq9x
N0&offerid=11111&type=14&subid=0&u1=my_u1_number”;
</script>
<!--from OTHER_HTML.media_url-->
<script language=“JavaScript” src=“http://www.merchant.com/linkshare/
medial.js”
</script>
The Java script will be executed by user's browser to produce the final HTML code:
TABLE VI
<P>This product SKU01234 is great!
(A HREF=“http://click.linksynergy.com/fs-bin/click?1Mh2Xiq9x
N0&offerid=11111&type=14&subid=0&u1=my_u1_number&tmpid=
1&RD_PARM1=SKU01234”>
Click here to buy</A>
The Rich Media feature allows third-party vendors to partner with the Merchants, and offer their Rich Media creative directly to Affiliates through the Network. Third-party vendors will need to comply with the above specifications in order to provide their Rich Media creative to the Affiliates. A Web area is provided where Merchants can directly upload this code for their Affiliates. The system will check this code for compliancy, and process it in the system. On the Affiliate side, the system provides a Create Links area of the Affiliate interface where an Affiliate can generate the appropriate code for such creative.
Affiliate Side—Rich Media
The Affiliate interface to accommodate the new Rich Media creative offerings will have the following characteristics:
Join Programs/Account—Page
This is the page Affiliates see either 1) before they apply to a Merchant's program in order to find out more information about the program (Join Programs), or 2) after they have been approved and want to review information about a program in which they are already participating (Account). Within this page is an area that indicates the types of links which are available from a particular Merchant. If a Merchant has uploaded a Rich Media banner, the words “Rich Media” should appear in a new box under “Link Types Available”.
Create Links—Page
When an Affiliate selects a Merchant for which to generate links, he accesses the page above. This page displays all the link types which are available to the Affiliate. If a Rich Media banner has been uploaded into a particular Merchant's account, the Rich Media link should appear in the left hand tool bar for that Merchant. When an Affiliate clicks on the link for Rich Media creative, he should arrive at a page that looks like this:
Rich Media creative available to the Affiliate will be displayed by Category. There will also be a search tool above in case the Affiliate knows exactly what Rich Media creative he is looking for. The categories displayed here are the same as the Image Categories. However, if there is a Category for which there are no Rich Media creative assigned, the Category name will not appear as a choice to the Affiliate. If the Affiliate clicks on a Category, the system will return all Rich Media links uploaded into the system available to this Affiliate under that particular Category.
Note that matches are returned with 25 entries to a page. The Affiliate can click to the next page, or jump to any page by using the page index at the top and bottom of the screen. Rich Media links are displayed by Name and Description entered by the Merchant upon upload into the system. If the Affiliate types in a query to search for a specific keyword in all categories, the system will return all matches broken down by Category.
Note that it shows a maximum of five entries for each Category. To see additional matches, the Affiliate clicks on “More Matches in Category Name” and retrieves the full listing just as it would appear in the Category page above. Once the user finds a Rich Media link he/she would like to use, he/she simply clicks on the Rich Media link name to generate the appropriate code, which appears to the Affiliate.
A sample of the Rich Media creative appears with the appropriate code for the Affiliate to place on his/her site.
Reports
Rich Media links will drive impressions, clicks, and sales just like any other link type. As such, activity generated by Rich Media links will be rolled up into reports just like all the other link types. Total impressions, clicks, and sales generated from Rich Media links will be included within all reports.
Merchant Side—Rich Media
Several modifications will also have to be made in the Merchant interface to accommodate the new Rich Media creative offerings. The interfaces that will be affected are as Links/Merchandising, Reports.
Links/Merchandising
The “Rich Media” section of the Clearinghouse allows Merchants to upload their Rich Media creative. The Merchant specifies the name of the Rich Media link, as well as the type of link he/she is uploading, using a drop down menu or similar for type selection from a pre-established list. This drop down will display the names of third-party vendors approved by the Clearinghouse, as well as providing a “Custom” option for those Rich Media links which the Merchant has designed him/herself.
When a Merchant uploads code for their Rich Media link, the LinkShare system will perform a series of checks to ensure that the code is legitimate. For example, if the Merchant is uploading code for a specific third-party vendor partner, and selects the appropriate vendor, the system will check to make sure that the code uploaded meets certain criteria for that specific vendor.
As discussed briefly above, the application of these protocols allows implementation of a select processing tool known as a “search box”. Under this protocol and for the preferred configuration, these search boxes should conform to the following conventions:
Search Convention
The query will search database to return all entries which match at least one of the words entered, unless advanced syntaxes are used (see below).
1. Searched Fields (in Create Links and Links/Merchandising)
Submitted queries will search all of the following fields for matches: Name, ID, Description.
2. List All
Affiliate types a “*” and hits “Go” to list all entries within a specific Category, Size, or Type.
3. Partial Word Match
Place a * at the end of a word to return right side partial matches. For example, link* will return all entries containing matches with link, links, linked, linking, and LinkShare.
Place a * at the beginning of a word to return all left side partial matches. For example, *share will return all entries containing matches with mindshare, LinkShare, and TrafficShare.
If an Affiliate simply types “link” or “share”, the search will NOT return any of the terms above. It is important to note that only exact matches will be returned.
4. Phrase Matching
Place quotes around a set of words to find results that match all words in that exact sequence. For example, “LinkShare Network” would return all results in which the word LinkShare appeared directly before the word Network.
5. Required and Prohibited Words
Use a + sign in front of a word to require that the word be found in all of the search results. For example, program would return all results with the word program whereas program+Affiliate would return all results that contained both Affiliate and program.
Use a − sign in front of a word to require that the word not be found in any of the search results. For example, Affiliate-program would return all results that contained the word Affiliate, but not the word program.
Turning now to FIG. 2 , Affiliate interaction with the Clearinghouse is provided and initiated via entry of the appropriate Affiliate ID and password, block 710 . Test 720 queries on joining as an Affiliate. A positive response branches logic to block 730 and the display of program details. If acceptable, Yes to Test 740 creates the new account Aff(I), which is then subject to approval, Test 760 .
Continuing with FIG. 2 , after approval, the specific Affiliate accounts details are presented, block 780 , including Rich Media promotions under a separate heading. Test 790 allows selection of this category and display of choices on the site at block 800 . If the Affiliate funds an appropriate promotion, _is selected, Test 810 and then directly downloaded to the Affiliated at block 820 . Logic continues at block 830 .
Dynamic Text Links
The Dynamic Text link feature allows the Merchant to create text links that can be dynamically updated or modified on an Affiliate's site. The Merchant can combine images with text, and change the entire content and layout dynamically across his/her Affiliate sites instantaneously. Dynamic Text Links can be as simple as a single word, to a list of top ten bestsellers with images surrounding the text. The difference between Rich Media and Dynamic Text Links is that Dynamic Text Links are to be used for basic HTML creative that combines simple text with simple images. The focus is on textual content vs. creative imagery. Dynamic Text Links can typically be created by an Affiliate program manager, whereas Rich Media links often require the expertise of a specialist.
Affiliate Side-Dynamic Text Links
Several modifications will have to be made in the Affiliate interface to accommodate the new Dynamic Text Link offerings. The interfaces that will be affected are as follows: Create Links, Reports.
Create Links
Dynamic text links will be offered to Affiliates visiting the Clearinghouse server, by selective presentation of “Create Links”.
The page will conform to the new standard of presenting links and will mirror how Rich Media links are presented. A search box is provided, and will allow the Affiliate to query by Category or by Type (Dynamic or Static, instead of “Size” used in the Rich Media link search box).
The Create Links area will present both current Static links, as well as the new Dynamic Text links. The new interface will present all links by category, and allow the Affiliate to drill down or search for the specific link he/she is interested in. The list of entries will distinguish all text links as either Dynamic or Static. It will also show Name, ID, and either description (Dynamic) or the actual text link (Static). When Affiliates find the link that they want, they click on “Get Code”. If it is a Static Text Link, a screen will appear with the code for both a text link as well as an email link:
http://alogin.linksynergy.com/php-bin/aff/showmerchant.shtml?oid=6919&subid=&roid=&link type=3&showcode=Y&is special=&pid=3
If it is a Dynamic Text Link, the screen will show an example of the Dynamic Text Link, as well as provide the appropriate code.
Reports
Dynamic Text Links will drive impressions, clicks, and sales just like any other link type. As such, activity generated by Dynamic Text links will be rolled up into reports just like all the other link types. Note that Dynamic Text Links are to be treated just like regular text links-type=3. Total impressions, clicks, and sales generated from Dynamic Text Links will be included within all reports, requiring no modifications to any of the report appearances. It is important to note that a drill down in the Link Type report will be necessary as follows:
Link Type Report
The Text Link line item in the Link Type report should drill to a breakdown of activity between Static vs. Dynamic Text Links. Each of these will then drill down further to activity by specific text link ID.
Merchant Side-Dynamic Text Links
The Merchant interface to accommodate the new Dynamic Text Link offerings are Links/Merchandising, Reports.
Links/Merchandising
A new link for “Dynamic Text Links” will be available for Merchants under the Links/Merchandising area. Access to this new “Dynamic Text Links” upload area must be restricted only to those Merchants who have opted in to this new feature.
The screen lists the Dynamic Text Links that have already been created, to allow the Merchant to modify these links at any time. The screen shows the first ten, and allows the Merchant to view the links on the next page or by jumping directly to subsequent screens. The Merchant can edit any existing link by simply clicking on the ID number. A Merchant can also modify the status of a link, assign it to specific Programs, or assign it to specific Groupings. To create a new Dynamic Text Link, the Merchant clicks on “Create New Link”.
This brings a new screen that provides the Merchant with a series of Dynamic Link templates. These templates simply provide the basic HTML foundation for each of the various formats. Because Dynamic Text Links are using the Rich Media API structure, a Merchant can essentially upload anything in this section. However, anything uploaded here will be classified as a Dynamic Text Link in the system. Exemplary templates provided to the Merchant are as follows:
Text Only
Provides the outline for creating a link for Affiliates that consists only of text—great for content, news, stories, and any other text copy that a Merchant would like to syndicate across Affiliate sites.
Vertical Display
Provides the outline for creating a text link underneath an image—recommended for product highlights to provide both graphical and textural descriptions of the featured products.
Horizontal Display
Provides the outline for creating a link that displays image and text side by side—recommended for product highlights with longer descriptions, or for content that may be supported with an image.
List
Provides the outline for creating a list of product or content features—ideal for highlighting top ten products, services, headlines, stores, gift ideas, etc.
Custom
No outline is provided. Merchant can completely customize their Dynamic Text Link—for advanced users who are familiar with HTML and who want to design a customized display for their Affiliates.
Note that each of the template screens includes an option for the Merchant to activate a “Remote Update”. If the Remote Update check box is checked, the Merchant must enter a URL location where the Dynamic Text code resides and under the Merchant's control. The Merchant is responsible for updating the remote location with new content. This remote location must house the code exactly as it would be uploaded into the LinkShare system. The Remote Update feature provides a way for Merchants to update their Dynamic Text Links without having to log in to their merchant account each time.
A Preview button allows the Merchant to view the Dynamic Text Link as uploaded by the Merchant. This allows the Merchant to check for errors in the HTML coding.
The Reset button refreshes the screen, and returns the screen back to the default. If the Merchant has altered any of the code within the code box, it will be erased, and the original template code will appear in the code box. This is to allow a Merchant to start all over if he/she has made any mistakes.
The Submit button uploads the Dynamic Text Link into the Clearinghouse system. Once a Merchant clicks on the Submit button, the screen will refresh to the index screen, showing the page where the newly submitted link appears. The Merchant can then continue to assign programs and groupings. The link is “Active” upon submission.
A simplified flow diagram for the merchant side is depicted in FIG. 3 , starting at block 1000 and entry of Merchant ID and password at block 1010 . Test 1020 queries on whether the Merchant has selected an upload “RM” command, indicating a desire to install a new creative. A positive response directs system logic to blocks 1030 - 1040 , and the entry of the RM details, e.g., the “name” and “type”. At Test 1050 , the system tests the uploaded RM for compliance with successful passage resulting in storage of the RM, block 1060 .
Third Party Ad Serving
Merchants have the option of hosting link promotions or having the Clearinghouse or any third-party provider, or the Affiliate serve the image. A Merchant can dynamically update banners being used by Affiliates by simply uploading the new banner into the Clearinghouse system, if the image is served by the Clearinghouse. If the image is served by a third party, the Merchant can only dynamically update banners by changing the image stored at the image URL—the image URL itself cannot change. By using the Rich Media API feature to wrap a pre-select tag around the image URL, Merchants can change the image URLs directly on an Affiliate's Web Site by simply uploading the new URL into the Clearinghouse system. The Merchant is further enabled to completely change serving parties without requiring Affiliates to generate new code and replace links.
Merchant Side-Third Party Ad Serving
If a Merchant wishes to utilize Rich Media API enabled images, he should upload the image URL as usual, and select Enabled in the Image Serving Party drop down box. A check box also allows the Merchant to specify that a Clearinghouse selected URL is to be used for the Rich Media API enabled image. This is necessary if the Merchant wishes to keep their options open about the serving party of their images.
Dynamic Search Box
In the past, Merchant clients offered Search Boxes to their Affiliates. The code for these Search Boxes was manually uploaded into the system by the technical department, via Technical Consultants. They are then provided to Affiliates, and copied by Affiliates directly onto their sites. As such, if any changes or updates to the Search Box are made by the Merchant, the Affiliate is required to generate new code, and replace the current code on his/her site.
This is replaced by the inventive process discussed above relating to the Rich Media features. The only difference is the type of creative. Search Box is associated with search box and drop down banners, while Rich Media is associated with all other types of links that feature interactivity and designed using Java, XML, and other special coding. While the process for tracking these two forms of promotion are kept separate, the operative characteristics for implementation are the same, as discussed below:
Affiliate Side-Dynamic Search Box
Nothing changes on the Affiliate side, except that when code for a Rich Media API enabled image is provided to an Affiliate, the Image Serving Party is labeled as Enabled. The initial screen includes an index of Search Boxes available to the Affiliate in the same format that we do for Rich Media, Textual/Email, etc.
Merchant Side-Dynamic Search Box
At the Clearinghouse server, a Web area is created for access and is called the Search Box. In this application, the drop down box for type of link will be either Static or Dynamic. If Static, then the code that a Merchant uploads is provided directly to the Affiliate. If Dynamic, then the system wraps a Clearinghouse API script tag around the code so that the code can be changed and updated at any time.
EXAMPLE 1
The following is an example of the present invention, and specifically the use of a select Rich Media API to wrap code for use in the promotion of products on the Network.
1. Merchant will enter these as a template in ‘other_html’. The “cut here” reflects the ease of cut and paste application of the requisite coding.
----------cut here----------
<HTML>
<BODY>
<applet code= jCard.class″
codebase= http://bigstar.epod.com/bigstar″align=“baseline” width=
238
height=271 archive=“jCard.jar”>
<a href=http://www.bigstar.com><img border=)
src=http://bigstar.epod.com/bigstar/Component/c15/default.gif width=
238 height=271></a>
<PARAM NAME=“obj” VALUE=15″>
<PARAM NAME=“kioskid” VALUE=15″>
<PARAM NAME=“affksk” VALUE=1000000863″>
<PARAM NAME=“attribute” VALUE=A00018″>
<!--LinkShare required parameters-- >
<PARAM NAME=“lsn_click_url”
VALUE= “<lsn click>&tmpid=1&RD_PARM1=
<RD_PARM1>”
<PARAM NAME=“productlist” VALUE=”AB0001/AB0002/
AB0003”
<!--end of LinkShare-- >
</applet>
</BODY>
</HTML?
----------end----------
2. The Clearinghouse will generate this linking code for the Affiliate:
----------cut here----------
<script src=“http://ad.linksynergy.com/fs-bin/show?id=
1Mh2Xiq9xN0&bids=11111.1&type=14&subid=0”>
</script>
----------end----------
3. The Clearinghouse ‘show’ program will generate Java script that writes out:
----------cut here----------
<HTML>
<BODY>
<applet code=“jCard.class”
codebase=“http://bigstar.epod.com/bigstar” align=“baseline” width=
238
<HTML>
<BODY>
<applet code= jCard.class″
codebase=“http://bigstar.epod.com/bigstar” align=“baseline” width=
238
height=271 archive=”jCard.jar”>
<a href=“http://www.bigstar.com”><img border=0
src=”http://bigstar.epod.com/bigstar/Component/c15/default.gif
“width=238 height=271></a>
<PARAM NAME=“obj” VALUE=15″>
<PARAM NAME=“kioskid” VALUE=15″>
<PARAM NAME=“affksk” VALUE=1000000863″>
<PARAM NAME=“attribute” VALUE=A00018″>
<!--LinkShare required parameters-- >
<PARAM NAME=“lsn_click_url”
VALUE= http://click.linksynergy.com/fs-
bin/click?id=1Mh2Xiq9xN0&offerid=4506&u1=1234&sku=
<RD_PARM1>>
<PARAM NAME=“productlist” VALUE=“AB0001/AB0002/
AB0003”
</applet>
</BODY>
</HTML?
----------end----------
4. At this point, the Merchant will display their Java and VB script, etc. If the user clicks on any product, Merchant will replace the <RD_PARM 1 > in the Clearinghouse “lsn_click_url” variable with the sku number that user clicks on:
----------cut here----------
Location: http://click.linksynergy.com/fs-bin/click?id=
1Mh2Xiq9xN0&offerid=4506&u1=1234&sku=AB0001
----------end----------
Although the invention has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention. For example, although Rich Media presentations are described throughout the specification, this is for illustrative purposes, as other forms of visual and/or audible presentations could be provided. Such variations are within the spirit and scope of the invention. | A novel communications network tracks and manages Merchant and Affiliate promotional efforts in a seamless, integrated fashion. Operative characteristics include central control over new, Rich Media promotional links, allowing sophisticated promotions employing Java-based presentations or similar to be easily applied across a broad network of connected Affiliate sites. The system accomplishes this, in part, by providing a selective API for use in wrapping the promotional links. In accordance with this protocol, these links may be hosted by the Clearinghouse or Merchant, and sourced from a variety of third-party vendors. | 6 |
FIELD OF THE INVENTION
The invention relates to a process for the storage and removal of vehicles in a parking structure, as well as to the parking structure The structure can also be used as a storage means for other purposes.
BACKGROUND OF THE INVENTION
For the solution of the parking space problem existing particularly in metropolitan areas mechanical parking devices of various shapes are known.
French Publication No. A 1 407 816 suggests a parking device with a movable platform and a transfer device in the shape of a liftable and lowerable transfer grate with grate arms extending in the longitudinal direction and movable in a transfer direction. The transfer grate is moved by means of a rope gear and the same gear also lifts and lowers it. According to this arrangement, it is necessary for the rolling surface, i.e. the floor in the area of the movable platform to have a slot allowing for the entrance of the ropes. The arms of the transfer grate are moved separately and their movements are controlled by a light barrier arrangement.
U.S. Pat. No. 3,497,087 shows a parking arrangement with a transfer device in the shape of a telescopic bogie wagon. The stations and the wagon have transverse arms consisting of over-mounted jibs (gibbets). The station and the transfer device do not have a solid floor. For the transfer of a vehicle at the deposit, storage and removal stations the telescoped bogie wagon is lifted and lowered by an elevator, the grates penetrating one another.
WO Publication No. A 86/02678 also features a parking device with transverse grates and a telecopable bogie wagon. The stations have guide rails for the wagon, but no solid floor.
AT-PS No. 246 046 shows a spiral storage system, wherein the vehicles are driven on a platform along a spiral path to the surrounding parking lots and then stored or picked up through a transfer device. It consists of a swivelable and height-adjustable gripping device which grips the front wheels of the vehicle to be moved, lifts them and moves the vehicle into or out of its parking space.
Other designs are known from the Merkblatt Stahl (information brochure steel) No. 211, "Parkbauten" (parking buildings) by the "Beratungsstelle fuer Stahlverwendung" (information center for the employment of steel), 2nd edition 1972. This reference discloses a Paternoster-elevator system which requires a large amount of time and energy, as all vehicles have to be moved for the parking and removal. Also, slide systems are described, wherein the vehicles are maneuvered from the deposit stations or entrances to elevators and from there to the parking spaces and back through gravity conveyors or conveying or hauling paths.
Another known system works with pallets, on which the vehicles are deposited for storage. The pallets are then moved to free parking spaces by means of floor conveyors. Due to the pallets this system is expensive. The system requires complicated construction and can only be realized in one-story car parks. The access time for the parking and removal of the cars is too long in all of the mentioned prior art.
SUMMARY OF THE INVENTION
Therefore, the invention has the task of creating a possibility for the faster, cheaper and more reliable parking and removal of goods, and especially of vehicles.
According to the invention, a storage arrangement is provided with several storage, deposits and removal stations. A transport device is provided, and a transfer device is provided. The transfer device has an actuated transfer plate with a multi-armed station grate. Station grates are provided in stations. Station grates are substantially identical to the multi-armed stationed grate. The grates have counter profiles for penetrating on another such that the transfer grate may be moved into the station grate and can be lifted and lowered through them. All of the grates have arms made from box or U-profile portions which are arranged spaced a distance from one another and parallel to one another in the longitudinal direction. The arms of the transfer grate are equipped with a running gear. The arms are connected to one another by means of a ty-bar or cross arm. The drive of the transfer grate acts on the ty-bar. The arms are provided with a lifting device separate from the drive and a transfer device for use during the transfer movement. The lifting device is provided so that it rolls along a solid floor in the individual stations.
According to an advantageous arrangement of the invention the arms of the transfer grates are cross-connected with regard to one another and are moved together by running gears. The transfer grate gains more stability and cannot cant while moved. The transfer grate rolls on a solid floor in the corrugation-shaped storage grates of the stations and of the transverse devices and can carry heavier loads than known devices. This arrangement is especially of importance when the load, such as a motor vehicle, is supported only by a few of the grate arms. Furthermore, the running gear and the lifting device are separated, which makes for more security during operation under load.
At least three running gears are arranged under the arms of the transfer grates for the achievement of a large carrying capacity.
The invention also allows for a wide range of variations in number and arrangement of the deposit and removal stations. The stations are universally usable due to their identical design and can be used for the deposit or the removal of vehicles according to choice With the arrangement of several of such stations and the optimization of the conveyor system with simultaneous vertical and horizontal movements preferably controlled by a computer the waiting time at the removal station can be minimized considerably.
The preferred embodiments of the storage device optimize the possibilities to adapt and change with regard to the given property situation and adjoining buildings. The parking units can be onestory or multi-story buildings, they can have a round, square or rectangular shape and can be varied accordingly. The module construction system creates the possibility of later changes and a more advantageous cost-effectiveness ratio. It is advantageous for the module construction system that the deposit and the removal station are identical.
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 obtained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments o the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front view of a parking device with several stations and a transport device for depositing, parking and removal of vehicles or items;
FIG. 2 is a top view of a parking device with several stations and a transport device for the depositing, parking, and removal of vehicles or items;
FIG. 3 is a top view of a transfer means;
FIG. 4 is a top view of a transfer means;
FIG. 5 is a top view of a transfer means;
FIG. 6 is a side view showing a vehicle in a position to be lifted;
FIG. 7 is a side view of the transfer plate in FIG. 6 showing the vehicle in a lifted position;
FIG. 8 is a cross sectional enlarged detail view o the transfer plate of FIG. 6;
FIG. 9 is a cross sectional enlarged detail view of a version of the transfer plate of FIG. 7;
FIG. 10 is a front view of a transfer plate;
FIG. 11 is a top view of a transfer plate variation according to FIGS. 8 and 9 at a first stage of the operation;
FIG. 12 is a top view of the transfer plate variation according to FIGS. 8 and 9 at a second stage of the operation;
FIG. 13 is a diagrammatical representation explaining the transfer process;
FIG. 14 is a detailed front view of the upper part of the central column of the transport device, shown in partial cross section according to FIG. 18;
FIG. 15 is a detailed top view of a sleeve or bushing of the central column of the transport device, according to embodiment of FIG. 18.
FIG. 16 is a front view of the central column of the transport device, showing center pieces used for the possible extension of the central column, according to the embodiment of FIG. 18;
FIG. 17 is a detailed front view of the lower part of the central column of the transport shown in partial cross-section, according to the embodiment of FIG. 18;
FIG. 18 is a front view of the sleeve or bushing of the transport device according to the embodiment of FIG. 18;
FIG. 19 is a detailed top view of the sleeve or bushing of the transport means according to the embodiment of FIG. 18;
FIG. 20 is a top view showing the running gear of the transport boxes according to the embodiments of FIGS. 18 and 19;
FIG. 21 is a side view showing the running gear arrangement of the embodiment according to FIGS. 18 and 19;
FIG. 22 is a front view of the running gear and transport box arrangement of the embodiment of FIGS. 18 and 19;
FIG. 33 is a front cross sectional view showing the details of the running gear arrangement;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1, 14 and 18 show the front view of a parking device 1 with several storage stations 3 to which the vehicles deposited at one or more deposit stations 4 are moved through a transport device 2 with a transfer device 6. The vehicle is removed through the inverse process and is picked up at the removal stations 5. In the embodiment according to the FIGS. 1, 2 and 18, 19 the parking device 1 has the shape of an essentially cylindrical tower, wherein the equally spread stations 3, 4, 5 surround the central transport device in an annular arrangement. In FIGS. 1 and 2 the stations 3 are superposed in several separate levels, the transport device 2 for the distribution of the vehicles executing rotating movements as well as lifting and lowering movements. In the embodiment shown in FIGS. 18 and 19 the stations 3, 4, 5 are arranged on a continuous level turning upward in a helical or spiral form. The transport device 2 also executes rotating movements as well as lifting and lowering movements, but due to the helical path they are coupled. In FIGS. 1 and 2 the movements are independent of each other.
FIG. 14 shows a parking device 1 with a linear arrangement of the stations 3, 4, 5 in one or several rows above and/or next to one another. Accordingly the transport device 2 executes linear sliding movements and/or lifting and lowering movements. Herein a row of stations 3, 4, 5 may be arranged on both sides of the transport device 2 (see FIG. 17).
In all embodiments the transport means 2 comprises a conveyor means 8 with one or several transport boxes 7, in which the vehicles are moved forward and backward between the stations 3, 4, 5. By means of a transfer device 6 the vehicles are transferred to the stations, resp. removed from them.
The transfer device 6, according to the FIGS. 3 to 13, consists of one or several transfer plates 13 with profiled transfer grates 14 and of corresponding station grates 15 in the various stations 3, 4, 5. The vehicles stand on the transfer grates 14 and the station grates 15. The design of the station grates 15 is identical in all stations 3, 4, 5, so that the deposit stations 4 may also be used as removal stations 5 and reverse. The transfer plates 13 are usually allocated to the transport boxes 7, each of transfer plates having its own transport box.
In the shown embodiments the transfer grates 14 and the station grates 15 have the shape of multi-armed grates with complementary profilings. In addition the grates 14, 15 are open at least to one side, so that the transfer grates can enter the station grates 15 in vertical direction. The grates 14, 15 can also slide into one another in their longitudinal direction.
Before the description of design details the function of the transfer device 6 will be explained on the basis of FIG. 13. For the removal of a vehicle from a station 3, 4, 5 the transport box 7 with the transfer plate 13 is positioned opposite the station. The transfer plate 13 with its transfer grate 14 is moved into or under the station grate 15. During the following lifting movement the transfer grate 14 goes through the station grate 15, slides under the vehicle wheels and lifts it off the station grate 15. Then the transfer plate 13 with the lifted transfer grate 14 is moved back onto the transport box 7 and lowered if necessary. The procedure is reversed when the vehicle is deposited in the station. The transfer plate 13 with the lifted vehicle is moved into the station. Then the transfer grate 14 is lowered through the station grate 15, so that the vehicle stands on the latter. Once the transfer plate 13 is withdrawn, the transfer process is completed and the transport box 7 can be moved to a different station to pick up another vehicle.
The transfer device 6 has corrugation-shaped grates 14, 15. The grate arms 54 are arranged parallel to one another spaced a distance to one another and parallel to one another in the longitudinal direction of the sliding movement. The grate arms consist of box-section or U-section of steel 51, 52. For the station grate 15 the grate profiles 52 are set on a solid and continuous floor 11 A larger space is left in the middle than between the other grate profiles 52.
Other than the grate 14 the transfer plate 13 also has a traversing mechanism 16 and a lifting device 17 for the grate arms 54 and a drive 19 for the transfer movement. With this design the bottom 12 of the transport box 7 also features a grate 15 corresponding to the grate of the station 3, 4, 5 and which is in alignment in the transfer position of the transport box. The transfer grate 14 is therefore always moved in a rail-like manner, during its homeposition in the transport box 7 as well as during the transfer process.
The drive 19 is in the form of a motor 19 arranged at the end of the transport box 7, which actuates a slide 20 through a spindle 50. The spindle 50 extends inside and along the widened central groove of the grate 15. The slide is engaged with a traverse at the rear end of the lifting device 17 through a peg guide 21. The lifting device 17 connects the freely corbelling out arms 54 of the transfer grate 14 to one another at their backward end.
The movement of the slide 20 is therefore transformed into a linear transfer movement of the grate 14. The size of the deposit surface available for a vehicle is determined by the length of the transfer grate 14, which is a little shorter than the length of the two grates 15 for a complete transfer. The transfer grate does also have an enlarged space in the middle.
Below the U-shaped profiles 51 of the transfer grate 14 running gears 16 are arranged, by means of which the profiles on the floor 11, 12 roll during the transfer movement in the spaces of the grates 15. In the embodiment according to FIGS. 6 and 7 the running gears 16 comprise a housing 49, here in the shape of a rod, for each roller, which is encroached by the grate profiles 51. The housings 49 are connected to a hydraulic cylinder or another drive of the lifting device 17 through a toggle lever gear 22 and also to the grate profiles through small swivelling levers 51. As shown in FIG. 6, the grate profiles 51 sit on the housing 49 when the lifting device 17 is relaxed, so that their surface is below the surface of the station grates 15. If the lifting device 17 according to FIG. 7 is actuated, the toggle lever gear 22 pulls the housing 49 with the rollers backward with regard to the grate profiles 51, herein the grate profiles 51 are lifted above the level of the station grate 15 through a swivelling movement of the small swivelling levers. Herein also the housing of the lifting device 17 connected to the transfer grate 14 is lifted. The peg guide 21 remains engaged, so that the transfer grate 14 can be moved back onto the transport box 7 by means of the drive 19. The housing of the lifting device 17 has recesses in the area of the arms 54 of the two grates 15, so that it can move over the grates 15 even in its lowered position.
Variations of the shown embodiment are possible by means of kinematic reversal, wherein the lifting device 17 is rigidly connected to the running gear 16 and acts on the grate profiles 51. In the shown embodiments the longitudinal direction of the vehicles coincides with the transfer direction, resp. the longitudinal direction of the grates 14, 15. However, the vehicles can also be arranged at a right angle with regard to the longitudinal direction of the transfer and grate direction. Then the grates are shorter and wider. This version allows for shorter transfer distances.
FIGS. 8 and 9 show a variation with regard to the running gears 16 and the lifting device 17. The running gear groups, of which three are arranged under each profile 51 (see FIG. 11), have a box-shaped housing 49, which is encroached by U-shaped profiles 51. At the ends of the housing 49 angle modules with open tops are arranged, in which rectangular hydraulic cylinders 45 of the lifting device 17 are fitted with adequate play. On the outside two catch webs 46 are arranged for the guidance and limitation of the lifting movement. The profiles 51 are screwed together with the outer part of the hydraulic cylinders 45 on the outside of the latter with countersunk screws to reduce the spreading forces on the U-shaped profiles 51 under extreme loads. Through the hydraulic cylinders 45 and the angle modules the running gears 16, too, are led into the longitudinal direction relative to the grate profiles 51. Hydraulic lines 47 for the pressure supply of the cylinders 45 are arranged in the longitudinal direction between the housing 49 and the grate profiles 51. The lines 47 are prevented from being crushed by distance blocks arranged near the cylinders, which also reduce the vibration forces in the lowered position of the grate profiles 51. Upon operation of the hydraulic cylinders 45 the transfer grate 14 is lifted. Herein the multitude of cylinders can generate extreme lifting power.
The profile grates 51 are connected on the back by means of a traverse, which serves at the same time as a slide 20 for the transfer drive 19 (see FIG. 11). The slide 20 is engaged with a spindle 50. The slide 20 also comprises the central hydraulic supply and distribution for each cylinder 45. FIG. 10 shows the arrangement described above in front view, while FIGS. 11 and 12 are top views in operation and in a home position.
The transfer device 6 transfers the vehicle while it is standing, and it does not require any exact positioning in the deposit station 4. During the transport the vehicle can neither tip nor roll nor change its position in any other way. The partition of the grates 14, 15 in the embodiments 3 to 12 is chosen so that a safe position of the vehicle wheels is guaranteed at all times during the transfer from one grate to the other.
FIG. 14 shows a parking unit 1 in front view with deposit and/or removal stations 4, 5, which have the same width and length as a double storage station 3. Therefore the stations 3, 4, 5 form modules which can be combined at will in a unit construction system and a corresponding transport device. In FIG. 15 this arrangement is shown in top view for a single-row parking unit 1, while FIG. 17 shows a double-row parking unit 1 with a transfer device 6 working on both sides. Due to the large deposit and removal stations even inexperienced drivers have no problem to drive the vehicle in any position onto the deposit area determined by the size of the grate in the deposit station 4. The passengers can get out of the car easily and leave the station by means of foot paths arranged on both sides. The removal station 5 is built in the same way. The stations 4, 5 can be used for depositing a car as well as for picking it up. Therefore, all stations can be used at all times according to the requirements.
The stations 3, 4, 5 and the transport device 2 with transfer device 6 can be installed in a stationary building or they can be executed as a steel construction in a unit construction system. Such parking units 1 according to FIGS. 14 to 17 can be extended at will in width or height and they also allow for a volume extension by transformation from a single-row arrangement to a double-row arrangement according to FIG. 17. The cylinder tower according to FIGS. 18 and 19 can also be extended in height by additions. The parking units 1 with their various parts are controlled by a central computer, which manages the deposit stations 3 and which moves the transport device 2 with the transport boxes 7 correspondingly.
The conveyor device 8 of the parking unit 1 of FIGS. 1 and 2 consists of a tower-shaped frame 9, which is lowered in the ground and mounted rotatably on a bearing ring (turntable) 25. Its rotation is effected by a drive 26. Four lifting devices or elevators 10 are arranged crosswise in the frame 9, which move two-story transport boxes 7 up and down. Herein each transport box comprises its own transfer device 6, so that 8 vehicles can be stored or picked up simultaneously. Even with a breakdown of single components the device can still be operated. It offers optimal access time as various lifting and rotating movements of the transport device 2 can be effected at the same time. On the first floor a smaller or larger number of deposit and storage stations 4, 5 can be arranged depending on the traffic and the desired access time. These can be defined as deposit stations or removal stations or can be used as required. A barrier bars the entrance and opens for the vehicle only once a transport box is ready for its reception. The two-story transport boxes 7 are loaded and unloaded in two steps, the box being lowered or lifted in the process. It is also possible to provide entrances and exits 4, 5 on two stories or even more in correspondence with the transport boxes 7 and therefore to load all transport boxes 7 simultaneously. During the following transport cycle the frame 9 rotates, and at the same time the transport boxes 7 are lifted to the desired height. A computer-supported and optimized management allows for the loading of all transport boxes 7 at the storage stations 3 in a single cycle and during the next cycle a complete transfer at the entrances and exits 4, 5.
The embodiments according to FIGS. 14 to 17 differ from the above mainly in their linear arrangement, wherein the frame 9 consists mainly of one or several towers arranged adjacent to one another, which operate either separately or they are connected through running gear arrangements or longitudinal drives 25' along a row of stations. The conveyor device 8 can also be a scissor-type lift, which is economical and sensible especially for separate superimposed modules.
In the example according to the FIGS. 27 and 29 the frame 9 comprises a hollow central column 27, which is rotated by means of a hydraulic drive 26 or such like. Here the lifting device has the shape of a sleeve or bushing 28, on which four transport boxes 7 in the shape of platforms are mounted offset with regard to one another by a quarter of the spiral height of a 360° segment. The transport boxes 7 are connected to one another by means of supporting stays (see FIG. 29). The central column 27 and the sleeve 28 have a rectangular or a square cross section, the sleeve 28 being mounted longitudinally movable on the central column through roller bearings 29 and guided rotatably. The transport boxes 7 have running gears 39 at their free ends, by means of which they are supported on a helical guide rail 37. With a rotating movement of the central column 27 the sleeve 2 and its transport boxes 7 are moved up or down in a spiralling line. The storage stations 3 are arranged adjacent to one another in steps along the spiralling line. Herein the next story is reached after 360°.
FIGS. 20 to 22 show the storage stations 3 in module construction. Between annularly arranged vertical stays 32 traverses 35 are mounted (compare FIGS. 18 and 19). The inner stays 33 arranged in an inner ring are connected to one another in the same fashion. Stiffness in radial direction is achieved by diagonal traverses 34 between neighboring stays 32, 33. The floor 11 with the station grate 15 rests on the traverses 35. It protrudes a little over the stays 33 and is mounted on radial support flanges 36 at its end. The support flanges also carry the helical guide rail 37, which runs at an angle with regard to the horizontal station grates 15 (FIG. 23). As FIG. 29 shows, the ends of the grates 14, 15 are bevelled in correspondence with the guide rail 37 for an accurate transition.
The shown steel construction with the module construction system for the stations 3, 4, 5 allows for an extension of the parking unit 1 at will. The central column 27 is designed in several parts accordingly. The upper part shown in FIG. 23 has arms 38, over which the hydraulic-, energy supply- and signal lines 30 are led in a loop to the transport boxes 7 with their transfer devices 6. The current- and hydraulic lines 30 are led up from the bottom along the central column 27 on its outside and are encroached by the respective roller bearings 29 in the area of the sleeve 28. The sensitive signal lines 30 ar led through the inside of the column 27 and only in the head part are they led out through the arms 38. The bottom part of the column 27 shown in FIG. 26 has a toothed gear for the connection with the drive 26. The lines 30 on the outside are led into the interior of the central column 2 by means of a ring coupling 31 and through elastic line parts to a stationary supply point. For the adjustment of any column height center pieces are provided according to FIG. 25, which are coupled with the other column parts by means of a plug connection. Respective couplings can be provided for the lines 30.
FIGS. 30 to 32 show the running gear 39, with which the transport boxes 7 are guided on the guide rail 37. The running gear 39 comprises two rollers 40 encroaching the guide rail form-lockingly, which are mounted on a connecting rod 41 with a C-shaped cross section and bent according to the guide rail 37. The connecting rod 41 is connected to the C-flange of a bearing rod or mounting bar through a vertical kingpin 42 (see FIG. 32) which is clamped by a pressure spring. The bearing rod 44 is longitudinally movable and rotatable in a guide sleeve 43, which is flanged centrally onto the bottom 12 of the transport boxes 7. The running gear 39 does therefore represent a 4-way suspension, which features several degrees of freedom due to the rotation and sliding of the bearing rod 44, the spring-biassed height offset of the connecting rod 41 at the kingpin 42 as well as the rotation around the kingpin 42. Herein irregularities in the helical path of the guide rail 37 can be compensated for, which may be caused by constructive tolerances, dirt accumulation, wind, temperature changes etc.
While specific embodiments of the invention have been shown and 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. | A storage device for automatic storage of items such as vehicles including a deposit station and removal station. A plurality of storage stations are provided having a deposit and a removal opening. A transport device is provided for transporting the item from adjacent the deposit station to adjacent one of the plurality of storage stations. The transport device also takes the item from adjacent the storage station to adjacent the removal station. A transfer device is provided for transferring the items from the transport device to the storage stations. The transfer device includes a transfer grate having parallel grate arms connected to each other by a ty-bar, a lifting mechanism connected to the grate arms and a transversing mechanism including running gears for moving the transfer grate horizontally. The storage stations each have cooperating storage grates which have cooperating counter profiles for engagement with the transfer grates such that grate arms of the transfer grate fit in between the grate arms of the storage grate. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the production of multifilament yarns from synthetic polymers and more particularly to a unique process for drawing and orienting the yarns.
2. Description of the Related Art
Most fiber-forming polymers are relatively weak after they are extruded from a spinneret and cooled to form filaments. Thus, the filaments must usually be extended, or drawn, to develop optimum physical properties. This hot or cold stretching of the filaments helps to align and arrange the crystalline structure of the molecules and improves the yarn's tensile properties. A draw ratio for the multifilament yarns can be obtained by measuring the yarn's final length to original length per unit weight of yarn. During the drawing process, it is known to impinge hot air or steam on thermoplastic multifilament yarns in order to localize the draw point, reduce drawing tension, and reduce the coefficient of denier variation in the drawn products.
For example, Pitzl, U.S. Pat. No. 3,303,169 and U.S. Pat. No. 3,452,130, discloses nylon polyamide yarns and a hot fluid process for drawing them, and Pitzl, U.S. Pat. No. 3,452,132, discloses a similar process applied to polyester. Roberts et al., U.S. Pat. No. 3,048,467, concerns steam-drawing of polyolefins, particularly polyethylene and polypropylene. Bierbaum et al., U.S. Pat. No. 3,413,397, discloses steam-drawing and heat-setting of polypropylene which may be pigmented. The aforementioned references disclose other benefits of hot jet drawing, such as higher fiber tenacity, higher draw ratios, fewer broken filaments, and reduction of fiber shrinkage in boiling water. However, the benefits of hot fluid-drawing are considered economically insufficient to justify the cost on most polyamide and polyolefin production lines; as a result, hot fluid-drawing is normally used only on polyester.
A property of drawable polymeric filaments which is critically important in determining the optimum drawing conditions is the Natural Draw Ratio (NDR), described in greater detail below.
Generally, if the yarn is machine drawn at a draw ratio below the NDR of the yarn, there will be denier variation along the length of each filament, with corresponding segments of thick and thin diameter. The incompletely drawn sections of larger diameter will tend to dye darker than the more completely drawn material. The incompletely drawn sections will also appear darker if the yarns are pigmented.
Generally, if the yarn is machine drawn at a draw ratio above the NDR of the yarn, there will be less denier variation. The diameter along the length of a filament in such a yarn tends to be more uniform and there is increased fiber tenacity. Thus, it has been found that the optimum Machine Draw Ratio (MDR) for a yarn usually lies about 5-20% above its NDR. However, in some cases, it is very difficult to machine draw the yarns at such a draw ratio, because the yarns have very high NDRs. For example, the natural draw ratio for certain solution dyed nylon 66 yarns may be about 3.35:1 and possibly even greater, but the machine draw ratio for such yarns is typically set at about 2.8:1. If an attempt is made to draw such a yarn at a draw ratio 5-20% above its NDR, the process becomes inoperable with frequent filament breaks, resulting in an unacceptable product.
The present invention provides a process for drawing yarns having a natural draw ratio greater than the machine draw ratio used in the process.
Another difficult problem arises when two or more spun, but undrawn yarns, having different NDRs must be drawn on a single set of feed and draw rolls at a single machine draw ratio which is unlikely to be optimum for all of the yarns. For example, one of the yarns may have a NDR greater than the machine draw ratio and the other yarn may have a NDR less than the machine draw ratio. In other instances, both of the yarns may have different NDRs, but each is greater than the machine draw ratio.
In particular, the natural draw ratio for a yarn usually varies directly with the viscosity of the polymer and inversely with the degree of any copolymerization. Both of these factors are well known and controlled in the processing of conventional polymeric yarns. The addition of titanium dioxide as a delustrant raises the NDR, but the small amount usually employed (0.05-0.30 weight percent) has only a slight effect. Therefore, variation of the NDR has not been a serious problem in the past. More recently, larger amounts, such as 1 to 4 weight percent (wt. %), of color concentrates which include pigments and various other additives, such as UV stabilizers, antioxidants, delustrants, etc. have been incorporated into fiber-forming polymers. These color concentrates have been initially added to polyolefin polymers, since these polymers do not normally accept conventional dyes.
For example, a manufacturer of polypropylene carpet yarns has to supply its customers with a wide range of colors, some of which must be specially prepared on short notice. Pigmented polypropylene typically has a NDR of about 2.7:1 to 3.9:1. However, as shown in greater detail below, the different colorants and polymeric components of color concentrates can drastically change the NDR of the spun filaments in unpredictable directions. Thus, the optimum spinning and drawing conditions for each new color must be determined by a time-consuming and tedious process.
The drawing of solution dyed nylon carpet yarns also presents difficulties. For example, there are problems with drawing dark plum nylon yarns and light wheat nylon yarns over the same set of feed and draw rolls at a single draw ratio, because of the different natural draw ratios for the yarns. Furthermore, the dark plum nylon yarns have a higher NDR than the machine draw ratio typically used in the process.
Two references which disclose processes for drawing two or more yarns on the same set of rolls are Borenstein et al., U.S. Pat. No. 31,783, and Hatcher, U.S. Pat. No. 4,012,816, although there is no indication that the feed yarns used in these processes differ in any way.
The present invention provides a process, where two or more undrawn yarns having different natural draw ratios, at least one of which is greater than the machine draw ratio, are drawn on a single set of feed and draw rolls at a single machine draw ratio.
SUMMARY OF THE INVENTION
The present invention provides a process for drawing a multifilament thermoplastic yarn having a natural draw ratio (NDR) greater than the machine draw ratio used in the process. The invention also includes a process for drawing a plurality of thermoplastic multifilament yarns having different natural draw ratios, at least one of which has a natural draw ratio greater than the machine draw ratio.
This process involves impinging high velocity hot fluid on the undrawn filaments to separate them and to heat them rapidly as the yarns progress from a lower-speed feed roll to a higher-speed draw roll. The fluid may be air or, more preferably, steam. The steam is either saturated or superheated.
In one embodiment, at least two of the yarns are of a different color. Preferably, either polyamide or polypropylene yarns are used. The yarns may contain about 1 to 4 weight percent of a color concentrate. The color concentrate may be composed of pigments and various other additives such as, UV stabilizers, antioxidants, delustrants, etc. The undrawn polypropylene and polyamide yarns generally have a natural draw ratio of about 2.7:1 to 3.9:1 and are spun at about 500-700 yards per minute (ypm). The machine draw ratio is generally in the range of about 2.6:1 to 3.3:1.
The invention further includes a process comprising feeding the multifilament feed yarns substantially in parallel over the same feed roll(s) and through a device where high velocity hot fluid is impinged on them to separate the filaments and to heat them rapidly, passing the yarns substantially in parallel over the same draw roll(s), and winding them up either together on a single package or on separate packages.
The feed roll and/or draw rolls may be heated. Furthermore, the process may additionally include the steps of passing the yarns from heated draw rolls through a hot fluid jet bulking device where the filaments are crimped individually to produce random three-dimensional curvilinear crimp, cooling the crimped filaments at low tension, and then entangling the filaments of the component yarns under higher controlled tension before winding them together on a single package.
The invention also encompasses yarns made by the process of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows stress-strain diagrams of three pigmented polypropylene filament species, pointing out Natural Draw Ratios and other characteristics.
FIG. 2 is a schematic drawing of the process of this invention.
FIG. 3A is a schematic drawing of individual polypropylene filaments of Comparative Example 2 mounted on a card. The yarns composed of these filaments were drawn without steam.
FIG. 3B is a schematic drawing of individual polypropylene filaments of Example 3 mounted on a card. The yarns composed of these filaments were drawn with steam.
FIG. 4A is a schematic drawing of individual nylon filaments of Example 5 mounted on a card. The yarns composed of these filaments were drawn without steam.
FIG. 4B is a schematic drawing of individual nylon filaments of Example 5 mounted on a card. The yarns composed of these filaments were drawn with steam.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a process for drawing a multifilament yarn having a natural draw ratio (NDR) greater than the machine draw ratio (MDR) used in the process. The invention also includes a process for drawing a plurality of yarns having different natural draw ratios, at least one of which has a natural draw ratio greater than the machine draw ratio.
By the term, "natural draw ratio (NDR)", as used herein, it is meant the ratio of a yarn's final length to original length per unit weight of yarn, as determined by the "Testing Methods", described below. The polypropylene and polyamide yarns in the present invention generally have a natural draw ratio of about 2.7:1 to 3.9:1.
By the term, "machine draw ratio (MDR)", as used herein, it is meant the ratio of a yarn's final length to original length per unit weight of yarn as predetermined by the feed roll speed, draw roll speed, and other known conditions in the drawing process. Those skilled in the art are familiar with setting the machine draw ratio. In the present invention, the machine draw ratio is generally in the range of about 2.6:1 to 3.3:1.
The process of this invention is illustrated in FIG. 2, where two or more undrawn or partially drawn yarns (1), (2) and (3), at least one of which differs from the others in NDR and at least one of which has a NDR greater than the machine draw ratio, are taken from their respective supply packages (4), (5) and (6), brought together at guide (7), and progress in parallel to and around feed roll (8) and its associated separator roll (9). If feed roll (8) is heated, it is preferably surrounded by an enclosure (10). Since the yarns are under a high degree of tension in the subsequent drawing zone, they may occasionally slip off rolls (8) and (9). Thus, an additional set of predraw rolls (11) and (12), running at a lower speed than rolls (8) and (9), is provided to prevent slippage of the yarns. The arrangement of these predraw rolls (11) and (12) assists in obtaining a high level of uniformity in the drawing operation.
The yarns then enter draw jet (13) supplied with hot fluid, preferably steam, from a source (not shown). The highly pressurized hot fluid is forced through a narrow passage of the draw jet and is impinged at a high velocity onto the filaments to separate them. The hot fluid rapidly heats the filaments and initiates drawing of them within the jet device. The yarns then contact draw rolls (14) and (15) running several times faster than feed roll (8). These rolls (14) and (15) are preferably heated to reduce the shrinkage of the drawn yarns and/or to preheat them for subsequent bulking. Enclosure (16) is optionally provided. A bulking device (17) supplied with hot fluid from a source (not shown) may be of the type which forms an accumulation of hot crimped filaments, such as the device described in Burkhardt et al., U.S. Pat. No. 4,691,947. Subsequently, the hot or partially cooled yarns are removed by metering roll (18) and deposited at low tension on drum (19), where ambient air is drawn through the yarns by suction within the drum to complete the cooling. Alternatively, the bulking device (17) may be of the type described in Coon, U.S. Pat. No. 3,525,134, in which case, the hot crimped yarns are deposited directly on drum (19).
When the component yarns are to be entangled together to form a larger coherent bundle, they pass through entangling jet (21) which may be of a type shown in Nelson, U.S. Pat. No. 4,505,013. In such a jet (21), high velocity fluid intermingles the filaments to provide cohesion and color blending if the component yarns are of different color or dyeability. The tension of yarns undergoing the entangling process is carefully controlled by the speeds of rolls (20) and (22). The combined yarns then pass through optional finish applicator (23) and to wind-up (24), where it is wound on package (25).
In the process of the present invention, it is preferable to employ draw jet devices of the type shown in the above-mentioned Pitzl patents which heat the filaments rapidly and localize the draw point in contrast to the long steam chambers described in the Roberts et al. and Bierbaum et al. patents.
The difference in uniformity of crimp between yarns treated by the process of this invention versus yarns treated by a conventional process can be seen in FIGS. 3A and 3B.
FIG. 3A shows polypropylene filaments having a NDR greater than the machine draw ratio and which have been crimped by the process illustrated in FIG. 2, except these filaments did not enter the hot fluid draw jet (13) and were not subjected to hot fluid during the drawing phase. The filaments have been extracted carefully from the entangled yarns and have been attached to a transparent surface under just enough tension to straighten their centerlines without significantly diminishing their crimp. Since the filaments contain a deep blue pigment, regions of larger transverse dimension due to incomplete drawing are easily seen. These regions, indicated by (E) also have fewer crimps due to the difficulty of crimping the larger diameter portions of the filament.
FIG. 3B shows polypropylene filaments having a NDR greater than the machine draw ratio and which have been crimped by the process illustrated in FIG. 2. The yarns were drawn with a hot fluid draw jet using saturated steam at about 139° C. in accordance with the present invention. It can be seen that the filament transverse dimensions are substantially uniform and all regions contain approximately the same degree of crimp.
The yarns used in the process of this invention may be composed of thermoplastic fiber-forming polymers, such as polyamides, e.g., nylon 6 and nylon 66, polyesters, polyolefins, e.g., polypropylene, and polyacrylonitriles. The resulting yarns exhibit a substantially uniform degree of crimp and may be tufted into carpets by techniques known in the art.
TESTING METHODS
Natural Draw Ratio (NDR)
The natural draw ratios for the filaments may be calculated by the method described below. Referring to FIG. 1 showing stress-strain diagrams of three undrawn pigmented polypropylene filaments, as they are extended, stress is shown on the vertical axis in grams and strain is shown on the horizontal axis as draw ratios. Diagram 1 represents a fiber containing Coral color concentrate (3.1 wt. %, Color Index No. 26293-F2); Diagram 2 represents a fiber containing Flint color concentrate (1.92 wt. %, Color Index No. 26063-F2); and Diagram 3 represents a fiber containing Forest color concentrate (1.7 wt. %, Color Index No. 26067-F2).
A one-inch (2.54 cm) sample of undrawn and unheated filament is placed in an Instron tensile tester and extended at the rate of 5 in/min. (0.127 m/min) to at least a draw ratio of 6:1. Stress rises rapidly until yield point (A) is reached, at which time a region of smaller diameter or "neck" forms and the stress drops. In region (B), the filament continues to draw at the neck until the entire sample is of the smaller diameter, at which time the stress equals that of yield point (A). The draw ratio at this point, shown as point (C) on the diagrams, is termed the natural draw ratio for the particular polymer.
The natural draw ratio is also found to be equal to the ratio of the filament's larger diameter before the draw neck to the filament's smaller diameter after the neck in region (B). As drawing continues beyond this point in region (D), the tenacity of the fiber increases as its diameter is further reduced until it breaks. The natural draw ratio, as reported in the following Examples, is the average of the natural draw ratio calculations for 10 filament samples. It can be seen that the three different colored filaments represented by diagrams 1, 2 and 3 have yield points (A) which differ greatly from each other.
The following examples further describe the invention but should not be construed as limiting the scope of the invention.
EXAMPLES
In the following examples, the color concentrates were obtained from Americhem, Inc.® (2038 Main Street, Cuyahoga Falls, Ohio 44221). The color index numbers refer to Americhem identification numbers. The color concentrates used for producing nylon yarns generally contain pigments, nylon 6 polymer, and nylon 6/66/610 terpolymer, and various other additives such as delustrants and antioxidants. The color concentrates used for producing polypropylene yarns generally contain polypropylene polymer and various other additives such as delustrants and antioxidants.
EXAMPLE 1
In this example, the Natural Draw Ratios (NDRs) for various polypropylene yarn samples were determined. Polypropylene pellets having a Melt Flow Rate (MFR) of 15 and an intrinsic viscosity of 1.69 were melted in an extruder at 250° C. A different color concentrate for each yarn sample, as further described below in Samples A-C, was then added to the extruder and blended with the molten polymer to produce fiber-spinnable melts. Each polymer melt was then spun through a 45 hole spinneret into trilobal shaped pigmented filaments having a cross-section modification ratio of 2.9. After exiting from a quench chamber, a finish oil was applied to the undrawn yarns to keep them cohesive. The undrawn yarns were then fed to a wind-up roll where the yarns were wound-up at a rate of 666 yards per minute (ypm). The yarns had a total denier of about 2380 and about 53 denier per filament (dpf).
SAMPLE A
The fiber-spinnable melts for producing yarns of this sample contained about 3.1% by weight of color concentrate, Coral (Color Index No. 26293-F2), available from Americhem, Inc. The stress-strain relationship of these filaments is shown as Diagram 1 in FIG. 1. The Natural Draw Ratio (NDR) of the yarn was 2.76:1.
SAMPLE B
The fiber-spinnable melts for producing yarns of this sample contained about 1.92% by weight of color concentrate, Flint (Color Index No. 26063-F2), available from Americhem, Inc. The stress-strain relationship of these filaments is shown as Diagram 2 in FIG. 1. The NDR of the yarn was 3.29:1.
SAMPLE C
The fiber-spinnable melts for producing yarns of this sample contained about 1.7% by weight of color concentrate, Forest (Color Index No. 26067-F2), available from Americhem, Inc. The stress-strain relationship of these filaments is shown as Diagram 3 in FIG. 1. The NDR of the yarn was 3.68:1.
EXAMPLE 2 (COMPARATIVE)
In this comparative example, undrawn yarns were spun according to the process described in Example 1, but a different color concentrate was used. The fiber-spinnable melts for producing yarns in this sample contained about 1.95% by weight of color concentrate, Midnight Blue (Color Index No. 26358-F2), available from Americhem, Inc. The NDR of the yarn was 3.73:1.
The undrawn yarns were prepared at 600 yards per minute (ypm) spin speeds. The undrawn yarns had a total denier of about 2640 and about 59 denier per filament (dpf).
As shown in FIG. 2, the undrawn yarns were then fed across feed rolls heated at 100° C. and through a drawing zone at a nominal draw speed of 1500 yards per minute (ypm), but the yarns were not treated with a hot fluid while passing through the drawing zone. The Machine Draw Ratio was 3.28:1.
The yarns then passed across draw rolls heated at 140° C., and finally through a bulking jet which impinged the yarns with air heated to 155° C. The highly fluctuating degree of crimp in these filaments can be seen in FIG. 3A.
EXAMPLE 3
In this example, the fiber-spinnable melts for producing the undrawn yarns contained about 1.95% by weight of color concentrate, Midnight Blue (Color Index No. 26358-F2) available from Americhem, Inc., as described in Example 2. The NDR of the yarn was 3.73:1.
The undrawn yarns were prepared at 600 yards per minute (ypm) spin speeds, as described in Comparative Example 2. The undrawn yarns had a total denier of about 2640 and about 59 denier per filament (dpf).
As shown in FIG. 2, the undrawn yarns were then fed across feed rolls heated at 60° C. and through a drawing zone at a nominal draw speed of 1500 yards per minute (ypm), where the yarns entered a hot fluid draw jet. The filaments were impinged with saturated steam at a pressure of 60 psi within the draw jet. The Machine Draw Ratio was 3.28:1.
The yarns then passed across draw rolls heated at 140° C., and finally through a bulking jet which impinged the yarns with air heated to 155° C. The substantially uniform degree of crimp in these filaments can be seen in FIG. 3B.
EXAMPLE 4
In this example, fiber-spinnable melts were prepared according to the procedures described in Example 1, except different color concentrates were used, the polypropylene pellets had a melt flow rate (MFR) of 12, rather than 15, and the pellets were melted in the extruder at 235° C., instead of 250° C.
SAMPLE D
The fiber-spinnable melts for producing yarns of this sample contained about 1.85% by weight of color concentrate, Midnight Blue (Color Index No. 26358-F2), available from Americhem, Inc. The NDR of the yarn sample was 2.95:1.
SAMPLE E
The fiber-spinnable melts for producing yarns of this sample contained about 1.66% by weight of color concentrate, Moonbeam (Color Index No. 26062-F1), available from Americhem, Inc. The NDR of the yarn sample was 2.56:1.
SAMPLE F
The fiber-spinnable melts for producing yarns of this sample contained about 2.85% by weight of color concentrate, Wedgewood (Color Index No. 26060-F1), available from Americhem, Inc. The NDR of the yarn sample was 2.98:1.
Three yarn samples of the above different colors were spun, drawn and crimped by the process shown in FIG. 2 which included passing the yarns through a hot fluid draw jet, where the filaments were impinged with saturated steam. For comparative studies, the yarn samples were also fed through the steps shown in FIG. 2, except the yarns were not treated with a hot fluid while passing through the drawing zone. Referring to FIG. 2, in both of the above-described processes, the yarns were removed from drum (19) without passing through subsequent operations. It was found that the filaments were considerably easier to separate by this method, than if they were entangled by jet (21). The following process conditions were used during the drawing and bulking phases.
TABLE 1______________________________________ Drawing Drawing With Steam Without Steam______________________________________Feed Roll Temp. 60° C. 95° C.Nominal Draw Speed 1250 ypm 1250 ypmMachine Draw Ratio 2.9:1 2.9:1Steam-Draw Jet 60 psi None(Saturated Steam Pressure)Draw Roll Temp. 130° C. 130° C.Bulking Jet Air Temp. 175° C. 175° C.______________________________________
The denier of 5 filaments from each yarn sample (D-F) was measured at 10 places along the length of each filament and the standard deviations (sigma) were calculated for the filaments of yarns drawn with steam and without steam. The results are presented in TABLE 2.
It can be seen that the denier uniformity of all the colored filaments is improved by the use of steam.
TABLE 2______________________________________ Drawing Drawing With Steam Without Steam (Std. Dev.) (Std. Dev.)______________________________________Sample DFilament(Fil.) #1 2.38 6.51Fil. #2 1.74 8.78Fil. #3 2.81 6.25Fil. #4 2.39 6.36Fil. #5 2.34 6.44Sample EFil. #1 1.75 2.15Fil. #2 1.37 2.08Fil. #3 1.55 2.97Fil. #4 1.43 3.56Fil. #5 2.17 2.00Sample FFil. #1 2.83 4.39Fil. #2 2.78 6.23Fil. #3 2.60 3.80Fil. #4 2.43 7.64Fil. #5 2.16 6.47______________________________________
EXAMPLE 5
In this example, undrawn nylon 66 yarns were prepared according to the process conditions shown in TABLE 3.
TABLE 3______________________________________Polymer Base Nylon 66Color Conc. (Color Index No., 27787-F2available from Americhem, Inc.)Color Dark PlumWt. % Color Conc. 1.96Throughput 270 gm/min (2 ends)Feed Roll Speed 500Holes in 2 Ended Spinneret 128Cross-Section of Filament Square Hollow Filament______________________________________
NATURAL DRAW RATIO (NDR) OF UNDRAWN YARNS
The undrawn nylon yarns were extended on an Instron tensile tester, as described under "Testing Methods", and found to have a natural draw ratio (NDR) of 3.35:1.
The nylon yarn samples were drawn and crimped by the process shown in FIG. 2 which included passing the yarns through a hot fluid draw jet, where the filaments were impinged with saturated steam. For comparative studies, the nylon yarn samples were also fed through the process shown in FIG. 2, except the yarns were not treated with a hot fluid while passing through the drawing zone. The following process conditions were used during the drawing and bulking phases.
TABLE 4______________________________________Drawing of Undrawn Yarns______________________________________Feed Roll Speed 700 ypmDraw Roll Speed 1960 ypmMachine Draw Ratio 2.8:1Draw Roll Temperature 180° C.Bulking Jet (psi) 115Bulking Jet Air Temperature 220° C.Saturated Steam Pressure With Steam-Draw 60 psi______________________________________
The appearance of the filaments was visually examined on cards and it was found that filaments drawn without steam exhibited a nonuniform thickness with marked thick and thin sections as shown in FIG. 4A, while the filaments drawn with steam generally exhibited a more uniform thickness, as shown in FIG. 4B. The denier of 5 filaments from each nylon yarn sample (1-5)was measured at 10 places along the length of each filament and the standard deviations (sigma) were calculated for the filaments of yarns drawn with steam and without steam. The results are presented in TABLE 5. It can be seen that the denier uniformity of the filaments is improved by the use of steam.
TABLE 5______________________________________Drawing Without Steam Drawing With SteamFilament Avg. Denier Std. Dev. Avg. Denier Std.Dev.______________________________________#1 21.2 5.64 20.8 4.85#2 24.9 8.22 21.9 7.87#3 22.2 4.37 19.9 3.74#4 21.8 5.34 18.3 3.77#5 25.5 8.63 19.1 2.63Overall 23.1 6.44 20.0 4.57Avg.______________________________________
The natural draw ratio (NDR) of the undrawn nylon yarns was determined to be 3.35:1. Thus, to be fully drawn, the machine set draw ratio should be in excess of 3.35:1. However, at such draw ratios, the drawing process becomes inoperable with many breaks, so a draw ratio of 2.8:1 was used which is typical in the art. It is unusual to find that steam-drawing would yield uniformity of draw even at machine draw ratios lower than NDR. This same phenomenon was observed with polypropylene. | A process for drawing thermoplastic multifilament yarns, wherein the yarns have different natural draw ratios, at least one of which is greater than the machine draw ratio used in the process. The yarns are first impinged with a hot fluid to heat them to an elevated temperature and then stretched over a set of draw rolls at a single machine draw ratio. In a preferred aspect of the invention, the yarns are crimped after stretching. Preferably, the thermoplastic yarns are either polypropylene or polyamide yarns. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/486,834, filed Jul. 11, 2003.
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to the field of cutting tools, particularly to a device and method to cut a control line downhole in a well.
2. Related Art
With the advent of intelligent completions, running multiple control lines downhole along completions equipment is common practice. Unfortunate occurrences sometimes require cutting the downhole tubing to retrieve the completion equipment. In those cases, the control lines can complicate the retrieval operations if the control lines are pulled apart above the tubing cut. Ideally, the control lines are cut below the tubing cut to recover as much of the control lines as possible and leave a clean “fish” downhole.
Prior systems use a “splice sub” in which the control lines are anchored above and below the tubing cutting target length. A tubing cutter such as an Explosive Jet Cutter (EJC) is run to target depth and detonated to cut the tubing. Excess impact from the EJC at least partially cuts the control lines. When the tubing is removed, the control lines, if not completed severed, break at the damaged area, leaving the remaining control line portions in the vicinity of the remaining tubing. The remaining tubing is more easily “fished” if it is clear of control line remnants.
SUMMARY OF INVENTION
The present invention provides for a cutting device and associated method to cut one or more downhole control lines such that the cut ends of the control lines will not interfere with subsequent fishing operations.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an exploded perspective view of a cutting tool constructed in accordance with the present invention.
FIG. 2 shows a cross-sectional view of an eccentric embodiment of the cutting tool of FIG. 1 .
FIG. 3 shows a first sectional view of the cutting tool of FIG. 2 .
FIG. 4 shows a second sectional view of the cutting tool of FIG. 2 .
FIG. 5 shows a cross-sectional view of a concentric embodiment of the cutting tool of FIG. 1 .
FIG. 6 shows a first sectional view of the cutting tool of FIG. 5 .
FIG. 7 shows a second sectional view of the cutting tool of FIG. 5 .
FIG. 8 shows a cross-sectional view of an alternate embodiment of the cutting tool of FIG. 1 in which dual tubing is used.
FIG. 9 shows a sectional view of the cutting tool of FIG. 8 .
FIG. 10 shows a cross-sectional view of an alternate embodiment of the cutting tool of FIG. 1 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a cutting tool 10 comprises four primary components: a mandrel 12 , a cutting sleeve 14 , a housing 16 , and lugs 18 . FIG. 1 also shows a single control line 19 , though the invention is not limited to just one control line. Other figures (e.g., FIGS. 3 and 4 ) show, for example, five control lines 19 . Control line 19 may be, for example, a hydraulic conduit, an electric cable, a fiber optic cable, or a combination of those, as well as other devices manifested as a relatively small diameter longitudinal line. A seal 21 is mounted near the lower end of mandrel 12 and serves to prevent the upward invasion of dust and debris.
In FIG. 1 , housing 16 is shown retracted from its operational configuration to expose the underlying components. Housing 16 normally encloses mandrel 12 and sleeve 14 . Mandrel 12 provides a tubing cutting target 20 and carries a cutting base 22 near its lower end below target 20 . Base 22 can be integral to mandrel 12 or can be made as a separate component and attached to mandrel 12 . Mandrel 12 mounts at its upper end to an upper end of housing 16 , and at its lower end to a lower portion of a tubing 24 . Housing 16 attaches at its upper end to an upper portion of tubing 24 . Tubing 24 , housing 16 , and mandrel 12 , when so assembled, form a continuous passageway for fluid flow.
Sleeve 14 is carried on the lower end of mandrel 12 and can move in both rotation and translation relative to mandrel 12 and base 22 . The relative motion provides a cutting action. Base 22 and sleeve 14 have mating helical surfaces 28 and each has a longitudinal passageway through its respective sidewall to accommodate control line 19 . Those passageways are initially aligned. Axial holes 31 in mandrel 12 and axial holes 33 in base 22 of FIG. 1 show the passageway openings accommodating control line 19 .
Lugs 18 are carried in slots 26 of sleeve 14 and placed in sliding engagement with the lower end of mandrel 12 . Lugs 18 extend into a groove 29 in the inner surface of housing 16 , linking sleeve 14 to housing 16 while permitting sleeve 14 to rotate relative to housing 16 . A recess 35 in mandrel 12 allows lugs 18 to disengage from housing 16 upon sufficient displacement of sleeve 14 .
In operation, a tubing cutter 34 such as an explosive jet cutter is placed in the vicinity of tubing cutting target 20 . The cutter 34 is actuated to sever mandrel 12 somewhere along the length of target 20 . Once mandrel 12 is severed, the upper portion of tubing 24 is pulled upward by the operator. Because housing 16 is attached to the upper portion of tubing 24 , housing 16 is pulled upward as well. Since lugs 18 extend into groove 29 of housing 16 , sleeve 14 is also pulled upward. Thus, housing 16 provides a mechanical link between the upper portion of tubing 24 (that has now been severed from the lower portion of tubing 24 ) and cutting sleeve 14 to generate the relative motion required for cutting control line 19 .
Helical surfaces 28 between sleeve 14 and cutting base 22 cause sleeve 14 to rotate relative to base 22 when sleeve 14 is pulled upward. The rotational motion advances the cutting edge of sleeve 14 through control line 19 , thereby cutting control line 19 . With sufficient upward travel of cutting sleeve 14 , lugs 18 encounter and retract into recess 35 in mandrel 12 to release housing 16 .
Once housing 16 is released, the upper portion of tubing 24 , along with housing 16 and the upper portion of (severed) mandrel 12 can all be removed from the well. The newly cut end of the upper portion of control line 19 is enclosed inside housing 16 during retrieval. The severed end of the lower portion of control line 19 left in the well is enclosed inside sleeve 14 . The lower portion of tubing 24 remains in the well and the uppermost end of the severed lower portion of mandrel 12 is clear of control lines 19 . Preferably the severed end of mandrel 12 is beveled to allow for easy overshoot. Additionally, the outside diameter of sleeve 14 is preferably small enough to be swallowed up (i.e., enclosed and captured), for example, by a burner mill. This allows for removal of the remaining portion of the completion assembly from the well.
FIGS. 2–4 show an embodiment of cutting tool 10 in which the elements are eccentrically aligned. The eccentric design accommodates more or larger control lines 19 .
FIGS. 5–7 show an embodiment of cutting tool 10 in which the elements are concentrically aligned. When requirements permit, a concentric design allows for simpler manufacture.
FIGS. 8–10 show alternative embodiments of cutting tool 10 in which the roles of cutter sleeve 14 and base 22 are reversed. A thrust bearing 36 is placed above cutter sleeve 14 to better allow sleeve 14 to rotate. Base 22 can be integral to mandrel 12 or can be made as a separate component and attached to mandrel 12 . Base 22 and cutter sleeve 14 remain the two arms of the scissors and their helical profiles induce relative rotation between them. They can be manufactured from the same tube to ensure a conformable mating surface. The roles are reversed because the lower portion (base 22 ) is now fixed to mandrel 12 . The upper portion (sleeve 14 ) is now the component that rotates.
FIGS. 8 and 9 show an embodiment in which dual tubing strings are used. Primary string 38 and secondary string 40 mount in a fashion similar to that described above to housing 16 and mandrel 12 . If it becomes necessary to cut control lines 19 , tubing strings 38 , 40 are first cut as before. Gaps in sleeve 14 around string 40 and within housing 16 allow sleeve 14 to rotate, cutting control lines 19 .
FIG. 10 also shows other features such as housing 16 having a channel 41 along its entire length such that housing 16 effectively forms a “C-ring”. That allows control lines 19 to be laid through channel 41 alongside mandrel 12 without regard to alignment holes 31 . Channel 41 in housing 16 is rotated to align with the channels (instead of holes 33 ) in the base 22 and cutter sleeve 14 and control lines 19 are installed through the channels one line at a time. Housing 16 can then be rotated over control lines 19 to protect them from external hazards in the well. To avoid hoop stresses in housing 16 , square threads 42 and square lugs 18 are preferred. Lugs 18 may also need to be spring loaded to insure proper retraction from housing 16 . Base 22 can be restrained by clutch 43 to limit the motion of base 22 to translation only.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words “means for” together with an associated function. | A cutting device cuts one or more downhole control lines such that the cut ends of the one or more control lines will not interfere with subsequent fishing operations. The cutting device comprises a mandrel, a cutting sleeve and a housing supported on a tubing. Movement of the tubing induces relative motion of the cutting sleeve to cut the one or more control lines. | 4 |
RELATED APPLICATIONS AND CLAIM OF PRIORITY
This patent document claims priority to U.S. provisional patent application No. 62/271,488, filed Dec. 28, 2015, the disclosure of which is hereby incorporated by reference in full.
BACKGROUND
The advent of light emitting diode (LED) based luminaires has provided sports arenas, stadiums, other entertainment facilities, and other commercial and industrial facilities the ability to achieve instant on-off capabilities, intelligent controls and adjustability while delivering excellent light quality, consistent light output, and improved energy efficiency. Because of this, users continue to seek improvements in LED lighting devices. For example, new and improved ways to direct light in multiple directions, and to provide luminaires with high light output in a compact package, are desired.
This document describes new illumination devices that are directed to solving the issues described above, and/or other problems.
SUMMARY
In an embodiment, a light fixture includes a body portion with a housing. The housing has an opening at a first end, and a set of light emitting diode (LED) modules. Each LED module includes a circuit board and one or more LEDs, and is positioned within the opening. The housing also includes a sensor cavity in which one or more sensors are positioned, and conduits that provide a sealed path between the LED modules and the sensor cavity. In this way, the circuit boards and LEDs of the LED modules, the conduits and the sensor cavity are configured so that various environmental conditions are maintained at a constant levels within the sealed path. The sensors are configured to monitor the environmental conditions in the sealed path.
Optionally, the housing also includes a circuit board cavity that includes a circuit board with control electronics. If so, the conduits also provide a sealed path between the LED modules, the sensor cavity, and the circuit board cavity. The housing also may include a power supply cavity that contains a power supply, and if so the conduits may also provide a sealed path between the LED modules, the sensor cavity, and the power supply cavity.
Optionally, each LED module includes: one or more lenses, each of which is positioned over a corresponding LED or group of LEDs; a circuit board on which the one or more LEDs are mounted; and a frame that holds the one or more LEDs, lenses and circuit board.
The sensors may include one or more of the following: a pressure sensor, a temperature sensor, a humidity sensor, a chemical substance sensor, a fire sensor, a particulate sensor, a biological agent sensor, a moisture sensor, an air speed detector, or an orientation sensor. The environmental conditions may include one or more of the following: pressure, temperature, humidity, chemical substance presence, or particulate matter presence.
The light fixture also may include a processor in communication with the one or more sensors and a computer-readable medium containing programming instructions. The programming instructions may be configured to cause the processor to receive data corresponding to the environmental conditions from the one or more sensors, and analyze the data to determine if at least one of the environmental conditions has undergone one or more of the following: (i) a change so that a value of the at least one environmental condition exceeds a threshold level; (ii) a threshold change compared to corresponding constant level; (iii) or a rate of change that is greater than a threshold value. In response to detecting a change that exceeds the threshold level, the threshold change or the rate of change that is greater than the threshold value, the processor may cause the light fixture to execute a corrective measure and/or generate an alert. Examples of corrective measures include, but are not limited to, shutting off power to one of the LED modules of the light fixture, shutting off power to all of the LED modules of the light fixture, or causing a motor to adjust an orientation of the light fixture.
In an embodiment, the light fixture includes a processor in communication with the one or more sensors, and a computer-readable medium containing programming instructions that are configured to cause the processor to turn off one or more of the LED modules upon receipt of data from the one or more sensors indicating that an air pressure level or humidity level within the sealed path has risen above an upper threshold level.
In an embodiment, the light fixture includes: a vent; a processor in communication with the one or more sensors; and a computer-readable medium containing programming instructions that are configured to cause the processor to open the vent upon receipt of data from the one or more sensors indicating that the air pressure level or humidity level within the sealed path has risen above an upper threshold level.
In an embodiment, the light fixture includes: a pump; a processor in communication with the one or more sensors; and a computer-readable medium containing programming instructions that are configured to, when executed by the processor, cause the fixture to initiate operation of the pump upon receipt of data from the one or more sensors indicating that the air pressure level or humidity level within the sealed path has fallen below a lower threshold level.
In an embodiment, the light fixture includes: a processor in communication with the one or more sensors; a computer-readable medium containing programming instructions that are configured to cause the processor to receive data from the one or more sensors and cause the light fixture to perform a self-diagnostic function; and a transmitter configured to transmit the data from the one or more sensors, an output of the self-diagnostic function, or both to a remote receiver.
In some embodiments, the sensor cavity is positioned proximate a rear end of the body portion that is opposite the opening, and the conduits pass from the opening to the sensor cavity through the body portion. In some embodiments, the body portion comprises a heat sink between the opening and the sensor cavity.
In an embodiment, a method for performing self-diagnosis in a light fixture includes receiving data corresponding to environmental conditions from one or more sensors. The sensors are positioned in a sensor cavity of a light fixture, and a set of conduits provide a sealed path between a group of LED modules of the light fixture and the sensor cavity such that the LED modules. A processor will analyze the data to determine if at least one of the environmental conditions in the sealed path has undergone one or more of the following changes: a change so that a value of the at least one environmental condition exceeds a threshold level; a threshold change compared to a corresponding constant level; or a rate of change that is greater than a threshold value. In response to detecting that at least one of the environmental conditions has undergone at least one of the changes, the method will include automatically implementing a corrective measure in the light fixture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a front view of an example of one embodiment of the illumination devices disclosed in this document.
FIG. 2 provides a perspective view of the device of FIG. 1 .
FIG. 3 illustrates an embodiment of the lighting device, viewed from the rear.
FIG. 4 illustrates a view of the heatsink, as viewed from the opening (front) of the device with the LED modules removed.
FIGS. 5 and 6 illustrate cutaway views of the lighting device of FIG. 1 , showing a pathway between the LED modules and the power supply contained within the heat sink.
FIG. 7 illustrates a flowchart for an example method of performing self-diagnostics in an illumination device of FIG. 1 , according to an embodiment.
DETAILED DESCRIPTION
As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” means “including, but not limited to.”
When used in this document, terms such as “top” and “bottom,” “upper” and “lower”, or “front” and “rear,” are not intended to have absolute orientations but are instead intended to describe relative positions of various components with respect to each other. For example, a first component may be an “upper” component and a second component may be a “lower” component when a light fixture is oriented in a first direction. The relative orientations of the components may be reversed, or the components may be on the same plane, if the orientation of a light fixture that contains the components is changed. The claims are intended to include all orientations of a device containing such components.
“Electronic communication” refers to the ability to transmit data via one or more signals between two or more electronic devices, whether through a wired or wireless network, and whether directly or indirectly via one or more intermediary devices.
When this document uses the term “processor” or “processing device,” unless expressly stated otherwise it is intended to include embodiments that consist of a single data processing device, as well as embodiments that include two or more data processing devices that together perform various steps of a described process.
When this document uses the terms “memory,” “memory device,” “computer-readable memory,” “computer-readable medium,” or “data storage facility,” unless expressly stated otherwise it is intended to include embodiments that consist of a single memory device, embodiments that include two or more memory devices that together store a set of data or instructions, or one or more sectors or other portions of a memory device.
FIG. 1 illustrates a front view of an example of one embodiment of the illumination devices disclosed in this document. FIG. 2 illustrates a view from one side of the device of FIG. 1 , while FIG. 2 provides a perspective view. The illumination device 10 includes a housing 25 that encases various components of a light fixture. As shown in FIG. 1 , the housing 25 includes an opening in which a set of light emitting diode (LED) modules 11 - 15 are secured to form a multi-module LED structure. The LED modules 11 - 15 are positioned to emit light away from the fixture. Each LED module includes a frame that holds a set of LEDs arranged in an array or other configuration. In various embodiments the number of LEDs in each module may be any number that is sufficient to provide a high intensity LED device. Each LED module will also include a substrate on which the LEDs, various conductors and/or electronic devices, and lenses for the LEDs are mounted.
The opening of the housing 25 may be circular, square, or a square with round corners as shown in FIG. 1 , although other shapes are possible. The LED modules 11 - 15 may include five modules as shown, with four of the modules 11 - 14 positioned in a quadrant of the opening and the fifth module 15 positioned in the center as shown. Alternatively, any other number of LED modules, such as one, two, three, four or more LED modules, may be positioned within the opening in any configuration.
The device's housing 25 includes a body portion 27 and an optional shroud portion 29 . The body portion 27 serves as a heat sink that dissipates heat that is generated by the LED modules. The body/heat sink 27 may be formed of aluminum and/or other metal, plastic or other material, and it may include any number of fins 22 a . . . 22 n on the exterior to increase its surface area that will contact a surrounding cooling medium (typically, air). Thus, the body portion 27 or the entire housing 25 may have a bowl shape as shown, the LED modules 11 - 15 may fit within the opening of the bowl, and heat from the LED modules 11 - 15 may be drawn away from the LED modules and dissipated via the fins 22 a . . . 22 n on the exterior of the bowl.
While the LED modules are positioned at the front of body portion 27 , the opposing side of the body portion may be attached to a power supply unit 30 , optionally via a thermal interface plate. The power supply unit 30 may include a battery, solar panel, or circuitry to receive power from an external and/or other internal source. A power supply unit 30 may be positioned at the rear of the body (i.e., at the bottom of the bowl), and the interior of the unit may include wiring or other conductive elements to transfer power and/or control signals from the power supply unit 30 to the LED modules 11 - 15 . The power supply 30 may be positioned at or near the rear of the body as shown, or it may be placed into the housing so that it is flush or substantially flush with the rear of the body 27 , or it may be configured to extend to some point between being flush with the body portion 27 and an extended position. A sensor cavity 32 may be attached to the power supply and/or other part of the device as shown, and it may contain sensors and/or control and communications hardware for sensing parameters of and controlling the device, receiving commands, and transmitting data to remote control devices.
The housing 25 may be formed as a single piece, or it may be formed of two pieces that fit together as in a clamshell-type structure. In a clamshell design, a portion of the interior wall of the clamshell near its opening may include a groove, ridge, or other supporting structure that is configured to receive and secure the LED structure in the opening when the clamshell is closed. In addition, the fins 22 a . . . 22 n may be curved or arced as shown, with the base of each fin's curve/arc positioned proximate the opening/LED modules, and the apex of each fin's curve/arc positioned distal from the opening/LED modules to further help draw heat away from the LED modules. The housing may be attached to a support structure 40 , such as a base or mounting yoke, optionally by one or more connectors 81 . As shown, the connectors 81 may include axles about which the housing and/or support structure may be rotated to enable the light assembly to be positioned to direct light at a desired angle. The light fixture may include or be connected to a motor 82 that, when actuated, causes the housing to rotate about the connectors and adjust an orientation of the lighting device. Other motors may be used in different locations (such as attached to the mounting yoke) to adjust pitch, yaw, or other positional aspects of the lighting device.
The power supply unit 30 may be detachable from remainder of the lighting device's housing 25 so that it can be replaced and/or removed for maintenance without the need to remove the entire device from an installed location, or so that it can be remotely mounted to reduce weight. The power supply unit 30 and/or a portion of the lighting unit housing 25 may include one or more antennae, transceivers or other communication devices 85 that can receive control signals from an external source. For example, the illumination device may include a wireless receiver and an antenna that is configured to receive control signals via a wireless communication protocol. Optionally, a portion of the lighting unit housing 25 or shroud 29 (described below) may be equipped with an attached laser pointer that can be used to identify a distal point in an environment to which the lighting device directs its light. The laser pointer can thus help with installation and alignment of the device to a desired focal point.
FIGS. 1 and 2 show that the device may include a shroud 29 that protects and shields the LED modules 11 - 15 from falling rain and debris, and that may help direct light toward an intended illumination surface. The shroud 29 may have any suitable width so that an upper portion positioned at the top of the housing is wider than a lower portion positioned at the bottom and/or along the sides of the opening of the housing. This may help to reduce the amount of light wasted to the atmosphere by reflecting and redirecting stray light downward to the intended illumination surface. FIG. 2 illustrates that in an embodiment, some or all of the fins 22 a - 22 n of the housing may be contiguous with fin portions 23 a - 23 n that extend across the shroud 29 . With this option, the shroud 29 can also serve as part of the heat sink.
The fins 22 a . . . 22 n may be positioned substantially vertically (i.e., lengthwise from a top portion of the LED array structure and shroud 29 to a bottom portion of the same). Optionally, one or more lateral supports may be interconnected with the fins to provide support to the housing. The lateral supports may be positioned substantially parallel to the axis of the fins, or they may be curved to extend away from the LED structure, or they may be formed of any suitable shape and placed in any position. Each support may connect two or more of the fins. The fins and optional supports form the body portion 27 as a grate, and hot air may rise through the spaces that exist between the fins and supports of the grate. In addition, precipitation may freely fall through the openings of the grate. In addition, any small debris (such dust or bird droppings) that is caught in the grate may be washed away when precipitation next occurs.
FIG. 3 illustrates an embodiment of the lighting device as viewed from the rear. As with the other views, the fins 22 a . . . 22 n may be positioned substantially vertically to form a heat sink. The power supply 30 and sensor cavity 32 may be connected at the rear of the device as shown.
FIG. 4 shows the front of the device with the LED modules removed, to expose a mating surface 41 to which the LED modules are mounted. The mating surface 41 is connected to the fins and has a front surface with a lateral dimension that is parallel to the fins, so that the mating surface substantially fills the opening in front of the lighting device, and the fins extend away from the mating surface toward the rear of the device. In an embodiment, the mating surface and fins may be formed by being cast or molded from a common material, such aluminum, an alloy, or a ceramic material. The mating surface 41 includes a number of landing pads 61 - 65 that corresponds to the number of LED modules. Each landing pad comprises an area of the surface with one or more connectors 43 (such as openings to receive a bolt) that are configured to secure an LED module to the mating surface 41 . Each landing pad also may include one or more openings 51 - 54 that serve as openings to conduits (described below in the discussion of FIGS. 5 and 6 ) that provide a sealed path between the LED modules and other components of the lighting device.
FIG. 5 illustrates a cut-away view of the device 10 , in which the power supply unit 30 is connected to an electronic control board 37 and one or more sensors 39 that are contained in the sensor cavity 32 . Some or all of the LED modules 15 are connected to the housing and also to one or more conduits 48 that provide a sealed path via which wires or other conductors extend between the sensor cavity 32 , power supply 30 and/or control board 37 and the LED modules 15 for delivery of power and/or control signals. In an alternate embodiment, one or more sensors may also be included in the conduit. Each LED module may include a corresponding conduit so that each LED may receive its power and control signals from the control board 37 , and so that the environment within the conduit may be monitored by the sensors 39 in the sensor cavity 32 and/or the conduit. FIG. 6 illustrates a different cutaway section showing how conduits 44 , 46 may lead from LED modules 12 , 13 to a channel that contains the control board 37 . Examples of the one or more sensors may include, without limitation, a pressure sensor (such as barometer), a temperature sensor, a humidity sensor, a chemical substance sensor, a fire sensor, a particulate sensor, a biological agent sensor, a moisture sensor, an air speed detector, a micro-electro-mechanical system type sensor (such as an accelerometer, gyroscope or other orientation sensor, a pressure sensor), or the like.
The conduits 44 , 46 , 48 may be made of aluminum, plastic, or another lightweight, weather-resistant material. The conduits 44 , 46 , 48 are sealed to the LED modules at one end and to the sensor cavity 32 at the other end, and thus provide a sealed path that is sealed to external elements and is airtight and water-resistant. In this way, the desired optimal conditions may be maintained in the conduit (sealed path), such as a constant air pressure, constant temperature, or the like. For example, in an embodiment, the sealed path may be maintained at a pressure of about 0.9 atm to about 1.1 atm. Furthermore, the sensors may be able to monitor the conditions within the sealed path without external influence, which may be used as an indication of the conditions associated with the LED modules and/or the LEDs. For example, the sensors may include a humidity, temperature, and/or pressure sensor positioned to monitor the air pressure, temperature, and/or the humidity within the sealed path. A chemical sensor may be included to detect the presence of one or more particular substances in the sealed path.
In an embodiment, the sensors may be connected directly to or proximate the rear of the LED modules. Alternatively and/or additionally, the sensors may be positioned so that one or more other components, such as the power supply and control board, are also in the sealed path. Because the path is sealed from the external environment, a single pressure sensor, a single temperature sensor, a single humidity sensor, and/or a single chemical sensor may be sufficient to monitor the pressure, temperature, humidity, or chemical substance within the electronics component housing, LED modules, and the intervening conduits.
The components of an illumination device may malfunction if the conditions surrounding the LED modules and/or other components vary from the desired optimal conditions (based on threshold values) and/or change suddenly. For example, humidity or moisture levels above a threshold level may cause short-circuiting, presence of particulates like dust above a threshold level may affect the quality of light, or other similar malfunctions. Alternatively and/or additionally, such changes in the conditions surrounding the LED modules and/or other components may be an indication of currently existing faults in the illumination device. Examples may include, without limitation, a change in temperature may be indicative of a fault with the heat sink of the illumination device which if unchecked may lead to breakdown of the illumination device; a change in pressure may be indicative of cracks or faults in the lens cover of an illumination device; presence of a chemical substance may be indicative of outgassing (such as from windings of an inductive magnetic coil) or of component degradation that can be adversely deposited upon a viewing surface; or the like. Hence, it is important to monitor the conditions surrounding the LED modules and/or other components of an illumination device, detect changes and/or rates of change, perform error corrective steps, and/or generate an alert in response to the detection. Hence, in an embodiment, the lighting device may include software and/or firmware that uses data detected by the sensors to perform a self-diagnostic function to detect changes and/or rates of change, perform corrective steps (such as activating a pump 83 to increase pressure or opening a vent 84 to relieve pressure in the sealed path), and/or generate an alert in response to the detection.
In an embodiment, the illumination device may include a control card and/or a processor that is in electronic communication with the sensor cavity so that it can receive data receive data generated from one or more sensors and process the above data to perform the self-diagnostic function. Alternatively and/or additionally, the processor may transmit the detected data to a remote device and receive instructions to perform some or all of the self-diagnostic functions.
The illumination device may also include a computer-readable medium containing programming instructions that, when executed, cause the illumination device's processor to analyze data received from the sensor cavity to detect changes and/or rates of change, perform error corrective steps and/or generate an alert in response to the detection.
FIG. 7 illustrates a flowchart corresponding to an example method for performing self-diagnostics in an illumination device. As shown in FIG. 7 , a processor may receive 701 sensor data from one or more sensors in the sensor cavity. As discussed above, the sealed cavity may be maintained at the desired optimal conditions such as temperature, pressure, humidity, etc. In an embodiment, one or more sensors in the sensor cavity may monitor the conditions in the sealed cavity and may transmit the monitored data to the processor continuously, at fixed time intervals and/or occurrence of a triggering event. Examples of triggering events may include without limitation, user instructions, turning on and/or off of the illumination device, during manufacturing and quality testing, and occurrence of a fault or the like.
The processor may analyze 702 the received sensor data to detect 703 changes in one or more optimal conditions of a sealed path (i.e., the conduit). In an embodiment, the processor may analyze the received sensor data by comparing the received values for a condition with a threshold range and/or value and detect a change if the received value is above or below a threshold value and/or outside the threshold range. For example, the processor may detect a change if the received pressure value is outside a threshold range of about 0.9 atm to about 1.1 atm. Alternatively and/or additionally, the processor may also analyze the data to detect changes in the conditions of the sealed path by measuring a rate of change of a condition and comparing it to a threshold value. For example, the processor may compare a measured rate to change and determine whether the rate of change is more than a threshold value (i.e., rapid change). The processor may determine the rate of change by analyzing the sensed data over a period of time.
In an embodiment, if the processor detects a change, it may initiate corrective measures 704 to rectify currently existing faults in the illumination device (if the change is caused by a currently existing fault) and/or prevent malfunctioning of one or more components of the illumination device. Corrective measures are actions to change a setting, function, or other physical property of the illumination device in order to enable the illumination device to continue functioning after a fault, or to protect the illumination device and/or nearby devices from potential faults. Examples of corrective measures include, without limitation: (i) activating a switch or otherwise interrupting current to shut off power to the LED module in response to detection of high humidity levels (i.e., a humidity sensor detecting a humidity level above a threshold in the sealed cavity, or a rate of change of the humidity level in the cavity exceeding a threshold) in order to avoid short-circuiting of components while other modules such as communication modules may be kept active; (ii) causing a motor to adjust a position of the device in response to detecting that the device is not property oriented; (iii) opening a vent (which may include a valve) in the sealed cavity to release pressure in the cavity until a threshold pressure is achieved; (iv) activating a pump to increase pressure in the cavity until a threshold pressure is achieved; or other protective actions. In an embodiment, the processor may shut down all LED modules of the illumination device rather than just a single module. In an embodiment, the processor may shut down the illumination device completely until the corrective action is complete.
Alternatively and/or additionally, the processor may also generate alerts 706 upon detection of a change and/or determines that the rate of change is above a threshold value. In an embodiment, the alert may include information relating to a detected change and/or instructions for a user to perform corrective actions. In an embodiment, an alert may also convey information regarding the corrective measures initiated by the processor (if any). In an embodiment, an alert may be associated with a specific pattern that may be configured to provide information about the detected change. For example, rapidly blinking lights may indicate a failure of the heat sink causing a change in temperature of the illumination device, blinking lights at a different rate may be associated with a change in humidity, or the like. In an embodiment, the
One possible corrective measure may include recalibration of air pressure inside the sealed cavity. In this embodiment, the system also may include a pump positioned to increase pressure in the sealed path when activated, and a vent positioned to relieve pressure in the sealed path when open. However, a pump may not be necessary in all embodiments. For example, pressure in the sealed path may be increased simply by heat generated by the LED modules and/or the power supply.
Embodiments that include a pump, the control card or other components may include a storage medium with programming (software and/or firmware) configured to cause a processor to activate the pump upon receipt of a signal from the pressure sensor indicating that the pressure in the sealed path has dropped below a lower threshold level, and to keep the pump running until pressure sensor data indicates that at least the lower threshold level has been restored. The software and/or firmware also may be configured to cause a processor to command the vent to open upon receipt of a signal from the pressure sensor indicating that pressure within the sealed path has risen below an upper threshold level, and to close the vent when the pressure has been relieved so that it has fallen below the upper threshold. The software and/or firmware also may be configured to cause a processor to command the LED modules to dim or turn off when the sensor(s) detect that pressure and/or humidity exceed an upper threshold value, or if at least a threshold amount of a chemical substance is present. The LED modules may remain dimmed or off for a set period of time, or until the sensor(s) detect that pressure and/or humidity and/or chemical substance concentration has dropped below a lower threshold value.
Optionally, the sensor cavity, control board, or other components of the system may be configured to transmit data from the sensor, an output of the self-diagnostic function, or both to a remote receiver. For example, in an embodiment, the illumination device may also include a wireless communication module configured to send and/or receive information to and/or from another device. In an embodiment, the communication module may be electrically connected (such as via an I 2 C communication protocol) to the sensors and may transmit detected data to a remote device. Examples communication methods may include, without limitation, a short-range communications such as near field communication (NFC), Bluetooth or Bluetooth low energy (BLE), ZigBee, radio frequency identification (RFID), LoRa or LoRaWAN, or long range communications such as Wi-Fi, over cellular networks, or the like.
Returning to FIG. 2 , the power supply unit 30 may be detachable from the lighting device's housing 25 so that it can be replaced and/or removed for maintenance without the need to remove the entire device from an installed location, or so that it can be remotely mounted to reduce weight. The power supply unit 30 , sensor cavity 32 and/or a portion of the lighting unit housing 25 may include one or more antennae, transceivers or other communication devices that can receive control signals from an external source. For example, the illumination device may include a wireless receiver and an antenna that is configured to receive control signals via a wireless communication protocol. Optionally, a portion of the lighting unit housing 25 or shroud 29 may be equipped with an attached laser pointer that can be used to identify a distal point in an environment to which the lighting device directs its light. The laser pointer can thus help with installation and alignment of the device to a desired focal point.
The fins 22 a . . . 22 n may be positioned substantially vertically (i.e., lengthwise from a top portion of the LED array structure and shroud 29 to a bottom portion of the same). Optionally, one or more lateral supports may be interconnected with the fins to provide support to the housing. The lateral supports may be positioned substantially parallel to the axis of the fins, or they may be curved to extend away from the LED structure, or they may be formed of any suitable shape and placed in any position. Each support may connect two or more of the fins. In this embodiment shown in FIG. 4 , the fins and optional supports form the body portion 27 as a grate, and hot air may rise through the spaces that exist between the fins and supports of the grate. In addition, precipitation may freely fall through the openings of the grate. In addition, any small debris (such dust or bird droppings) that is caught in the grate may be washed away when precipitation next occurs.
It is intended that the portions of this disclosure describing LED modules and control systems and methods are not limited to the embodiment of the illumination devices disclosed in this document. The LED modules, control systems and control methods may be applied to other LED illumination structures, such as those disclosed in U.S. Patent Application Pub. No. 2014/0334149, titled “High intensity light-emitting diode luminaire assembly” (filed by Nolan et al. and published Nov. 13, 2014), and in U.S. Patent Application Pub. No., 2015/0167937, titled “High intensity LED illumination device” (filed by Casper et al. and published Jun. 18, 2015), the disclosures of which are fully incorporated herein by reference.
The features and functions described above, as well as alternatives, may be combined into many other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments. | A light fixture includes a sealed path between a group of LED modules and a sensor cavity. The light fixture performs self-diagnosis and implements corrective measures upon detection of one or more environmental condition changes in the sealed path. In response to detecting an environmental condition change, the light fixture will automatically implement a corrective measure. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a process for the preparation of silylisocyanates.
Various methods for the preparation of silylisocyanates are known (see, e.g., Houben Weyl, 13/5, page 126 et seq (1979)). According to German Offenlegungsschrift No. 1,965,741, silylisocyanates may be prepared by reacting silylhalides with salts of cyanic acid. Methods employing urea instead of cyanic acid salts have been investigated by J. Goubeau and D. Paulin (see Ber. 93, 111 (1960)). Since urea is not split to give off isocyanic acid until it reaches a temperature of about 130° C. and silylchlorides are already gaseous at this temperature at atmospheric pressure, Goubeau and Paulin were forced to carry out the synthesis reaction under pressure. They found that the reaction of trimethyl silylchloride with urea started at 240° C. and that a maximum yield of trimethyl silylisocyanate (amounting to 65-75% of the theoretical yield) was obtained within 4 to 5 hours if the reaction was carried out at 300°±20° C. However, reaction of dimethyl silyldichloride with urea yielded at most 5-10% of the theoretical yield of dimethyl silyldiisocyanate and substantial quantities of [(CH 3 ) 2 SiO] 3 and [(CH 3 ) 2 SiO] 4 as well as biuret, ammonium cyanate, cyanuric acid and tricyanile urea as by-products. A considerable proportion of the starting compounds therefore reacted to form by-products which could not be recycled.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for the production of silylisocyanates.
It is also an object of the present invention to provide a process for the production of silylisocyanates in high yield which process may be carried out at atmospheric pressure.
It is a further object of the present invention to provide a process for the production of silylisocyanates from silanes containing at least one halogen atoms.
It is yet another object of the present invention to provide a process for the production of silylisocyanates from silanes containing at least two halogen atoms in which the halogen atoms may be substituted stepwise by isocyanate groups.
These and other objects which will be apparent to those skilled in the art are accomplished by reacting a halogen silane corresponding to a specified formula with urea in a polar solvent at a temperature greater than or equal to 100° C. and atmospheric pressure.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a process for the preparation of silylisocyanates corresponding to the general formula:
R.sub.a Si(NCO).sub.b X.sub.c
wherein
R represents an aliphatic hydrocarbon group having a total of 1 to 18 carbon atoms which group is optionally olefinically unsaturated and optionally contains inert substituent(s); an aromatic hydrocarbon group having a total of 6 to 18 carbon atoms optionally containing inert substituent(s); an araliphatic hydrocarbon group having a total of 7 to 18 carbon atoms optionally containing inert substituent(s); a cycloaliphatic hydrocarbon group having a total of 5 to 18 carbon atoms optionally containing inert substituent(s); an alkoxy group having 1 to 18 carbon atoms; or an aryloxy group having 6 to 18 carbon atoms;
X represents chlorine or bromine,
a represents an integer of from 1 to 3,
b represents an integer of from 1 to 3, and
c represents an integer of from 0 to 2, and
the sum of a+b+c is 4. In this process, halogen silanes corresponding to the general formula:
R.sub.a SiX.sub.b+c
(in which the substituents and subscripts have the same meaning as given above) are reacted with urea in a polar solvent at a temperature of at least 100° C. Application of external pressure to the reaction mixture is unnecessary.
Any halogen silane corresponding to the general formula may be used as a starting material in the process of the present invention. Halogen silanes in which "R" represents a saturated aliphatic hydrocarbon group having 1 to 4 carbon atoms (particularly a methyl group) and "X" represents chlorine are preferred.
The following are examples of suitable halogen silanes: methyl silyltrichloride, dimethyl silyldichloride, trimethyl silylchloride, dimethyl silyldibromide, di-n-butyl-silyldichloride, distearylsilyldichloride, dicyclohexyl-silyldichloride, phenyl-silyltrichloride, benzyl-silyltrichloride and dimethyl-ethyl-silylchloride.
The starting material to be reacted with the halogen silanes exemplified above is urea.
The reaction between the halogen silanes and urea is carried out in the presence of a polar solvent or of solvent mixtures consisting substantially of polar solvents. The solvent or solvent mixtures should have a boiling point at atmospheric pressure of at least 110° C., preferably at least 140° C. and most preferably at least 190° C. Sulfolane and/or organic acid amides which are liquid under the reaction conditions, such as dimethyl formamide, dimethyl acetamide, N-methyl pyrrolidone, tetramethyl urea, tetraethyl urea and/or ε-caprolactam are particularly suitable solvents. The solvent or solvent mixture should be one in which urea may be readily dissolved in order to eliminate unwanted side reactions, particularly the formation of cyanuric acid.
In the process of the present invention, the reactants are used in quantities such that from 0.8 to 2 mol (preferably 1 to 1.5 mol) of urea are present for each mol of halogen bound in the halogen silane if complete replacement of the halogen substituents by the isocyanate substituents is desired. If silanes containing both isocyanate groups and halogen substituents are to be prepared from halogen silanes containing several halogen atoms, it is advisable to use from 0.8 to 1.2 mol (preferably 1 mol) of urea for each mol of halogen which is to be substituted by an isocyanate group.
The reaction of the present invention is carried out in the temperature range from 100° C. to 200° C., preferably from 130° C. to 160° C.
The process of the present invention is generally carried out by first introducing the urea dissolved in solvent into the reaction vessel, preheating the solution to about 100°-120° C., adding the halogen silanes (with vigorous mixing) and further raising the reaction temperature. The silylisocyanate formed is preferably continuously removed from the reaction vessel by distillation and then fractionated. Any unreacted halogen silanes obtained may be reused. Towards the end of the reaction, it is advisable to raise the sump temperature sharply (e.g., to 180° C.) in order to expel the silylisocyanates as completely as possible.
When using sulfolane, it may be advisable (e.g., for preparing trimethyl isocyanate) to expel the isocyanate quantitatively towards the end of the reaction with a lower boiling auxiliary solvent (e.g., toluene) at a sump temperature of 170° C.
When preparing methyl triisocyanatosilane, the end product must be removed from the reaction mixture by application of a vacuum after the reaction has been completed.
The best method for removing the products (by distillation) is dependent upon the boiling point of the product and upon the solvent(s) used. The optimum conditions may, however, be determined by a simple preliminary test. When preparing high boiling products, it is preferred to use comparatively low boiling solvents such as dimethyl formamide or N-methyl pyrrolidone. In such cases, working up of the reaction mixture may advantageously be carried out by adding a non-polar solvent (such as toluene, xylene, cleaning petrol or chlorobenzene) to the reaction mixture to precipitate by-products, particularly any ammonium halides formed. The filtrate freed from these precipitates may then be worked up by evaporating off the solvent. The end products are obtained as distillation residue.
The preparation of isocyanatosilanes containing halogen substituents (for example, the preparation of dimethyl chloroisocyanatosilane from dimethyl dichlorosilane) may be carried out by rapidly pumping about one mol of dichlorodimethyl silane at about 140° C. into a solution of one mol of urea in sulfolane and continuously distilling off the product mixture. This mixture includes dimethyl chloroisocyanatosilane formed as main product and unreacted dimethyl dichlorosilane and dimethyl diisocyanatosilane. If the formation of dimethyl diisocyanatosilane is to be substantially suppressed, it is advisable to use the dichlorodimethyl silane in excess (based on the quantity of urea).
The process of the present invention is generally carried out using 4-10 molar solutions (preferably 6-8 molar solutions) of urea in the above-mentioned solvents. The solvents may be recovered by distillation after the reaction mixtures have been worked up by distillation. Before recovering the solvent by distillation, any ammonium halides formed may be removed by filtration and washed out using an apolar solvent such as toluene.
The halogen-free isocyanatosilanes obtained as products of the process of the present invention are valuable intermediate products for organic syntheses. They are useful, for example, in the preparation of acyl isocyanates from organic acid chlorides as described, for example, in Soviet Union Pat. No. 498,290. Such acyl isocyanates are valuable dehydrating agents for pigments in lacquers sensitive to moisture. The halogen-substituted isocyanatosilanes obtained as products of the process of the present invention may also be used as polymer additives in hydraulic liquids or in dielectric materials.
Having thus described my invention, the following examples are given by way of illustration. The percentages given in these examples are percentages by weight, unless otherwise indicated.
EXAMPLES
EXAMPLE 1
210 g (3.5 mol) of urea were heated in 400 ml of sulfolane and as the sump temperature rose, 759 g (7 mol) of trimethyl silylchloride were introduced into the sump phase over a period of 3 hours, starting at a sump temperature of about 110° C. The temperature of the solution was gradually raised to about 145° C. Trimethyl silylisocyanate and unreacted trimethyl silylchloride were removed by way of an attached reflux condenser heated to 100° C. When all the trimethyl silylchloride had been added, the temperature was briefly raised to 180° C. 733 g of distillate were obtained. According to gas chromatographic determination, this distillate was made up of 48.6% of trimethyl silylchloride and 51.4% of trimethyl silylisocyanate.
370 ml sulfolane were recovered from the sump by suction filtration of the precipitated ammonium chloride.
EXAMPLE 2
120 g (2 mol) of urea were added to 500 ml of N-methyl pyrrolidone and the mixture was heated. From 100° C. upward, 271 g (2.5 mol) of trimethyl silylchloride were slowly pumped into the sump phase. The temperature was maintained at 140°-150° C. Trimethyl silylisocyanate and unreacted trimethyl silylchloride were distilled over into a receiver by way of a reflux condenser heated to 100° C. Trimethyl silylchloride was distilled from this receiver through a packed column (60 cm). The trimethyl silylchloride thus recovered was returned to the reaction vessel. The cycle was stopped when no more trimethyl silylisocyanate was formed. The end point of the reaction was readily seen from the stationary equilibrium established in the separation of silylchloride/silylisocyanate. 172 g of trimethyl silylisocyanate (Boiling point 91° C.) were isolated after fractional distillation.
EXAMPLE 3
The procedure was the same as in Example 2 with the exception that 450 ml of dimethyl formamide were used as solvent. According to gas chromatographic analysis, the sump phase of the silylchloride/silylisocyanate separation contained 200 g of trimethyl silylisocyanate.
EXAMPLE 4
189 g (3.15 mol) of urea were heated in 600 ml of N-methyl pyrrolidone and from 100° C. upward 325 g (3 mol) of trimethyl silylchloride were slowly pumped in. Unreacted trimethyl silylchloride was returned to the reaction vessel by the method described in Example 2. Towards the end of the reaction, the reused trimethyl silylchloride already contained some trimethyl silylisocyante. After completion of the reaction, the sump phase was heated to the reflux point of N-methyl pyrrolidone to expel the silyl compounds quantitatively.
320 g of reaction product were isolated. This product was determined by gas chromatography to contain 288 g of trimethyl silylisocyanate and 28 g of trimethyl silylchloride.
EXAMPLE 5
420 g (7 mol) of urea and 1200 ml of sulfolane were heated to 100° C. and the temperature was slowly raised to 180° C. while 677 g (5.25 mol) of dimethyl dichlorosilane were introduced. Unreacted starting material and the reaction products formed were removed by way of a reflux condenser heated to 180° C. After the reaction was complete, the receiving vessel contained 530.4 g of liquid which was determined by gas chromatography to contain 21% of dimethyl dichlorosilane, 30.3% of dimethyl chloroisocyanatosilane and 46% of dimethyl diisocyanatosilane. The last two products were identified by GC/MS coupling. The following boiling points were obtained when the reaction product was redistilled.
Dimethyl chloroisocyanatosilane 103°-105° C.; and
Dimethyl diisocyanatosilane 135°-137° C.
EXAMPLE 6
120 g (2 mol) of urea were heated in 500 ml of sulfolane and when the temperature reached 120° C., 258 g (2 mol) of dichlorodimethyl silane were pumped in over a period of 1.5 hours. The sump temperature was raised to 140° C. and unreacted starting material and end products were removed by way of a reflux condenser heated to 145° C. The sump temperature was briefly raised to 180° C. towards the end of the reaction. Analysis by gas chromatography showed that the 221 g of distillate collected contained 21.7% of dimethyl dichlorosilane, 44.4% of dimethyl chloroisocyanatosilane and 29.2% of dimethyl diisocyanatosilane.
EXAMPLE 7
150 g (1 mol) of methyl trichlorosilane were introduced into a solution of 180 g (3 mol) of urea and 500 ml of sulfolane at temperatures starting from 110° C. The reaction was exothermic and the reaction temperatures rose to 150° C. 60 g of a colorless liquid was distilled off at 58°-67° C. under a water jet vacuum. GC/MS coupling showed that the liquid was a mixture of about 30% methyl chlorodiisocyanatosilane and about 70% methyl triisocyanatosilane.
EXAMPLE 8
60 g (1 mol) of urea in 400 ml of sulfolane were heated to 130° C. and 168.5 g (1 mol) of diethoxy methyl silychloride were pumped in within 30 minutes. The sump temperature was raised to 145° C. during the pumping.
The volatile constituents were then distilled off under vacuum (14 torr) up to a sump temperature of 130° C. and the distillate was then redistilled. 100 g of diethoxymethyl silylisocyanate (boiling point 149° C.) were obtained. | This invention relates to a process for the preparation of silylisocyanates corresponding to the formula:
R.sub.a Si(NCO).sub.b X.sub.c
wherein
R denotes a hydrocarbon group,
X denotes chlorine or bromine,
a represents an integer of from 1 to 3,
b represents an integer of from 1 to 3, and
c represents an integer of from 0 to 2 and the sum of a+b+c=4.
These silylisocyanates are produced by reacting halogen silanes corresponding to the formula:
R.sub.a SiX.sub.b+c
with urea at atmospheric pressure in a polar solvent at a temperature of at least 100° C. | 2 |
RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 60/148,065, filed on Aug. 10, 1999, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
This invention relates generally to a method for preparing a toner cartridge for reconditioning and resealing the toner cartridge with a seal. The toner cartridges include the type used in laser printers, especially those in which the toner cartridge contain not only the toner or powder but also the ionizing means and photoreceptor drum in one package. The original seal design lends itself to lower cost maintenance of the printer or copying machine but significantly higher costs for replacing consumed toner.
While it is easy to remove the cartridge in a typical machine, and in fact this must be done in order to install a new cartridge, one would think most people would opt to refill their cartridges by adding toner themselves. Such is not the case, however, with most office personnel avoiding this task, if for no reason other than the difficulty of containing the inadvertent spilling of some of the toner, and the resultant soiling of hand, clothing and immediate surroundings. The spilling of toner is also the reason a seal must be provided if the cartridge is to be shipped or held in any position except in the normal or upright position. A simple, stiff, push-in, pull-out plastic seal is sometimes adequate, especially if hand or local delivery of the refilled cartridge is contemplated. However, this type of seal will not prevent toner spilling under even normal handling of a well packaged toner cartridge handled by postal or shipping organizations.
One difficulty with resealing is that impediments are placed in the toner cartridge by manufacturers to prevent resealing by toner cartridge reconditioners. The impediments can include a difference in the level of the sealing surface or a pin or post to block a resealing insertion tool. One method that avoids the impediments requires the complete splitting of the shell of the cartridge, often requiring extensive reworking of the mating surfaces, replacing and cementing a new styrene or similar gasket which provides the surface to which the new pull-tab seal is ultimately adhered to, and an adherence of a “U” shaped, thin plastic seal via pressure sensitive adhesive. The split shells of the cartridge are then recemented and other, time-consuming adjustments on other components of the cartridge are performed to make it functional. Because of the high cost of splitting and reassembling these cartridges and the inevitable deterioration of the appearance of the finished toner cartridge, other ways have been sought for refilling these cartridges, to take full advantage of the potential price differential of new cartridges and those that have been refilled. Usually, the other expensive components that make up a complete toner cartridge are, in general, in excellent condition and capable of performing well for at least a few refillings of the cartridge. Also, the lifetime of a printer and use thereof is such that the costs of toner cartridges, in general, often exceed the cost of the printer. Therefore, a need exists for an improvement method to overcome the problems described above.
SUMMARY OF THE INVENTION
The invention comprises a method for preparing a toner cartridge for reconditioning and resealing with a seal. A used toner cartridge is provided whose seal has been removed and the toner essentially consumed with the cartridge substantially otherwise intact. The interior of said cartridge is partially separated or penetrated so as to remove, modify or bypass any impediments present which would or could interfere with the resealing of the cartridge. A new seal is secured to the toner cartridge.
In another embodiment, a toner cartridge having a toner seal removed from an original seal position is provided. The toner cartridge includes the original seal position in a different plane from an insertion point for a replacement seal insertion tool into the toner cartridge. The replacement seal is inserted with the replacement seal insertion tool into the toner cartridge. The insertion tool includes a blade having a first portion of the blade in a first plane and a second portion of the blade in a second plane that is different from the first plane. The replacement seal insertion tool is removed from the toner cartridge while leaving the replacement seal attached in a sealing position, thereby sealing the toner cartridge.
In a further embodiment, a used toner cartridge having a seal removed from an original seal position is provided. An impediment is removed in the used toner cartridge without fully splitting the toner cartridge. The impediment interferes with the insertion of a replacement seal insertion tool into the toner cartridge for resealing with a replacement seal. The replacement seal is inserted with the replacement seal insertion tool into the toner cartridge. The replacement seal insertion tool is removed from the toner cartridge while leaving the replacement seal attached in a sealing position, thereby resealing the toner cartridge.
This method for resealing toner cartridges provides for the recharging of toner cartridges at a lower cost, greater convenience, and reliability than is presently possible with known resealing methods. Thus, a user can be provided with a refilled cartridge which is essentially identical in appearance to the manufacturer's original seal, including the peripheral application of adhesive on the seal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the steps of inserting a folded plastic strip having an adhesive pattern thereon and suitable for forming a seal with an insertion and/or sealing tool useful for inserting the plastic strip and forming a seal in a toner cartridge.
FIG. 2 is a schematic cross-sectional illustration of a second cartridge and a drilling jig.
FIG. 3 is a schematic cross-sectional illustration of a seal entrance of a cartridge.
FIG. 4 is a perspective view of a toner section of a toner cartridge.
FIG. 5 is a perspective view of a hole guide.
FIG. 6 is a perspective view of a magnetic roller section of a toner cartridge.
FIG. 7 is a perspective view of a tracking block.
FIG. 8 is a perspective view of an insertion pin.
FIG. 9 is a perspective view of a pin block.
FIG. 10 is a cross-sectional view of an insertion tool having a bend.
FIG. 11 is a cross-sectional view of a pressure pad.
FIG. 12 is a perspective view of a weight pad.
FIG. 13 is an exploded perspective view of another toner cartridge and sealing system.
FIG. 14 is a perspective view of a ribbon remover.
FIG. 15 is a perspective view of a drill block.
FIG. 16 is a perspective view of a ribbon protector.
DETAILED DESCRIPTION OF THE INVENTION
The features and other details of the methods and apparatus of the invention will be described with reference to the accompanying drawings. The same numeral in different figures represents the same item. It will be understood that the particular embodiments of the invention are shown by way of illustration and not as limitations of the invention. This invention is most advantageously used with a sealing system that could not normally be used if the impediments were not removed or their effects mitigated. The principle features of this invention can be employed in various embodiments of cartridges, normally using a variety of special tooling designed for a specific cartridge, without departing from the scope of the invention.
The basic techniques for practicing this invention primarily utilize a partial opening of a cartridge without splitting the cartridge, or, a drill-or-mill cutter penetration of the cartridge in the areas where impediments prevent the insertion of a seal. The impediments are then removed and their effects eliminated, or, sufficiently reduced, so that a seal can be inserted and the cartridge sealed. The basic procedure of partially splitting or similar form of penetrating a cartridge and modifying it to allow the insertion of a seal has the significant advantage of essentially preserving the structural integrity and dimensional tolerances of the original cartridge. This is not the case when a cartridge is split and separated. Additionally, a partial splitting generally retains the low costs associated with inserting seals when the same cartridge is sealed a second or more times since the impediments need no longer be removed. Since the location and degree of the partial opening of a cartridge to remove impediments, and the tools preferred to carry out these functions are specific to a particular cartridge design, diagrams and descriptions of some useful tools as they apply to particular cartridges will be shown below.
FIG. 1 illustrates a simplified cross section of a toner cartridge 10 , which is typical of the first two toner cartridges produced in volume of the all-in-one designs, such as the Canon CX and SX cartridges. These cartridges either had no impediments or impediments that were readily bypassed. The cartridge has an upper section, usually referred to as a magnetic (mag) roller section 12 , housing many of the critical components, such as the magnet roller, doctor blade, charging means and photoreceptor drum. The lower section, primarily carrying the toner and sealed with a user-removable seal, is commonly referred to as the toner section 14 . When a used toner cartridge is to be resealed, a seal 16 can be inserted into cartridge 10 with the aid of an insertion tool 18 . Seal 16 can be an insertable heat seal, as described in U.S. Pat. Nos. 5,370,761, 5,460,674 and 5,876,541, the entire teachings of each are incorporated herein by reference. These seals are available from Provide Technologies, Inc., 10 Packard Avenue, Somerville, Mass. 02144 U.S.A. A hot melt adhesive 20 is on the lower portion of seal 16 , which is folded at 22 at the end of insertion tool 18 prior to insertion. Mag roller section 12 has attached to it at least one foam gasket 24 , which has attached to and partially covering it plastic tape 26 . Plastic tape 26 can be the first impediment that was introduced to hinder the insertion of a seal with an insertion tool by presenting a thin edge of material that the seal-tool combination snagged (adversely affecting the foam gasket 24 performance) when being inserted into the cartridge 10 . This impediment is successfully bypassed with the use of a foam protector 28 , shown in FIG. 1, inserted under the plastic tape 26 , prior to the seal-tool combination being inserted.
A thin (typically 0.005 inch (0.127 mm)) hardened steel foam protector 28 is readily inserted into the cartridge without snagging the plastic tape 26 , prior to the seal-tool being inserted. The seal 16 is slipped under the foam protector 28 and plastic tape 26 (with the use of insertion tool 18 ) without snagging plastic tape 26 . Snagging plastic tape 26 will likely destroy the sealing performance of the foam gasket 24 , whose function is to prevent toner from leaking out of the cartridge opening when the cartridge is used in a printer. After a seal 16 is inserted into a cartridge 10 , insertion tool 18 is electrically heated, melting the hot melt adhesive 20 which, upon cooling, bonds to the sealing surface within the cartridge 10 , sealing the cartridge.
FIG. 2 shows a simplified cross-section of a newer-style cartridge 30 (e.g., similar to the 4000 series), supported by cartridge holder 32 . There are two major impediments to the insertion of a seal in contrast to the original cartridge design shown in FIG. 1 . The first impediment is a difference in the level of the sealing surface 34 , a surface not in line with the seal entrance 36 , schematically shown as a dotted line. The second impediment is the addition of a molded extension 38 , to the mag roller section 40 which forces foam gasket 42 to follow the “step-down” contour determined by molded extension 38 . The insertion of a tool and seal through the seal entrance 36 requires that either the molded extension 38 be removed, or, more practically, mag roller section 40 and toner section 44 be partially split and the opening enlarged to allow entrance of the tool and seal.
One preferred embodiment of partially splitting this cartridge is with the use of a precision drill jig 46 , which can be firmly and accurately hinged to cartridge holder 32 by hinge 48 . Two drill guides 50 are shown so located that when drill jig 46 is in the upright position, drill bits passed through the holes in the drill guides 50 will drill holes precisely in line with the welded seams which adhere mag roller section 40 to toner section 44 . This allows even an unskilled worker, using small drill bits, e.g., typically about 0.05-0.10 inches (1.27-2.54 mm) in diameter, to accurately drill out those portions of the welded seams that are to be separated to allow a partial splitting of the cartridge. This drilling action severs the welded seam wherever the drill bit has penetrated. Severing approximately one inch (2.54 cm) of the welded seam from either side of the 4000 series cartridge provides sufficient partial splitting to allow the seal entrance 36 to be spread apart (using various tools, one of which is described below), for the normal insertion of a seal. This sealing process becomes similar to the process described under FIG. 1 . In FIG. 2, drill jig 46 is located in front of the normal seal insertion opening. However, some cartridges are welded, not only along the two long lengths of the cartridge but also parallel and adjacent to the seal entrance 36 . To remove this impediment, a drilling jig can be precision positioned along a long side of a cartridge holder, drilling through the side of the cartridge seam and along the weld that runs parallel to the seal entrance 36 . The drill jig thus used allows an accurate extraction of the welded seam in that area, facilitating the removal or separation of this portion of the original equipment manufacturer cartridge, when required, for inserting a seal.
FIG. 3 represents another embodiment for partially splitting this type of cartridge (4000), through the use of two insertion pins, without the necessity of drilling the welded seams. An insertion pin 52 , whose width is about 0.125 inches (3.18 mm) but with a narrow portion 54 only about 0.10 inches (2.54 mm) wide (these dimensions chosen to split the seam without tearing the ridges within the cartridge, in the case of the 4000 series cartridge), is inserted in line with the “left” weld 56 . Insertion pin 52 is inserted just deep enough to split the welded seam approximately one inch. The remaining nine inches about (23 cm) of the welded seam remains intact. The “right” insertion pin, similar to insertion pin 52 , is inserted adjacent to the right side welded seam which enlarges the entrance to the cartridge, and sometimes also partially splits the welded seam. The introduction of the two insertion pins 52 results in the opening of seal entrance 36 enough to allow the insertion of an insertion tool and seal. Since the insertion pins 52 can remain in position when the seal and tool are inserted, these pins are designed so as not to interfere with inserting the seal. These details are discussed below when references to FIGS. 4 through 9 are made.
Whenever a cartridge is partially split, making it possible to enlarge seal entrance 36 , or any other area of a cartridge presenting some impediments to a seal insertion, a common aftermath is the possibility of removing or at least cutting away portions of these impediments and removing them permanently. Thus, subsequent resealing of the modified cartridge may not require anymore, or, only insignificant additional effort, to seal a cartridge than is required to seal a cartridge that never had any impediments. With reference to FIG. 2, it is possible to cut away both the portion of the foam gasket 42 (which is covered by plastic tape 26 ) and the plastic tape 26 , with the use of as simple a tool as a putty knife. Improved performance is achieved by sharpening the blade, preferably at a small angle from the original angle so that the blade cuts away the foam gasket 42 and plastic tape 26 serially across their width, not head on.
Other techniques for partially splitting a cartridge is to modify and use any cartridge splitting machinery being marketed, such as the rotary blade machinery described in U.S. Pat. Nos. 5,223,068, 5,407,518, 5,525,183, and 5,676,794 but without fully splitting the cartridge into the two major components, the mag roller section and the toner section. The entire teachings of U.S. Pat. Nos. 5,223,068, 5,407,518, 5,525,183, and 5,676,794 are incorporated herein by reference. Since any splitting mechanism for cartridges can usually be adapted for partially splitting a cartridge, e.g., splitting one inch (25.4 mm), five inches (127 mm) or, whatever is required, of the welded seams permits one to remove or mitigate the effects of impediments to seal insertion and thereby practice this invention. It is understood that the specific techniques and tools utilized will vary from one cartridge model to another, based primarily on the specific impediments the OEM utilizes which must be removed or bypassed.
In FIG. 4, toner section 44 is shown with sealing surface 34 , which in the 4000 series cartridge, is displaced approximately 0.125 inches (3.18 mm) below the lowest portion of the sealing entrance 36 . Welded seams 62 (two illustrated) run adjacent to the two long, outside edges of toner section 44 (as well as along the mating edges of mag roller 40 ). A 0.75-inch (19.05 mm) fill hole 64 is shown covered by fill cap 66 . An area of raised or embossed markings 68 are shown, a portion of which is covered by fill cap 66 . While not previously delineated as an impediment, a separate fill hole 64 is necessitated by the fact that the OEM has made the original fill hole (actually, a triangular plug inserted into a raised-edge hole) inaccessible without taking apart much more of the cartridge than is desired. The area where fill hole 64 can be conveniently drilled and the necessity to cover the hole so as not to leak toner requires that the placement of the fill hole 64 and fill cap 66 be accurately positioned and prepared. A preferred method to position the hole and cover using hand tools that are commercially valuable and effective is to use a hole guide 74 shown in FIG. 5 . Hole guide 74 is preferentially made of aluminum or steel, and, for the 4000 cartridge, be approximately 1.25 inches (32 mm) in diameter and 0.25 inch (6 mm) thick, with a 0.25 inch (6 mm) diameter hole 76 drilled in its center. The 0.25-inch (6 mm) pilot drill of a 0.75 inch (19 mm) hole saw is inserted into hole 76 , and, with the circumference of the hole guide 74 simultaneously touching the sides of toner section lip 72 and toner section lip 70 , guides the pilot drill to a position for drilling fill hole 64 . As soon as the pilot hole is drilled, hole guide 74 can be removed from the pilot drill of the hole saw, and the 0.75-inch (19 mm) hole can be drilled. A handle and chiseling blade (such as a No. 18 knife blade with heavy duty plastic handle 3205, made by X-ACTO, Speedball Road, Statesville, N.C. 28677), can then be used to deburr the edges of the hole and smooth out the raised or embossed markings 68 . Any raised markings 68 under fill cap 66 , even if only a few thousandths of an inch (a few tenths of a millimeter) high, can likely cause toner leakage, unless the fill cap 66 adhesive layer is extraordinarily thick and flexible, perhaps three or four times the preferred thickness of about 5 mils (0.13 mm).
In an embodiment of this invention, toner section 44 and mag roller section 40 are initially received welded together, i.e., the cartridge is in the original OEM configuration. To partially separate the cartridge, using the technique of partial splitting via insertion pins, a sequence of actions is usually carried out, although they can vary in some detail, depending on the specific cartridge being partially split and sealed.
FIG. 7 depicts a tracking block 78 , normally part of cartridge holder 32 in FIG. 2 and positioned in the general vicinity of drill guide 50 . Tracking block 78 provides tracking means 80 and 82 for guiding the insertion pin(s) 52 , for guiding the pin block 88 in FIG. 9, and for guiding the insertion tool 18 and seal 16 in FIG. 1 . An insertion pin 52 is shown in FIG. 8 in a preferred relative position to seal entrance 36 . Only one pin is shown for clarity but another pin, similar in design although usually slightly longer, would normally be used in pin track 82 . Insertion pin 52 is shown with a narrower portion 54 , designed for the 4000 cartridge to split the seams without tearing or ripping the side wall portions immediately adjacent to the welded seams. The hole(s) 92 of pin block 88 are placed over the insertion pin(s) 52 and pin block 88 is placed on top of tracking block 78 . Protrusion 90 of pin block 88 accurately fits into track 84 so that by pushing on handle 94 , a significant force can be exerted on insertion pin(s) 52 which are held and guided in tracking means 80 and 82 . The insertion pin(s) 52 , guided and forced into welded seams 62 , partially break the welded seams 62 , separating the mag roller section 40 from the toner section 44 in the vicinity of seal entrance 36 , sufficiently to allow insertion tool 18 and seal 16 (usually with the use of a foam protector 28 ) to be readily inserted into seal entrance 36 , as if there were no molded extension 38 impeding the normal insertion of a seal. Just prior to the full insertion of the seal/tool combination, insertion pins 52 are withdrawn from welded seams 62 , either by using hand force, or more conveniently and sometimes necessary, using the hole(s) 96 placed over pin(s) 52 to conveniently and with reasonable force, remove the pins 52 .
A modification of the normal insertion tool 18 for a preferred embodiment of a 4000 series insertion tool 98 , for the purpose of addressing the impediment presented by the difference in the level of the sealing surface 34 , a surface which is not in line with the seal entrance 36 , is illustrated in FIG. 10. A bend 100 is located so that when this insertion tool 98 has inserted a seal 16 , into a 4000 series cartridge (FIGS. 4 and 6 ), the seal 16 is forced down into contact with the whole of sealing surface 34 . To assure truly intimate contact of the seal 16 and sealing surface 34 for the majority of cartridges that are not perfectly flat, two more tools are preferred. Shown in FIG. 11 is a pressure pad 102 (usually used in pairs), and placed on the top of the seal/insertion tool combination after being inserted into the cartridge. The pressure pad 102 is placed through the opening in the top of mag roller section 40 (FIG. 6) and the beveled end 104 is pressed between the mag roller section 40 and the inserted seal/tool combination. A pressure pad 102 is pressed under both ends of mag roller section 40 , causing firm pressure between the seal and sealing surface in the vicinity of the pressure pads 102 .
Weight pad 106 , shown in FIG. 12, is a preferred embodiment for a tool, making possible and/or enhancing the sealing reliability of the 4000 series or similar cartridges. Its purpose is to supply a force on the seal/tool combination along the long directions of the sealing surface 34 , similar to the force supplied by pressure pad(s) 102 at the short ends of the sealing surface 34 . This force should be applied along the length of the seal 16 in spite of the existence of metal bars directly on top of the seal/tool combination. Weight pad 106 can weigh a little less than two pounds (0.9 kilograms) with most of the weight supplied by the stainless steel bar 108 supported by housing 112 . The weight can easily be changed by modifying the dimensions of the stainless steel bar 108 . The legs 110 of the housing 112 are designed to span the metal bars and apply the force directly to both edges of the seal/tool combination, both during the time the hot melt adhesive 20 is heated and melted, as well as during the cooling cycle, assuring intimate contact and adherence of the seal 16 to the sealing surface 34 . The shape and form of legs 110 are determined by the structure of the opening in mag roller section 40 , but it is usually quite narrow in width and long in length. Hence, to ensure that weight pad 106 remains upright and stable and to eliminate the possibility of toppling over when the cartridge ( 40 and 44 ), cartridge holder 32 and seal/tool combination are moved for the heating and cooling cycles, support member 113 is designed to just clear the cartridge molding adjacent to the opening through which legs 110 are inserted and prevents any motion that might topple the weight pad 106 .
After sealing the cartridge, some form of gasketing is often required to prevent leakage of toner through those areas that were partially split. This leakage can occur after the user has removed the seal and during the time the cartridge is being installed into a printer, or, after installation, when the cartridge is in use. Since the partial splitting process of this invention essentially precludes any relative motion between the mag roller section 40 and toner section 44 , the preferred embodiment for sealing these small separations is by the use of a silicone or similar sealant. Examples of suitable sealants are GE RTV100 series of silicone rubber (General Electric Company, 260 Hudson River Road, Waterford, N.Y., USA 12188), generally used with a small metallic or plastic clip at each separation. For more aggressive bonding, which may not require the permanent use of clips, GE RTV5223 has been effective as a bonding and gasket-forming sealant on the plastics presently used in cartridge manufacturing.
While the impediments being introduced in the newer cartridges are similar in nature, each cartridge design requires modifications to the techniques and tools used. As another example, the 8000 cartridge is schematically illustrated in FIG. 13. A preferred embodiment in preparing this cartridge for an insertable seal is to first extract the two hidden post impediments 114 (two shown), which are not externally visible or accessible. To accomplish the extractions, pin drill guide 116 is designed with a specific perimeter shape, a slot 118 and drill guide holes 120 , 122 and 124 , to match the physical configuration of the 8000 cartridge. Pin drill guide 116 is positioned under lower shelf 126 (marked “FIRST POSITION”) and held there with small binder clips (not shown). Drill guide hole 120 is thus positioned so that hole 128 can be drilled with a hand drill. The location of hole 128 is precisely in line with the location of hidden post impediment 114 . Pin drill guide 116 is then repositioned under the lip of seal entrance 36 (marked “SECOND POSITION”) and also temporarily held there with binder clips. Using drill guide hole 122 for positioning a drill, hidden post impediment 114 is drilled and removed without adversely affecting the toner section 129 . Likewise, using drill guide hole 124 for positioning a drill, being allowed access by using the previously drilled hole 128 , the second hidden post impediment 114 is drilled out. Pin drill guide 116 is then removed for use in a subsequent cartridge. An insertion tool and seal can be inserted into this cartridge, but for the fact that the seal entrance 36 is exceptionally tight, making the snagging and tearing of foam gasket 24 , plastic tape 26 (both in FIG. 1) and seal remnants 130 a common and unacceptable occurrence.
As in the previous example of partially splitting a 4000 series cartridge, depicted in FIGS. 4, 6 , 7 , 8 and 9 , a similar procedure is preferred for the 8000 cartridge. Tracking block 79 in FIG. 13 is similar in design to tracking block 78 shown in FIG. 7, except for the absence of pin track 80 and certain dimensional differences due to cartridge differences. While one can use two insertion pins 53 to partially split, it has been found that only one insertion pin 53 is necessary, provided the pin dimensions are properly chosen and the depth of insertion is controlled. Note that insertion pin 53 (FIG. 13) does not have the narrower portion 54 (FIG. 8) since a different welded seam 63 is encountered in the 8000 cartridge verses the 4000 cartridge. Using insertion pin 53 in pin track 83 and pin block 88 (shown in FIG. 9, and not in FIG. 13) either partially splits welded seam 63 , and parallel to seal entrance 36 , or seal entrance 36 is sufficiently enlarged by the insertion pin 53 , allowing for the insertion of foam protector 28 , seal 16 and insertion tool 98 .
In spite of the modification to the 8000 cartridge described above, it has been found that a nearly flawless level of sealing reliability can be achieved if seal remnants 130 are partially or wholly removed prior to sealing. FIG. 14 illustrates how this can be accomplished with the use of ribbon remover 132 , composed of handle 134 , blade 136 and rod 138 . Blade 136 , which is narrower than insertion tool track 84 (FIG. 13 ), is not centered on handle 134 , but biased to one side. This structure makes possible the removal of seal remnants 130 from both sides of the cartridge by turning the ribbon remover over. The ribbon remover 132 is used by first inserting a foam protector 28 and sliding blade 136 into the seal entrance 36 . The outside edge of blade 136 , i.e., the edge that is in line with handle 134 , rides against the edge of insertion tool track 84 , in line with one of the two seal remnants 130 which is to be removed. With reference to the enlarged view of the tip of the blade 136 , apex 140 is inserted under foam protector 28 , until hole 142 is visible within the cavity of toner section 129 . Rod section 144 is then inserted into hole 142 with enough force on rod 138 to assure that blade 136 is in intimate contact with sealing surface 34 . Upon further insertion of blade 136 , ribbon ram 146 engages ribbon remnant 130 , pushing it into the toner section 129 cavity, where it can be grasped with tweezers, pliers or even one's fingers and removed. With the use of the heat seal sealing system marketed by Provide Technologies, Inc., 10 Packard Avenue, Somerville, Mass., USA 02144, it is not necessary to totally remove the seal remnants 130 , because the thick, hot-melt adhesive used in that seal system can readily fill in typical voids or variances in sealing surface 34 and ribbon remnants 130 . Ribbon ram 146 is also depicted as a dotted line 147 , meant to indicate that the preferred angle of the ribbon ram need not be perpendicular to the direction of the ribbon remnants 130 . Another angle cut for the ribbon ram, indicated by the dashed line 147 , could help push out the seal remnant 130 into the center of the cartridge opening, depending on the style of weave and other characteristics of the ribbon remnants 130 and their adhesion to the sealing surface 34 . The blade curve 148 is a preferred innovation to bypass an impediment, resulting from the presence of a molded plastic ridge attached to the mag roller section 131 . With the presence of blade curve 148 , blade 136 is pushed towards the center of the cartridge opening, bypassing that impediment but allowing the ribbon ram 146 to engage the seal remnant 130 and removing it from the sealing surface.
Pin drill guide 116 (FIG. 13) is a commercially viable, low-cost tool for accurately guiding a drill bit for the removal of hidden post impediments 114 with a minimum of mechanical or esthetic affects on the cartridge. In a possible future cartridge design, in which the use of such a tool would be difficult, a preferred embodiment for removing hidden post impediments 114 can utilize a somewhat similar pin drill guide 116 but designed to be placed on the top surface of mag roller section 131 , with a general location over the seal entrance 36 . This would result in holes visible to the customer, which could be disguised with fillers or caps or other, more complex molded components. It is apparent that any preferred embodiments for tooling are primarily determined by the specific design of the OEM cartridges and by the level of professional finish and appearance demanded by the remanufacturer and final customers.
A preferred embodiment for sealing the recently introduced 8100 cartridge utilizes drill block 150 , shown in FIG. 15 . This is a schematic representation of a device which facilitates the guiding or positioning of appropriate tools for the removal of two pins and a molded extension that interfere with the insertion of a seal into the 8100 cartridge. Locator pins 152 , in conjunction with bored hole 154 match existing holes and a protrusion, respectively, molded at the end of an 8100 cartridge, and are used to precisely locate the drill block 150 at the end of an 8100 cartridge which is being resealed. Drill block 150 is machined with tolerances that readily allow the remanufacturer to position drill block 150 within approximately 0.004 to 0.008 inches (0.1 to 0.2 mm) of the desired location at the seal insertion end of the 8100 cartridge. With the drill block 150 so positioned, a rotary power tool with a jeweler's cutter, such as manufactured by The Foredom Electric Company in Bethel, Conn., U.S.A., is inserted into slot 158 , the tool bit exiting the slot 158 where 158 is indicated in FIG. 15 . By moving the rotary power tool along the trajectory defined by the slot 158 , allowing the smooth portion of the jeweler's cutter to ride along the slot 158 as a bearing surface, the molded extension, somewhat similar to molded extension 38 in FIG. 2, can be removed. Subsequently, without moving the drill block 150 position, and preferably using a 0.25 inch (6.35 mm) “special drill”, part number 8123, (manufactured by Provide Technologies, Inc. of Somerville, Mass., U.S.A.), inserted through the holes 156 , and into the 8100 cartridge where the two plastic posts, proximate to the seal entrance of the cartridge are located, (somewhat similar to the post impediment(s) 114 in FIG. 13 ), are completely removed without adversely affecting the appearance or performance of the cartridge.
While the ribbon remnants 130 remaining within the 8100 cartridge (now using FIG. 13 also as a schematic representation of the 8100 cartridge) after the original seal has been removed appear similar to the ribbon remnants 130 of the 8000 cartridge shown in FIG. 13, they are composed of different materials. The ribbon remnants 130 in the 8100 cartridge are of a metallic composition and those in the 8000 are a textile composition. The significance is that metallic ribbon remnants can not readily be partially or completely removed, without affecting the smoothness of the sealing surfaces 34 and the reliability of the seal. Therefore, the preferred embodiment for inserting a seal into an 8100 cartridge, after the two posts and molded extension referred to in the previous paragraph are removed, is to temporarily cover the ribbon remnants 130 . This temporary covering of the ribbon remnants 130 can be achieved by using two ribbon protectors 160 (one shown) in FIG. 16 as a cover for the ribbon remnants 130 when a seal-tool combination is to be inserted.
A preferred embodiment of a ribbon protector 160 can include handle 162 with a hole 164 providing a convenient finger hold for pulling on handle 162 , which is attached to a narrow, typically 0.375 inches (9.5 mm) wide, and thin, typically 0.005 inches (0.127 mm) thick, steel blade 166 . A ribbon protector 160 is installed by inserting a foam protector 28 , whose width is approximately 0.9 inches (23 mm) and then sliding this narrow foam protector 28 under the foam gasket 24 and plastic tape 26 , the objective being the avoidance of any contact with ribbon remnants 130 . One of the ribbon protectors 160 is then inserted under the foam protector 28 with the tip of the steel blade 166 slightly lifted and pulled over onto the top of one of the ribbon remnants 130 . The ribbon protector 160 is then straightened out to line up with the ribbon remnant 130 . Then the second ribbon protector 160 is inserted similarly to the first one, but pulled over the second ribbon remnant 130 and straightened out. While the steel blade 166 is approximately sixteen inches (40.6 cm) long, only one to two inches (2.5 to 5 cm) of the ribbon remnants 130 need be covered by the ribbon protectors 160 . The rest of the steel blades 166 rest in tracks (not shown) in tracking block 79 parallel to the insertion track 84 (FIG. 7 and FIG. 13) which conveniently retain the ribbon protectors 160 in position. Then, a wide foam protector, approximately 1.75 inches (4.45 mm) is inserted under the previously inserted narrow foam protector and on top of the ribbon protectors 160 , and then removing the narrow foam protector. Through this process, the wide foam protector 28 covers the foam gasket 24 and plastic tape 26 and the ribbon protectors 160 cover the ribbon remnants 130 so that a seal/tool combination can readily be inserted into the 8100 cartridge. The ribbon protectors 160 are removed by pulling on finger hole 164 soon after the seal/tool combination have been inserted about two inches (five cm), i.e., beyond the beginning of the ribbon remnants 160 . The seal/tool combination is then fully inserted and the tool is heated and cooled to produce a sealed 8100 cartridge without splitting the cartridge.
Drill block 150 is an embodiment of a drill-guide that accomplishes the tasks of enabling the same guide to accommodate the removal of impediments in two planes of the cartridge. It is apparent that the original equipment manufacturers could possibly design more complex cartridges, making the preferred embodiments for removing the impediments not amenable, acceptable or possible to the tool designs described herein. In these events, the preferred embodiments for removing or bypassing impediments to the insertion of viable seals will likely be through the use of milling machine-like techniques, albeit, simple milling machine designs. Specifically, since only plastic materials are likely to be removed, a cartridge holder can be constructed with guide rods surrounding all four sides and the top to which an adjustable motor mount with motor is attached. These can be “home made” or commercially purchased, allowing one to drill, mill or saw away any part of a cartridge or impediment, and practice the teachings of this invention.
It will be understood that the inventions may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the inventions are not to be limited to the details and claims given herein. | A method for preparing a toner cartridge for reconditioning and resealing with a replacement seal includes providing a used toner cartridge whose seal has been removed and the toner essentially consumed with the cartridge substantially otherwise intact. The interior of the cartridge is partially separated or penetrated so as to remove, modify or by-pass any impediments present which would or could interfere with the resealing of the cartridge. A new seal is secured to the toner cartridge. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of wireless communications, and more particularly to a method of and system for discovering and matching parties for wireless multi-party interactive sessions, such as games.
[0002] Today's mobile platforms often comprise multiple communication and radio interfaces such as wireless local area network (WLAN) (e.g., WiFi), Bluetooth, or cellular, for carrying real-time networked game play traffic in addition to wireless telephone and internet access. For players in close proximity to each other, it is preferred to run a multi-player game session over a low latency and high bandwidth network interface such as a WLAN (e.g., WiFi), which covers a range of about 100 m, or Bluetooth, which covers a range of about 10 m. Also, ad hoc peer-to-peer sessions using WiFi or Bluetooth are free of charge, whereas sessions over a third party network may involve charges. The emerging growth of high-bandwidth local area mobile communications capabilities and handsets will enable new opportunistic mobile gaming scenarios and businesses. For example, a mobile game player may discover and engage with other mobile game players opportunistically via high-bandwidth local wireless networks in places such as shopping malls, cafeterias, coffee shops, airports, schools, and the like.
[0003] The availability of multiple communication channels or radio interfaces on mobile devices for mobile casual game play can help a mobile user discover more game play opportunities but, at the same time, it presents new challenges. According to a recent study, the multiple wireless interfaces consume approximately 70% of the total power for a connected mobile device in idle mode. An overwhelming portion of the wireless interface power is consumed by the WiFi interface. For peer-to-peer (P2P) based opportunistic mobile game play, a game session hosting mobile device has to keep its WiFi interface powered up and wait for incoming connections. For an opportunistic mobile game player who wants to search for other available mobile game sessions via the WiFi interface, the mobile game player's mobile unit has to scan the air constantly or frequently in order to locate another nearby WiFi based game session. This type of P2P mobile opportunistic game session discovery and management is very inefficient in terms of power consumption.
SUMMARY OF THE INVENTION
[0004] Embodiments of the present invention provide systems and methods for establishing multi-party wireless interactive sessions. The system includes a session broker and a plurality of wireless units. The wireless units each include a first wireless device having relatively low power consumption and a second wireless device having relatively high power consumption. An example of wireless device having relatively low power consumption is a cellular phone radio. Examples of wireless devices having relatively high power consumption are WLAN radios, such as WiFi.
[0005] The game broker is configured to receive a session ready message, which includes location information for a first party, and search for a second party having location information matching the location information for the first party. Upon finding a matching party, the game session broker sends session available messages to the first and second parties. The session ready message is sent and the session available message is received using the first wireless device. Upon receiving the session available message, the first and second parties can establish a session using their respective second wireless devices. Preferably, the second wireless devices are maintained powered-off until a session available message is received.
[0006] Wireless units according to embodiments of the present invention may be configured to obtain location information. For example, a wireless unit may include a GPS receiver. Alternatively, a wireless unit may be configured to measure the signal strength of one or more sources, such as WLAN access points, Bluetooth proximity beacons, RFID tags, and the like. The session broker may be configured to determine a location from signal strengths and calculate the distance between locations.
[0007] The session broker may maintain session profile information for players. For example, in the field of games, session profile information may include preferred games, preferred opponents, preferred technology, and the like. A session ready message may include time availability information for a party. The session broker may maintain a list of players, and their respective locations, currently available to play. The session broker searches the list of currently available players for location matches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a system according to the present invention.
[0009] FIG. 2 is a block diagram of a game enabled mobile unit according to the present invention.
[0010] FIG. 3 is a high-level call flow diagram of an embodiment of the present invention.
[0011] FIG. 4 illustrates an embodiment of a session ready format according to the present invention.
[0012] FIG. 5 illustrates an alternative embodiment of a session ready message format according to the present invention.
[0013] FIG. 6 illustrates an embodiment of an active player list according to the present invention.
[0014] FIG. 7 is a high-level flowchart of an embodiment of mobile game unit processing according to the present invention.
[0015] FIG. 8 is a high-level flowchart of game session broker processing according to the present invention.
[0016] FIG. 9 is a high-level flowchart of active player list cleanup processing according to the present invention.
DETAILED DESCRIPTION
[0017] Referring now to the drawings, and first FIG. 1 , a system according to the present invention is designated generally by the numeral 101 . System 101 includes a packet radio service (e.g., GPRS, EDGE, CDMA) system 103 . Packet radio service system 103 enables a mobile unit, such as mobile game unit 105 , to access both a data network, such as the Internet 107 , and a public switched telephone network (PSTN) 109 . An originating mobile switching center (MSC-O) 111 provides an interface between a packet radio service system such as GPRS system 103 and PSTN 109 . In one embodiment where the packet radio service is GPRS, an HLR 113 provides MSC-O 111 subscriber and location information for the mobile units in its home area. A Gateway mobile switching center (G-MSC) 115 is connected to MSC- 0 111 and a visitor location register (VLR) 117 . VLR 117 provides location information to HLR 113 . A servicing mobile switching center (MSC-S.) 119 is connected to G-MSC 115 and a VLR 121 . VLR 121 provides location information to HLR 113 . MSC-S 119 is connected to a plurality of base stations, including base stations 123 and 124 , which use digital control channels (DCCHs) for paging and registration of mobile units and their respective areas.
[0018] A Gateway GPRS support node print (GGSN) 125 provides an interface between Internet 107 and GPRS system 103 . A GPRS HLR 127 provides GGSN 125 with location and subscriber information. GGSN 125 and GPRS HLR 127 are in communication with a servicing GPRS support node (SGSN) 129 , which communicates with mobile units in its area through a plurality of base stations, including base stations 131 and 132 . Base stations 131 and 132 use packet control channels (PCCHs) for paging and registration of mobile units in their respective areas.
[0019] System 101 includes a game session broker 135 . As will be explained in detail hereinafter, game session broker 135 communicates with mobile game units 105 and 133 . Game session broker 135 maintains game player profile information. Game session broker 135 maintains location information for registered mobile game units and it provides session availability information to registered mobile game units. While the present invention is illustrated and described with reference to interactive multiparty games, it will be recognized that embodiments of the invention may be applied to multiparty interactive sessions in general.
[0020] Those skilled in the are will recognize that GPRS system 103 is only one example of a wireless cellular communication system. GPRS system 103 enables communication between game session broker 135 and mobile game units 105 and 133 either via PSTN 109 or Internet 107 . However, game units 105 and 133 may also communicate with game session broker 135 solely through a cellular telephone system. Additionally, while game session broker 135 is illustrated in FIG. 1 as being outside GPRS system 103 , those skilled in the art will recognize that a game session broker could be part of the infrastructure of a cellular communication system.
[0021] System 101 may include one or more wireless local area network (WLAN) (e.g., WiFi) access points 137 and 139 . WLAN access points 137 and 138 may be interconnected by a local area network (LAN) 139 . LAN 139 may be connected to Internet 107 . As is known to those skilled in the art, mobile game units 105 and 133 may communicate with WLAN access points 137 or 138 and with each other either through WLAN access points 137 and/or 138 or directly with each other via ad hoc wireless communications. Mobile game units 105 and 133 may be GPS enabled, whereby they can obtain location information from one or more GPS satellites 141 .
[0022] Referring now to FIG. 2 , a block diagram of a game enabled wireless telephone is designated generally by the numeral 201 . A controller 203 receives inputs from and provides outputs to various devices. Game enabled wireless telephone 201 includes a low-power radio 205 , which in the preferred embodiment is a cellular phone transceiver. Game enabled wireless telephone 201 also includes at least one high-power radio 207 . High-power radio 207 may be a WLAN transceiver (e.g., WiFi) or any high-power transceiver in addition to low-power radio 205 . In some embodiments of a game enabled wireless telephone, there can be plurality of high-power transceivers. In addition, a game enabled wireless telephone may include a radio for short range communications, such as Bluetooth.
[0023] Game enabled wireless telephone 201 includes a speaker 209 and a microphone 211 coupled to controller 203 . Game enabled wireless telephone 201 also includes a display 213 coupled to controller 203 . Display 213 may be a touch screen display. Game enabled wireless telephone 201 also includes a keypad and other user input device, the indicated generally at 215 . In the embodiment of FIG. 2 , game enabled wireless telephone includes a GPS receiver 217 couple to controller 203 . Finally, memory 219 is coupled to controller 203 .
[0024] FIG. 3 illustrates a high level call flow diagram signaling according to an embodiment of the present invention. Mobile game unit 133 obtains location information, as indicated generally at block 301 . Location information may be obtained using the GPS system or by measuring the signal strength of access points (e.g., WLAN access point or a collocated Bluetooth device) in the vicinity of mobile game unit 133 . After obtaining location information using one or more radio interfaces (e.g., WLAN or Bluetooth), mobile game unit 133 can power off the radio interfaces that are either idle or in high power consumption, as indicated at block 303 . Then, as will be described in detail hereinafter, mobile game unit 133 sends a session ready message 305 to game session broker 135 .
[0025] Similarly, mobile game unit 105 obtains location information, as indicated at block 307 , and powers off its WLAN radio, as indicated at block 309 . Then, mobile game unit 105 sends a session ready message 311 to game session broker 135 . As will be explained in detail hereinafter, game session broker 135 maintains game profile information for registered mobile game units and it maintains location information for mobile game units that are available for play. When mobile game session broker 135 receives a session ready message it determines if another available mobile game unit is located near the mobile game unit from which it received the session ready message. In an example in FIG. 3 , game session broker 135 determines that mobile game units 105 and 133 are located near each other. Game session broker 135 sends session available messages 313 and 315 to mobile game units 133 and 105 , respectively. In response to receiving session available messages, mobile game units 105 and 133 power up their respective WiFi radios, as indicated at blocks 317 and 319 , respectively. Then, mobile game units 105 and 133 may establish a wireless game session 321 . Session 321 may be carried out over an ad hoc wireless network or through a WLAN access point or through a radio that is different from the radio interface used for uploading session information.
[0026] FIG. 4 illustrates a session ready message format according to an embodiment of the present invention. In the embodiment of FIG. 4 , location information is obtained with reference to one or more of WLAN access points. The format of FIG. 4 includes a unit ID field 401 , which contains an identifier for the wireless unit. It can be in the form of identifier such as a telephone number. The format of FIG. 4 includes a time field 403 , which indicates the time period during which the mobile game unit will be available for game play. In the embodiment of FIG. 4 , the time period is specified as a number of minutes following the sending time of the session ready message. In other embodiments, the time available for play could be specified in terms of an end time. In other embodiments, the time may be indefinite, in which case the player is maintained in the list of available players until the player logs out. The message format of FIG. 4 includes a service set identifier (SSID) field 405 . SSID field 405 contains a unique identifier for each WiFi access point within range of the mobile game unit. Finally, the format of FIG. 4 includes a signal strength field 407 , which contains the signal strength measured by the mobile game unit for each WLAN access point within range of the mobile game unit.
[0027] FIG. 5 illustrates a session ready message format according to another embodiment of the present invention. The message format of FIG. 5 includes a unit ID field, which contains the identification of the sending mobile game unit. The message format of FIG. 5 includes a time field, which specifies the time during which the mobile game unit is available for play. Finally, the message format includes a position field 505 (e.g., relative or fixed position such as GPS, CellID, or position relative to fixed access points), which contains fixed or relative geographical coordinates of the game unit.
[0028] FIG. 6 illustrates a list of available players according to an embodiment of the present invention. The list of available players is maintained by game session broker 135 . When game session broker 135 receives a session ready message, it populates the list of available players with the unit ID 601 , location 603 , and playtime window 605 of the mobile game unit from whom the game ready message is received. In one embodiment of the present invention, players are registered with the game session broker 135 . Game session broker 135 maintains profile information for each registered player. Profile information may include such things as preferred games 607 , preferred players, 609 , session technology 611 , and proximity 613 .
[0029] FIG. 7 illustrates a high-level flowchart of mobile game unit processing according to the present invention. In one embodiment where a mobile game unit is GPS enabled and/or WLAN enabled, the mobile game unit waits for user input, as indicated generally at block 701 . If, as determined at decision block 703 , the user wishes to send a game session ready message, the mobile game unit determines, at decision block 705 , if its WLAN radio is in the power off condition. If not, the mobile game unit powers off its WLAN radio, as indicated at block 707 . Then, the mobile game unit determines, at decision block 709 , if it is GPS enabled. If so, the mobile game unit captures its GPS coordinates, as indicated at block 711 . If, as determined at decision block 709 , the mobile game unit is not GPS enabled, the mobile game unit powers on its WLAN radio at block 713 . Then, as indicated at block 715 , the mobile game unit searches for a WLAN access point. If, as determined at decision block 717 , a WLAN access point is not found, the mobile game unit displays a session not available message to the user at block 719 and processing returns to block 701 . If, as determined at decision block 717 , an access point is found, the mobile game unit measures the signal strength associated with the access point at block 721 . Then, the mobile game unit searches for a next access point, as indicated at block 723 . If, as determined at decision block 725 , a next access point is found, then the mobile game unit measures its signal strength at block 727 and returns to block 73 . The mobile game unit continues to search for and measure access point signal strength until, no more access points are found. Then, the mobile game unit turns off its WLAN radio, as indicated at block 729 .
[0030] After the mobile game unit has determined its position, either with reference to captured GPS coordinates or WLAN access point signal strength, the mobile game unit prompts the user to enter a time window and then waits for user input, as indicated at block 731 . In some embodiments, the user may not be prompted to enter a time, in which the session availability time is indefinite. Upon receipt of the time window input, the mobile game unit sends a session ready message to the game session broker and waits for a session available message, as indicated at block 733 . In some embodiments, the mobile game unit may periodically determine its position and send a new session ready message whenever its position has changed since its last session ready message. Upon receipt of a session available message, the mobile game unit displays session available, as indicated at block 735 . The game unit may also issue an audible signal to alert the user that a session is available. Then, as indicated at block 737 , the mobile game unit powers on its WLAN radio and finds and sets up a game session, as indicated at block 739 .
[0031] FIG. 8 illustrates a high-level flowchart of an embodiment for the session broker processing according to the present invention. When the session broker receives a session ready message, as indicated at block 801 , the session broker determines, at decision block 803 , if their GPS position is specified. If not, the game session broker calculates a position with reference to WLAN access point signal strengths, as indicated at block 805 . The game session broker knows the geographic position of each WLAN access point in its area. The game session broker is able to estimate distance from signal strength. Accordingly, the game session broker can determine a mobile game unit's position by solving a range or triangulation problem. Additionally, if two mobile game units are in proximity to the same WLAN access point, then they are in proximity to each other. Those two mobile game units may establish a game session directly with each other through an ad hoc wireless network or through the WLAN access point. Similarly, if two mobile game units are in proximity to different WLAN access points that are members of the same LAN, they can establish a wireless game session through that LAN.
[0032] After having determined the sending game unit's position, the session broker determines, at decision block 807 , if the player is on the list of active players. If so, the session broker updates the list of active players with the player's position and session availability information, as indicated at block 809 . If the player is not already on the list of active players, then the session broker adds the player ID with its position and session availability time window to the list of active players, as indicated at block 811 . Then, the game session broker searches the list of active players for a match, as indicated generally at block 813 . The search for matches includes at least a search of matching locations. As used herein, locations are matching if the mobile game units can establish a wireless game session either through one or more WLAN access points or directly through an ad hoc wireless network. The search may also include search for a preferred players, preferred technology, and preferred games. If, as determined at decision block 815 , there is a match, the session broker sends session available messages to each matching player, as indicated at block 817 . If, as determined at decision block 811 , there are no matches, then the session broker sends a received message to the player, at block 819 .
[0033] FIG. 9 is a high-level flowchart of active player list cleanup processing according to an embodiment of the present invention. Periodically, the session broker goes to a first entry on the list of active players, as indicated at block 901 . The session broker tests at decision block 903 if time is expired for the first entry. If so, the entry is removed from the list, as indicated at block 905 . Then, the session broker tests, at decision block 907 , if there are more entries in the list. If so, goes to the next entry on the list. In the embodiment of the invention in which a player remains on the active player list until the play logs off, the session broker would remove the player from the active player list upon receipt of a log off message from the player.
[0034] From the foregoing, it may be seen that embodiments of the invention are well adapted to overcome the shortcomings of the prior art. While the invention has been illustrated and described with respect to presently preferred embodiments, those skilled in the art, given the benefit of this disclosure, will recognize alternative embodiments. Accordingly, the foregoing disclosure is intended for purposes of illustration and not of limitation. | A system for establishing multi-party wireless game sessions includes a game session broker and at least two wireless units. Each wireless unit includes a first wireless device having relatively low power consumption and a second wireless device having relatively high power consumption. The game session broker is configured to receive a session ready message that includes location information for a first player and search for a second player having location information matching the location information for the first player. Upon finding a matching player, the game session broker sends session available messages to the wireless units associated with the first and second players. Session ready messages are sent and session available message are received using the first wireless devices. Upon receiving the session available message, the first and second players can establish a wireless game session using their respective second wireless devices. Preferably, the second wireless devices are maintained powered-off until a session available message is received. | 8 |
TECHNICAL FIELD
The present invention relates to an emulator damping mechanism and more particularly, to a damping mechanism of a brake pedal feel emulator in a vehicle's wheel brake system for closely matching the performance feel of a conventional vacuum boosted brake apply system through dual stage operation.
BACKGROUND OF THE INVENTION
With a brake-by-wire, or similar type of vehicle braking system, where the application of fluid brake pressure to the wheel brakes can be generated by an electrically or an electro-hydraulically controlled means rather than by the manual application of force to the master cylinder, the master cylinder is typically isolated from the rest of the braking system during brake operation. This changes the response characteristics at the vehicle's brake pedal from those conventionally provided and can prevent the driver from experiencing the customary brake pedal travel and feel. These automated types of braking systems generally do not include a conventional booster between the brake pedal and the master cylinder, which may contribute to pedal response changes.
It is preferable that the vehicle driver experience a conventional pedal response when applying a vehicle's brakes on a vehicle with electric or electro-hydraulic brake control. In some applications, such a control system is preferably "transparent" to the driver, and the brake apply system would be perceived to respond the same as a conventionally boosted apply system. Accordingly, brake by wire systems include ancillary components to approximate conventional pedal characteristics during brake application. These ancillary components increase costs, require additional space and can interject discernible differences into the pedal feel characteristic during brake application cycles.
A known device that mimics the conventional pedal feel when the master cylinder is isolated from the remainder of the braking system is disclosed in U.S. Pat. No. 5,246,283 entitled Electro-Hydraulic Brake Apply System, which issued Sep. 21, 1993. That patent describes a stand alone accumulator with movable pistons separated by a pair of springs. The pistons move against the springs to provide compliance in the system, so that the driver experiences customary pedal feel and travel rather than a hard pedal.
Additional efforts have been directed at more closely approximating conventional brake apply feel at the pedal. The use of additional springs, providing gaps adjacent springs or integrating the device into a master cylinder have been found to help in this regard. One such device is disclosed in U.S. Pat. No. 5,630,217 entitled Compliant Mater Cylinder, which issued Feb. 18, 1997. That patent discloses a master cylinder with a compliant assembly that provides conventional pedal feel and travel characteristics when the master cylinder pistons are substantially immovable. The compliant assembly includes a push rod piston that is movable against a selected amount of fluid pressure and spring force.
The strides that have been made in approximating the conventional pedal feel characteristics of a brake apply system have resulted in good emulation of pedal travel versus pedal force for a typical passenger vehicle during various brake applications. Accordingly, automated apply systems are presently capable of providing acceptable pedal feel characteristics. However, because pedal feel is a subjective quantity, additional advancements in the art are still preferable, especially since a great many variables contribute to the pedal feel response of any given system.
SUMMARY OF THE INVENTION
The present invention provides a variable rate pedal feel emulator that supplies the typical brake pedal travel and feel characteristics to a brake system when the master cylinder is isolated from the wheel brakes. As part of the present invention it has been found that it is preferable for the emulator system to provide pedal damping characteristics in addition to supplying acceptable pedal travel versus force characteristics.
A preferred embodiment of the invention provides a pedal feel emulator assembly associated with the primary piston of the master cylinder and the brake pedal push rod. The emulator piston is movable against the force of a spring element and fluid forces upon the application of manual pressure to the brake pedal, even when the primary piston is substantially immovable due to isolation of the master cylinder from the remainder of the braking system. A brake master cylinder assembly according to this preferred embodiment includes a body having a master cylinder bore and at least one transverse bore. A fluid reservoir is carried near the body and communicates with the transverse bore. A compensation port extends through the body between the transverse bore and the master cylinder bore providing a means of communicating fluid between the master cylinder and the reservoir. Within the area of the transverse bore a damping piston operates in response to high flow rates through the compensation port. A specifically tuned flow restrictive orifice is provided in the damping piston between the variable chamber and the reservoir. In addition, a high return flow check valve is provided between the variable chamber and the reservoir.
In operation, when force is applied to the braking pedal of a vehicle incorporating the present invention and the master cylinder is isolated from the remainder of the hydraulic braking system, the push rod applies the pedal force to the emulator piston which is movable against the spring element and fluid forces providing the customary brake pedal travel and feel. This occurs while the primary piston remains substantially immovable due to the non-compressibility of the braking fluid trapped in the master cylinder's high pressure chambers. According to a preferred aspect of the present invention, when the emulator piston is moved from the at-rest position, fluid in the variable chamber between the primary piston unit and the emulator piston is forced through at least one orifice in the primary piston unit or emulator piston and is communicated through the compensation port and through the flow restrictive orifice in the damping piston to the reservoir. Flow rate of the fluid is dependent on the apply rate of the brake pedal. When the brake pedal is applied relatively slowly, the flow rate will be low and damping is not required. Sufficient flow volume will occur through the flow restrictive orifice and the damping piston will remain unmoved. As apply rates increase, a sufficient pressure differential will eventually be established across the damping piston to cause it to move. Damping piston movement compensates for rapid fluid displacement out of the variable chamber and enables a desirable pedal feel characteristic where pedal fore increases relatively slowly as pedal velocity rapidly increases. As the damping piston movement provides increasing volume the pressure differential drops across the damping piston and it will cease to move as flow is accommodated solely through the flow restrictive orifice. As this occurs, pedal force will increase more rapidly.
The preferred system is designed so that when the master cylinder is not isolated from the remainder of the associated braking system travel of the emulator piston effects movement of the primary piston. This ensures that the master cylinder can be utilized to provide a pressure source for braking application in a conventional manual apply manner when desired or needed. In such operation, the master cylinder's pistons are manually moved to pressurize the braking system through the high pressure chambers. During a manual apply mode the present invention provides a mechanical/hydraulic means of shutting off or by-passing the emulator. This occurs when preferred isolating solenoid valves open, permitting the primary and secondary pistons to move to generate braking pressure. The otherwise additional travel of the emulator is not added to pedal travel during manual mode operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross sectional view of a brake system's master cylinder and emulator assembly according to the present invention.
FIG. 2 is a graph of pedal velocity in inches per second versus pedal force in pounds for the assembly of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, illustrated in FIG. 1 is a brake apply system's master cylinder and emulator assembly in accordance with the present invention designated in the aggregate as 12. The master cylinder and emulator assembly 12 includes a body 15 formed of an acceptably rigid material such as metal or plastic and an associating fluid reservoir 14. The master cylinder and emulator assembly 12 is responsive to the manual application of force to a brake pedal 10, through the push rod 30.
A stepped longitudinal bore 16 extends through body 15 and slidably carries a plural piston arrangement including primary piston unit 19, secondary master cylinder piston 21 and emulator piston 25. The primary piston unit 19 is arranged in a subassembly that includes primary master cylinder piston 20 and intermediate piston 24 which, in the present embodiment are formed together as a one piece rigid body. A spring retainer 38 is slidably retained on primary master cylinder piston 20 by means of fastener 35. A return spring 39 is carried between spring retainer 38 and shoulder 57 of primary master cylinder piston 20. The primary piston unit subassembly also includes a seal 36 carried in a circumferential groove between shoulder 57 and shoulder 58 of primary master cylinder piston 20. The seal 36 bears against the wall of stepped longitudinal bore 16 in master cylinder bore 18 and provides fluid separation between primary high pressure master cylinder chamber 22 and intermediate chamber 23.
A seal 43 is carried on intermediate piston 24 and is spaced away from the wall of stepped longitudinal bore 16 in emulator bore 17. The seal 43 effects fluid separation between intermediate chamber 23 and chamber 26, when positioned to the left of step 100, where it bears against the wall of stepped longitudinal bore 16 formed by body 15. The seal 43 provides fluid communication between intermediate chamber 23 and chamber 26 when positioned to the right of step 100 as shown. Seals 36 and 43 of primary piston unit 19 define movable boundaries of chamber 26, intermediate chamber 23, and primary high pressure master cylinder chamber 22 within stepped longitudinal bore 16 as detailed below.
Primary piston unit 19 includes a longitudinal bore 48 that enters into the intermediate piston 24 within chamber 26 and extends partially through the primary piston unit 19. A plurality of orifices, represented by orifice 49, extend radially through primary piston unit 19 intersecting longitudinal bore 48. The longitudinal bore 48 defines variable chamber 28 in cooperation with the emulator piston 25. Variable chamber 28 is in continuously open fluid communication with chamber 26 through the orifices 49. The primary piston unit 19 and specifically, the primary master cylinder piston 20 is operable to selectively pressurize a braking circuit (not illustrated), through outlet opening 44.
Secondary master cylinder piston 21 is substantially spool-shaped and is slidably carried in master cylinder bore 18 of stepped longitudinal bore 16 to the left of primary master cylinder piston 20 as viewed in FIG. 1. Secondary master cylinder piston 21 is engaged by spring retainer 38 of the primary piston unit subassembly. A return spring 42 extends between the shoulder 56 of secondary master cylinder piston 21 and the spring seat 32 at blind end 37 of the stepped longitudinal bore 16. The return spring 42 biases the secondary master cylinder piston 21 toward the primary master cylinder piston 20. Similarly, the return spring 39 biases the primary master cylinder piston 20 toward the emulator piston 25.
Secondary master cylinder piston 21 carries a primary seal 46 fluidly separating master cylinder bore 18 into secondary high pressure master cylinder chamber 52 and secondary low pressure master cylinder chamber 53. Secondary master cylinder piston 21 also carries a secondary seal 47 that separates secondary low pressure master cylinder chamber 53 from primary high pressure master cylinder chamber 22 within the master cylinder bore 18. The secondary master cylinder piston 21 is operable to selectively pressurize a braking circuit (not illustrated), through the outlet opening 45.
Master cylinder body 15 is adapted to receiving bayonets 33 and 34 of a conventional reservoir 14 within bores 73 and 74, respectively. A compensation port 67 provides an opening between reservoir 14 and master cylinder bore 18 into secondary low pressure chamber 53. A bypass hole 68 provides an opening between reservoir 14 and master cylinder bore 18 into secondary high pressure master cylinder chamber 52 when the secondary master cylinder piston 21 is in the at-rest position shown in FIG. 1. During a manual apply mode, when the secondary master cylinder piston 21 is moved to an apply position, the primary seal 46 is moved to a position to the left, (as viewed in FIG. 1), of bypass hole 68 so that the bypass hole 68 provides an opening between reservoir 14 and secondary low pressure master cylinder chamber 53.
Similarly, a compensation port 69 provides an opening between reservoir 14 and the master cylinder bore 18 of stepped longitudinal bore 16 into intermediate chamber 23. Additionally, a bypass hole 70 provides an opening between reservoir 14 and master cylinder bore 18 of stepped longitudinal bore 16 into primary high pressure master cylinder chamber 22 when the primary master cylinder piston 20 is in the at-rest position shown in FIG. 1. During a manual apply mode when the primary master cylinder piston 20 is moved to an apply position, the seal 36 is moved to a position to the left, (as viewed in FIG. 1), of bypass hole 70 so that the bypass hole 70 provides an opening between reservoir 14 and intermediate chamber 23. The compensation ports 67, 69 and the bypass holes 68, 70 provide fluid routes between the reservoir 14 and the stepped longitudinal bore 16.
The primary piston unit 19 resembles a spool and includes an annular undercut 29 formed around its circumference defining intermediate chamber 23 in cooperation with the wall of stepped longitudinal bore 16. The seal 36 operates to permit fluid compensation flow into the primary high pressure master cylinder chamber 22 from the intermediate chamber 23 when the primary master cylinder piston 20 moves back to the illustrated at-rest position from an apply position. A stop pin 31 is threaded into the body 15 and forms the compensation port 69. The stop pin 31 engages shoulder 58 to limit travel of primary piston unit 19 to the right as viewed in FIG. 1. The primary piston unit 19 is biased toward the stop pin 31 by return springs 39 and 42.
The bore 74 is formed by an annular extension that projects from body 15 and includes annular flange 80 that supports the reservoir 14 and engages the bayonet 34, with a fluid tight seal provided therebetween. A damping piston 79 is slidably and sealingly disposed in the bore 74 and separates the bore 74 into a compensation chamber 81 and a damping chamber 82. The damping piston 79 carries a seal in an annular groove that engages the wall of bore 74 permitting the damping piston 79 to slide while substantially preventing the transmission of fluid around its outer perimeter. Damping piston 79 is biased toward end wall 83 by a spring 84 that engages the damping piston 79 and bears against annular flange 80. Damping piston 79 includes an annular rib 85 that operates as a stop against end wall 83 maintaining some volume in the damping chamber 82 when in the fully returned position shown. A first bore 87 extends through the damping piston 79 and includes a flow restrictive orifice 86 that provides a continuously open flow path between the damping chamber 82 and the compensation chamber 81. The flow restrictive orifice 86 is tuned for the specific performance desired in a given application. A second bore 88 extends through the damping piston 79 from damping chamber 82 to compensation chamber 81. The bore 88 includes a valve seat 89 that faces the damping chamber 82 and includes an annular ledge 90. A valve obturator in the form of ball 91 is carried in the bore 88 between valve seat 89 and ledge 90. The ball 91 is biased toward the valve seat 89 by a spring 92 and operates as a check, preventing fluid flow through the bore 88 from damping chamber 82 to compensation chamber 81 and permitting fluid flow through the bore 88 from the compensation chamber 81 to the damping chamber 82. This check valve feature provides a mechanism for allowing rapid back flow of fluid from the reservoir 14 into the variable chamber 28 during pedal release.
During operation of the associating braking system, the primary high pressure master cylinder chamber 22 and the secondary high pressure master cylinder chamber 52 typically become closed off and isolated from the remainder of the braking system preventing the communication of fluid through outlet openings 44 and 45. This means that the primary piston unit 19 becomes substantially immovable due to the non-compressible fluid trapped in the chambers 22 and 52. To provide desirable feel and travel characteristics to the brake pedal, compliancy is provided in the system by means of damping piston 79 and the emulator piston 25, elastomeric body 40, orifices 49, and slots 62.
Emulator piston 25 is slidably carried in emulator bore 17 of stepped longitudinal bore 16 and is maintained therein by retaining ring 41. The emulator piston 25 carries seal 50 to maintain the fluid tight integrity of the rear opening 51 to stepped longitudinal bore 16. The emulator piston 25 also includes a post 54 which extends toward the primary piston unit 19 and is coupled therewith by extending into longitudinal bore 48. A number of fluid relief slots are formed in post 54, representative of which is slot 62. The slot 62 provides a route for fluid to move between the variable chamber 28 and the chamber 26. The emulator piston 25 operates to provide a preselected response at the push rod 30 when actuated by brake pedal 10 during a braking event that effects hydraulic isolation of the master cylinder assembly from the vehicle's wheel brakes (not illustrated).
When the master cylinder assembly is isolated from the wheel brakes, fluid in chambers 22 and 52 is unable to move through outlet openings 45 and 44. In such a case, when force is applied to the associating brake pedal 10, push rod 30 is caused to apply force to emulator piston 25 such that movement of the emulator piston 25 occurs. Fluid is forced from the variable chamber 28 through the orifices 49 and slots 62 into the chamber 26. From chamber 26, fluid is forced around the outside diameter of seal 43 and is communicated into intermediate chamber 23. The fluid is contained in intermediate chamber 23 and chamber 26 by the seal 50 and the seal 36 which is held against the wall of stepped longitudinal bore 16 by trapped fluid in primary high pressure master cylinder chamber 22. Therefore, the fluid transmission effected into intermediate chamber 23 by displacement of emulator piston 25 is directed through compensation port 69 into bore 87 and toward reservoir 14.
The emulator assembly operates to provide the selected pedal response and feel through the push rod 30 even though the master cylinder pistons 20 and 21 are immovable. Optionally, the emulator assembly may be located remotely from the master cylinder. With such a stand alone embodiment, the variable chamber 28 may optionally contain air or other gas that is relieved to the atmosphere or an accumulator. The emulator assembly's elastomeric body 40 is a solid body of natural or synthetic rubber, or may be replaced with a variety of spring elements as are known in the art. Elastomeric body 40 includes a circular perimeter surface 76 that bears against the wall of longitudinal bore 48 in the present embodiment, with a space optionally provided between the circular perimeter surface and the wall of longitudinal bore 48. This will accommodate expansion of the body 40 in a radial direction, which may be preferable depending upon the response required at the pedal 10, for a given application. On a first side of the perimeter surface 76 the elastomeric body 40 has a curved surface 71 that bears against the end wall 78 of longitudinal bore 48. On a second side of the perimeter surface 76 the elastomeric body has a conical surface 72 with an end that bears against the post 54 of emulator piston 25.
The following description relates to operation of the present embodiment with the master cylinder isolated from the associated braking system. As the brake pedal 10 is applied, the post 25 moves toward the end wall 78 of longitudinal bore 48 reducing the size of variable chamber 28. Fluid is forced from the variable chamber 48 through the orifices 49 and slots 62. The orifices 49 and slots 62 are sized to provide a selected amount of resistance to fluid flow. This provides a manner of tailoring the response of the emulator assembly. As the variable chamber is reduced in size, the elastomeric body 40 is compressed between the post 25 and the end wall 78 and fluid is displaced into chamber 26, around seal 43 through intermediate chamber 23 and compensation port 69 into damping chamber 82. Fluid flow rate through this path is dependent upon the rate of apply at the brake pedal 10. When the apply rate is relatively slow, damping is not required and the fluid entering damping chamber 82 flows through the bore 87 and the flow restrictive orifice 86. The spring 84 keeps the damping piston 79 seated against the end wall 83 of bore 88, and the ball 91 prevents flow through the bore 88. Under slow apply rate conditions the pressure differential developed across the flow restrictive orifice is insufficient to move the damping piston 79 to compress the spring 84.
When apply rate at the brake pedal 10 is relatively fast, the pressure differential developed across the flow restrictive orifice, as applied on the damping piston 79 is great enough to cause the damping piston 79, to slide within the bore 88 compressing spring 84. The resulting expansion of damping chamber 82 allows for rapid fluid displacement out of the variable chamber 28 and effects a feel characteristic at brake pedal 10 allowing relatively modest increases in pedal force to effect significant pedal velocity rate increases. This damping characteristic is demonstrated graphically in FIG. 2. The initial stage 94 of the curve 93 shows that upon a rapid apply rate, the pedal velocity increases relatively rapidly as the pedal force increases relatively modestly.
When the damping piston 79 has moved providing significantly more volume in the damping chamber 82, the flow rate through the bore 87 drops and the pressure differential across the flow restrictive orifice 86 decreases. When flow conditions no longer effect additional displacement of the damping piston 79, fluid flow through the flow restrictive orifice is sufficient to accommodate the fluid displaced from the variable chamber 28. At this point the pedal damping characteristic of the system is shown by secondary stage 95 of the curve 93 where pedal force increases more rapidly and pedal velocity slows. The damping mechanism provided by damping piston 79 is adaptable to use on other pedal feel emulators that use fluid displacement. If the brake pedal 10 remains depressed, the fluid will flow out of damping chamber 82 to the reservoir 14 through the bore 87 and the damping piston 79 will reseat on end wall 83.
After a brake application, when the manually applied force is removed from the brake pedal 10, the elastomeric body 40 forces the emulator piston 25 to return to the at-rest position illustrated, drawing fluid into the variable chamber 28 through the orifices 49 and the slots 62. The return of the emulator piston 25 is not assisted by fluid force since the fluid source is the unpressurized reservoir 14. When the brake pedal 10 is released, the ball 91 will move to compress the spring 92 allowing additional flow through the damping piston 79 to refill the expanding variable chamber 28.
A means of ensuring that the master cylinder and emulator assembly 12 is operable without an excessive increase in pedal travel in the no-power mode is provided, to apply braking pressure by movement of the pistons 20, 21 if a sufficient amount of force is applied to the push rod 30. When the master cylinder is not isolated from the remainder of the associated braking system, fluid can exit through the outlet openings 44, 45 and the pistons 20, 21 are movable. In response to application of the brake pedal 10, the seal 43 will travel to the left of step 100 and sealingly engage the wall of bore 16. At this position, seals 43 and 50 isolate the non-compressible fluid in the chamber 26 and variable chamber 28. This forms a hydraulic lock in the variable chamber 26 and therefore, does not add additional travel to the no-power apply condition. This enables pressurization of the high pressure chambers 22 and 52 for the application of fluid pressure through the outlet openings 44 and 45 to the associating braking system. Therefore, the master cylinder and emulator 12 provides a second mode for operation of the braking system by means of a manual mechanism to actuate wheel brakes, when required or desired. | A brake system includes a pedal feel emulator and a master cylinder with a damping mechanism having a damping piston. When the emulator piston is moved from the at-rest position, fluid is displaced from the emulator through a compensation port and through a flow restrictive orifice in the damping piston to the reservoir. Flow rate of the fluid is dependent on the apply rate of the brake pedal. When the brake pedal is applied relatively slowly, sufficient flow volume will occur through the flow restrictive orifice and the damping piston will remain unmoved. As apply rates increase, a sufficient pressure differential will eventually be established across the damping piston to cause it to move. Damping piston movement compensates for rapid fluid displacement out of the variable chamber and enables a desirable pedal feel characteristic where pedal force increases relatively slowly as pedal velocity increases relatively rapidly. As the damping piston movement provides increasing volume, the pressure differential drops across the damping piston and it will cease to move as flow is accommodated solely through the flow restrictive orifice. As this occurs, pedal force will increase more rapidly providing a two-stage damping characteristic. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to improved packages and more particularly, to packages which can be sterilized by conventional means after sealing, which are capable of maintaining the sterility of the contents, which can be readily opened and which provide for the controlled removal of the contents by a sterile technique.
Surgical articles and the like have been packaged and then sterilized in order to reduce the hazard of cross-infection in hospitals. Many of the packages previously employed have, however, been found to have serious disadvantages. Some of these, for example, have been difficult to open, requiring tearing or cutting and, hence, exposing the article, when withdrawn, to contamination by the non-sterile, exterior, torn or cut edges of the package. Other prior packages have suffered from the disadvantage of not permitting positive control of the sterile contents while opening the package to prevent the contents from dropping out and being contaminated. Another disadvantage of some prior packages is that they have been found to have unsealed channels through the seal lines closing the package at points where more than two sheets of packaging material are joined. Packages of this type tend to breathe, particularly when stored under conditions where there is a wide variation in temperature or atmospheric pressure. This is highly disadvantageous since it makes possible the introduction of airborne bacteria which may contaminate the contents of the package and cause the loss of sterility.
U.S. Pat. No. 3,070,225, issued on Dec. 25, 1962 to M. A. Schwartz and U.S. Pat. No. 3,324,705, issued on Feb. 15, 1966, also to M. A. Schwartz, disclose packaging for sterile articles and, in particular, disclose that the channel problem, referred to above, may be solved by providing a thermoplastic "calking" adhesive to flow into and block such potential channels. The concept disclosed is to provide a package comprising a top and bottom sheet. The bottom sheet has a peripheral portion or side edge of each of its longitudinal sides folded inwardly to overlie the bottom sheet and form longitudinally extending side flanges. The article packaged may then be partially held under the flanges in a controlled and positive manner. These side flanges are tacked down by applied, spaced areas of adhesive. A top sheet is then laid over the bottom sheet with the article and the side flanges therebetween. The top sheet is sealed to the bottom sheet by longutidinal side seals in the area where the top sheet overlies the side flanges and by transverse end seals spanning the two side flanges. The problem of channeling toward which the Schwartz patents are directed occurs at the end seals where the seal passes first through at least three thickness of packaging material (corresponding to the bottom sheet, the flange at one side and the top sheet), then two thickness (corresponding to the top sheet and the bottom sheet) and then again three thickness (corresponding to the bottom sheet, the flange at the other side, and the top sheet). It is at the point where the seal crosses from three to two thickness of packaging material, that the channeling problem exists. The solution suggested in the aforementioned Schwartz patents is to provide, for the spaced adhesive areas used on the bottom sheet for tacking down the flanges, a thermoplastic adhesive which is applied to the bottom sheet so as to extend beyond the area of contact between the flange and the bottom sheet. In this manner, when heat and pressure are applied to produce the end seal, at the same time the thermoplastic adhesive will be activated and become flowable, thus acting as a calk to block the potential channels.
This solution has been highly satisfactory and is particularly effective when both the top sheet and the bottom sheet are provided with the same, or otherwise adhesively compatible, adhesives. By the term "adhesively compatible adhesives" it is meant two adhesives which, upon activation, will seal together at their interface. Unfortunately, it is not always possible or desirable to provide the top and bottom sheets with adhesively compatible adhesives. In the circumstance where the adhesive applied to the top sheet for side and end sealing is adhesively incompatible with the adhesive used on the bottom sheet to tack down the flanges, the solution offered by the aforementioned Schwartz patents is not only inappropriate, but actually aggravates the problem. In this case, the calking adhesive does flow, upon end sealing. Instead of creating a seal, however, a relatively long interface of noncompatible top and bottom sheet adhesive is created at portions of the end seal between and adjacent to each flange. Accordingly, because of the incompatibility of the adhesives, this long interface is, in effect, a channel into the interior of the package, rendering the same entirely unsuitable for sterile articles.
It is apparent, therefore, that the need exists for a package for sterile articles which does not suffer from these drawbacks.
SUMMARY OF THE INVENTION
In accordance with this invention, a package is provided which utilizes the general construction described in the aforementioned patents to Schwartz, but does not suffer from the drawbacks associated therewith when it is desirable to employ adhesively incompatible adhesives.
Specifically, the invention is directed to a package for containing a sterile article of the type comprising a bottom sheet having an inner surface and folded side edges providing longitudinally extending side flanges. A top sheet having an inner surface is provided overlying the inner surface and flanges of the bottom sheet. The two sheets are held together and form a chamber therebetween by means of a peripheral seal comprising two side seals bonding the sides of the top sheet to the flanges of the bottom sheet and two end seals bonding the ends of the top sheet to the ends of the flanges and to the ends of the inner surface of the bottom sheet between the flanges.
As in the Schwartz patents, a first adhesive is disposed on the inner surface of the bottom sheet in the areas which contact the flanges under the end seals to provide means for sealing the ends of the package under the flanges. The top sheet is provided with an overall coating of a thermoplastic adhesive which is adhesively incompatible with the first adhesive. The necessity for adhesive incompatibility between the top and bottom sheet adhesives arises from several considerations. Firstly, it is desirable that the top sheet be overall coated as this eliminates the need for perfect registration when sealing the top sheet to the bottom sheet. In connection with this, it is then necessary to accurately apply the first adhesive to limited areas on the bottom sheet with means such as printing being best adapted for this purpose. Thus, because one adhesive is to be overall coated while the other is to be printed, it is difficult to find adhesively compatible materials which lend themselves to both methods of application.
The side seals of the package are effected by applying heat and pressure along the sides of the package to activate the thermoplastic adhesive and hence, bond the sides of the top sheet to the flanges. The end seals are effected by again applying heat and pressure along the ends of the package, activating both the first adhesive under the flanges and the thermoplastic adhesive on the top sheet.
As described above, there is a tendency to form a channel into the package at a point in the end seal adjacent the flange edge. In accordance with the method of the aforementioned Schwartz patent, the solution to this problem is to extend the area of first adhesive disposed on the inner surface of the bottom sheet to a point inward of the package and beyond the edge of the flange. When activated, this adhesive acts as a calk to seal the channel. However, when the adhesive on the top sheet is adhesively incompatible with the first adhesive, a long non-sealed interface results and aggravates the problem. Accordingly, in contrast to the prior method and in accordance with the method taught herein, the disposition of the first adhesive is limited to only the areas of contact between the inner surface of the flange and the inner surface of the bottom sheet which lie under the end seals. The portion of the inner surface of the bottom sheet between flanges and under the end seal are free of the first adhesive. Said in other words, in the area of the end seal, at no point does the thermoplastic adhesive on the top sheet contact the first adhesive on the bottom sheet to form a non-adhering interface. Instead, upon applying heat and pressure to form the end seal, both the first adhesive and the thermoplastic adhesive are activated and it is the thermoplastic adhesive, overall coated on the top sheet which fills the potential channels existing at the edge of the flanges.
A better understanding of the invention and the advantages which accrue therefrom will be had be referring to the appended drawings taken in connection with the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a package embodying the instant invention;
FIG. 2 is a perspective, exploded view of the package of FIG. 1 with the one edge of the top sheet and one edge of a flange turned up to expose the inner surfaces thereof;
FIG. 3 is an enlarged, perspective view of the portion of the bottom sheet illustrated in FIG. 2 at one side of the end seal of the package;
FIG. 3A is an enlarged, perspective view of a portion of a prior art package corresponding to that of FIG. 3;
FIG. 4 is an enlarged, perspective, cross-sectional view of a portion of the end seal of the package illustrated in FIG. 1 and taken through line 4--4;
FIG. 4A is an enlarged, cross-sectional view of a part of the end seal of a prior art package corresponding to that of FIG. 4;
FIG. 5 is a perspective view of a partially folded bottom sheet employed in the package of FIG. 1;
FIG. 6 is a perspective view of a second package embodying the instant invention;
FIG. 7 is a perspective view of a partially folded bottom sheet employed in the package of FIG. 6; and
FIG. 8 is an enlarged, cross-sectional view of a portion of the end seal area of the package illustrated in FIG. 6 prior to effecting the end seal and subsequent to effecting the side seal.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2 of the drawings, the package 10 is formed from a bottom sheet 12 having an inner surface 13 and a top sheet 14. The side edges of the bottom sheet 12 are folded, along fold lines 16 and 18 to form longutidinally extending side flanges 20 and 22. The top sheet overlies both the bottom sheet and at least a portion of the flanges and is bonded thereto by a peripheral seal comprising side seals 24 and 26 and end seals 28 and 30. A sterile article, exemplified by the surgical sponge 32, may be placed within the chamber formed between the top and bottom sheets and held there in a controlled manner by the flanges 20 and 22. As shown in the drawings, end seal 28 is designed to be the mouth of the package and, accordingly, this end seal 28 is disposed at a point inward of the extreme end of the package so as the provide a tab portion 34 which may be gripped to peel back the top sheet 14 when opening the package 10. To this end, the end seal 18 is preferably in a v-shaped to reduce the forces required when peeling the package open from this end.
It is contemplated that the side seals 24 and 26 will be accomplished by applying heat and pressure with a heated sealing bar pressed against the externally facing surface of the top sheet to seal the sides of the top sheet to the flanges 20 and 22. Likewise, end seals 28 and 30 will similarly be affected by appropriately shaped heated sealing bars. It is therefore advantageous to apply a coating of thermoplastic adhesive 36 to the inner surface of the top sheet and further, rather than merely applying this adhesive to those areas lying directly under the seals, it is perferable to overall coat the inner surface of the top sheet. In this manner, the need for careful registration of the top and bottom sheet is avoided and even a gross misregistration will provide effective sealing. A wide variety of thermoplastic materials may be employed as this coating using such methods as extrusion coating, or the lamination of thermoplastic films onto the inner surface of the top sheet. Examples of suitable thermoplastic adhesives are both high and low density polyethylene, polypropylene, and the like.
By bonding the top sheet to the flanges, the sides of the package are effectively sealed against the intrusion of non-sterile matter.
In the case of the end seals, however, it is also necessary to seal the areas of contact, 38, 40, 42 and 44, underlying the end seals and between the inner surface of the bottom sheet and the inner surface of the flanges. Accordingly, an adhesive is disposed in these areas of contact, the adhesive being activated by the application of heat and pressure when the end seal is affected. Because this adhesive must be applied to discrete areas of contact, it is necessary to use a material which is capable of being accurately placed in a desired pattern by such methods as pattern printing. Generally, such printing methods involve passing the web on which the pattern is to be printed through print rollers which are embossed or engraved with the required pattern and which have passed through a reservoir of an emulsion of adhesive. Accordingly, the adhesive material chosen should be one capable of forming such an emulsion and preferably an aqueous emulsion, with polyvinyl acetate being the adhesive of choice. Unfortunately, such adhesives are adhesively incompatible with the thermoplastic adhesives preferred as an overall coating for the top sheet and this adhesive incompatibility gives rise to the problem of channeling, the solution to which this invention is directed.
Referring now to FIGS. 3, 3A, 4 and 4A, illustrated in FIG. 3 is an enlarged, perspective view of the portion of flange 20 and the bottom sheet 12 underlying end seal 28. It will be understood, this portion is typical of the remaining three areas under the end seals. FIG. 3A illustrates a portion of the prior art package, as disclosed in the aforementioned M. A. Schwartz patents, with primed numerals referring to parts corresponding to parts of the package of this invention.
Similarly, FIG. 4 illustrates, in perspective cross-section, a view of this same portion of the package of FIG. 1, and FIG. 4A illustrates a corresponding portion of the prior art package, again with primed numerals referring to corresponding parts.
As can be best seen in FIGS. 4 and 4A, as the end seal 28 passes from the edge of the package toward the center, the number of thickness of material being sealed together changes from three (corresponding to the top sheet 14, the flange 20 and the bottom sheet 12) to two (corresponding to the top sheet 14 and the bottom sheet 12). Accordingly, there is the tendency to form a channel into the package at the area 46 where the change in the number of thickness occurs.
Referring to FIG. 3A, the prior art method of solving this problem is to provide an adhesive coated area 38', employing a thermoplastic adhesive. This adhesive area is provided with an extended portion 39, extending beyond the area of contact between the flange 20' and the bottom sheet 12'. Thus, when heat and pressure are applied, the adhesive of this extended portion 39 will flow and act as a calk to fill the area 46', as is illustrated in FIG. 4A. Such a prior art method is effective, however, only when the adhesive coating 36' and 38' are adhesively compatible. As is illustrated in FIG. 4A, by employing the method of Schwartz, a relatively long transverse interface 48 is formed. When, for the reasons discussed above, it becomes necessary to employ adhesively incompatible adhesives for adhesives 36' and 46', this interface remains unsealed and results in a substantial channel into the interior of the package, thus severly compromising the sterility of the contents and making the solution disclosed by Schwartz wholly inappropriate.
In accordance with the instant invention, as illustrated in FIG. 3, the adhesive 38 is limited to the area of contact between the bottom sheet 12 and the flange 20. The area under the end seal 28 beyond flange 20 and between this flange and flange 22 is maintained free of such adhesive. To solve the aforementioned channeling problem, the adhesive 36, applied to the top sheet, is selected as a thermoplastic adhesive and, as can be best viewed in FIG. 4, it is this adhesive which flows into the area 46, sealing the potential channel. Because the adhesive 36 never makes substantial contact with adhesive 38, no non-adhering interface is formed and the fact that the two adhesives are adhesively in no way compromises the sterility of the contents.
Illustrated in FIG. 5 is a partially folded perspective view of the bottom sheet 12, shown with one side edge folded along fold line 16 to form flange 20. The other side edge has not yet been folded along line 18. Printed onto the bottom sheet 12 are the four adhesive areas 38, 40, 42, and 44. As is described above, it is important that the printing be such that upon folding the side edges to form flanges 20 and 22, each of the adhesive areas are limited to the area of contact between the flanges and the bottom sheet. To assure this, the printed areas are limited in the transverse direction to an inward distance A beyond the fold lines 16 and 18, respectively, which is less than the width B of the flanges. To assure that the flanges are fully bonded to the bottom sheet, the adhesive is applied to extend to the very edges 50 and 52 of the bottom sheet.
In manufacturing the package 10 illustrated in FIG. 1, it is contemplated that after superimposing top sheet 14 upon bottom sheet 12, end seal 30 and side seals 24 and 26 will be effected, forming an envelope with an open mouth for filling. In this connection, end seal 30 may be strengthened by applying crimps 31 either during or after the heat sealing operation. Upon filling, end seal 28 will be effected. As described above, and as is illustrated in FIG. 2, it is desirable that a portion of the contents 32 of the package be sandwiched between the flanges 20 and 22 and the bottom sheet so that when the package is peeled open, the contents will be held in place in a positive controlled manner. In order to do this, it is necessary that, upon effecting the side seals prior to filling, care is taken to avoid activating the adhesive in areas 38 and 40 in that should these areas be sealed, it will be difficult, if not impossible, to fill the package with the contents held under the flanges. Accordingly, in the embodiment shown in FIG. 1, the side seals must terminate at a point short of the adhesively applied areas 38 and 40 and the package sealed completely closed only after effecting end seal 28, e.g., by having end seal 28 be wide enough to slightly overlap the ends of side seals 24 and 26.
The need to prevent premature sealing of the adhesive areas 38 and 40 necessitates an interrupted application of heat sealing bars when effecting side sealing on a mass production basis. In another aspect of this invention, the printed pattern of adhesive areas 38, 40, 42, and 44 is varied to allow instead of continuous side sealing. Referring now to FIGS. 6-8, illustrated in FIG. 6 is a second embodiment of this invention, generally designated as package 60. As in the prior embodiment, package 60 is formed from a bottom sheet 62 having an inner surface 63 and a top sheet 64.
The side edges of the bottom sheet 62 are folded along fold lines 66 and 68 to form longitudinally extending side flanges 70 and 72. The top sheet overlies both the bottom sheet and at least a portion of the flanges and is bonded thereto by a peripheral seal comprising side seals 74 and 76 and end seals 78 and 80. End seal 78 is designed to be the mouth of the package and accordingly, this seal is disposed at a point inward of the extreme end of the package so as to provide a tab portion 84 which may be gripped to peel back the top sheet 64 when opening the package 60. As shown in this embodiment, the end seal 78 is provided in a pattern of multiple peak to reduce the forces required when opening the package. While this pattern is interchangeable with the v-shaped described in connection with FIG. 1, the multiple peak pattern eliminates the need for perfect registration of the end sealing bar when effecting the seal.
As in the prior embodiment, top sheet 64 is provided on its inner surface with an overall coating of a thermoplastic adhesive to effect the side and end seals by the application of heat and pressure. Again, an adhesive, incompatible with the thermoplastic adhesive on the top sheet, is applied in the areas of contact 88, 90, 92 and 94 underlying the end seals and between the flanges 70 and 72 and the bottom sheet 62. In accordance with this invention, these applications of adhesive are limited to the area of contact. The portion of the bottom sheet 72 lying under the end seals and between the flanges are free of this adhesive.
Unlike the side seals of FIG. 1, side seals 74 and 76 are effected by passing the full length of the package under a heated sealing bar so that a plurality of packages can be side sealed in a continuous manner. In accordance with this aspect of the invention, to avoid premature sealing of the flanges, the pattern of adhesive applied to the bottom sheet is varied from that of the prior embodiment, as is best illustrated in FIG. 7.
Referring now to FIG. 7, illustrated therein is a partially folded, perspective view of the bottom sheet 62, shown with one side edge folded along fold line 66 to form flange 70. The other side edge has not yet been folded along line 68. Printed onto the bottom sheet 62 are the four adhesive areas 88, 90, 92 and 94. Again, in accordance with this invention, the adhesive is limited to the area of contact between the flanges and the bottom sheet and so the adhesive areas are printed in a pattern such that the trasnverse inward distance A beyond the fold lines 66 and 68 is less than the width B of the flanges.
In accordance with this aspect of the invention, the printed adhesive areas are provided with gaps 96, 97, 98 and 99 corresponding to the area through which the continuous side seals 74 and 76 will pass. The effect of the gaps is best understood by referring to FIG. 8 which is a cross-sectional view of a portion of package 60 of FIG. 6 taken through line 7--7 at a time prior to effecting the end seal 78 and subsequent to effecting the side seal 76. It can be seen from this figure, that by passing the package continuously under a heat sealing bar, side seal 76 has been effected and the thermoplastic adhesive 100 coated to the top sheet 64 has been bonded to the flange 72. By virtue of the gap 97 in the applied adhesive area 90, the heat and pressure exerted by the bar can be controlled to avoid activating the adhesive area 90 when side seal 76 is effected. Said in other words, the absence of adhesive on the inner surface of flange 72, under side seal 76, insures that adhesive area 90 at this point is sufficiently remote from the application of heat and pressure applied in effecting side seal 76 so that such heat and pressure can be controlled to avoid activating any of the adhesive area 90 under the seal. Thus, the flange 72 will remain unbonded to the inner surface of bottom sheet 62 and the package may easily be filled to hold the contents in a controlled manner.
Referring once again to FIG. 6, package 60 is designed to be opened at the end adjacent to seal 78 and accordingly, this seal is disposed at a point inward of the extreme end of the package to provide a tab portion 84 which may be gripped to peel back the top sheet 64. To facilitate gripping the tab, it is preferred that the terminal portions 102 and 104 of the side seals 74 and 76, respectively, remain unbonded to the flanges 70 and 72. A simple means for affecting this is illustrated in FIG. 7. Printed onto the exterior surface of the bottom sheet 62 are areas 106 and 108. These areas are printed with a material (e.g., the adhesive 90) adhesively incompatible with the thermoplastic adhesive coating 100 on the top sheet and are placed in those areas of contact between the flanges and the superimposed top sheet which corresponds to the terminal portions 102 and 104 of the side seals 74 and 76. Accordingly, even though the sealing bar will continuously pass over these terminal portions and activate the thermoplastic adhesive 100 thereunder, because this portion of the adhesive coating 100 is opposed by an adhesively incompatible area, the top sheet will not bond to the flange in this area and the tab 84 will remain free for gripping. Many variations in the above-described embodiments are possible while still remaining within the scope and spirit of this invention. For example, while the above embodiments have been described in terms of packages 10 and 60, these being opened by peeling the respective top sheets back from the bottom sheets in a direction parallel to the side seals, it is equally possible to peel the top sheet back in a direction transverse to these side seals. In this case, the package would be opened by gripping a side edge of the top sheet and pulling it back to break the adjacent side seal and the two end seals to provide access to the contents. The method of opening the package notwithstanding, the teachings herein relating to the problem of channeling, when using adhesively incompatible materials, still apply.
The top and bottom sheets may be composed of any suitable, flexible packaging material. It is preferred, however, that at least one of these elements be composed of a flexible packaging material which permits sterilization of the contents of the package subsequent to sealing. Paper is most suitable for this purpose, since it permits sterilization by steam or sterilizing gases according to conventional procedures. Especially suitable for this purpose is a sterilizable bacterial barrier paper having a 35-40 lb. per ream basis weight, although higher weights, e.g. 60 lbs. per ream, is also suitable. | A package is provided especially for containing sterile articles which can be readily opened and which provides for the controlled removal of the contents. The package is sealed in a manner which precludes the formation of channels leading to the interior of the package and compromises sterility. Specifically, the end seal of the package is provided by providing a thermoplastic adhesive which acts as a caulk to seal such potential channels, the thermoplastic adhesive being disposed in a manner whereby it is assured that said adhesive does not contact adhesively incompatible areas. | 8 |
FIELD OF THE INVENTION
The present invention relates to a bearing assembly for wellbore drilling and, in particular, an oil-sealed bearing assembly for use in a wellbore drilling operation.
BACKGROUND OF THE INVENTION
In the drilling of bore holes into the earth, as in the case of drilling oil and/or gas wells, it is common to drive the drill bit by a downhole mud motor located at the end of a drill string. In particular, drilling fluid, generally referred to as drill mud, is circulated to drive the motor by positive hydraulic displacement or turbine action. The mud then passes through the ports in the drill bit and carries material loosed by the drill bit back to the surface through the annular space between the drill pipe and the resulting bore hole.
Bearing assemblies for wellbore drilling are mounted between the drill bit and the drill string to permit rotation of the drill bit. The drill bit is attached to a hollow drive shaft, also known as a mandrel that is located within a bearing housing. The mandrel is rotatably driven by the mud motor while the bearing housing is fixed to the drill string and remains relatively stationary. In its position behind the drill bit, the bearing assembly is subject to significant radial and axial loading. Radial and thrust bearings are thus located along the bearing assembly to react (absorb) radial and axial loads.
Lubrication between the rotator mandrel and stator housing may be achieved by oil or mud located in the annular space between those components. In the case of oil lubrication, an oil-sealed bearing chamber is formed by seals such as PolyPak® or KALSI SEAL®. The seals are acted upon by downhole drilling fluid pressures, including pump pressures and hydrostatic pressures, resulting in higher pressures above the sealed bearing chamber as compared to below the sealed bearing chamber. Such pressure differential results in damage to the seals, leading ultimately to seal failure. To reduce the pressure differential, a flow restrictor located above the sealed chamber is used to reduce the fluid flow in the annular passageway between the mandrel and housing.
In mud lubricated bearing assemblies, it is desirable to reduce the fluid flow through he bearings to prevent premature wear due to the effects of high drilling fluid pressures, as well as the abrasive actions of the mud itself. In this case, radial bearings serve as flow restrictors.
Despite the use of flow restrictors/radial bearings to increase the durability of the bearing assembly, the flow restrictors/radial bearings are themselves limited by their ability to withstand damage resulting from lateral and radial loads incurred during drilling. Carbide-containing flow restrictors are very expensive and damage thereto is of great concern.
The mandrel component of the bearing assembly is also susceptible to damage by drilling loads, as well as by the severe shock and vibration incurred during drilling applications. In particular, the mandrel is engaged to the housing by a split ring, also called a saver ring. The split ring includes two semi-cylindrical halves having annular grooves in their inner surfaces. The machined grooves engage into annular recesses formed on the surface of the mandrel. During assembly, the halves of the split ring are fit over the mandrel. This form of assembly requires that the fit between the mandrel and the split ring to be somewhat loose. This loose fit permits some vibration between the mandrel and the split ring, thereby causing mandrel failure by cracking.
There is a need, therefore, for improved construction of bearing assemblies which provides for a longer operational life of the assembly over current constructions.
SUMMARY OF THE INVENTION
A bearing assembly for wellbore drilling has been invented. In one embodiment, the bearing assembly has an extended life without repair by providing support for the flow restrictor/radial bearing (which will be termed herein, the flow restrictor). In another embodiment, a compression nut is threadedly engaged onto the mandrel to replace the split ring.
In accordance with a broad aspect of the present invention there is a bearing assembly comprising: a first elongate member adapted for connection to a drill bit assembly; a second elongate member adapted for connection to a drill string, the first elongate member and the second elongate member being telescopically disposed and being rotatable about a long axis of the bearing assembly one relative to the other; a first bearing disposed between the first elongate member and the second elongate member; a flow restrictor positioned between the first elongate member and the second elongate member to restrict flow between the members; and a second bearing adjacent the flow restrictor and on a side of the flow restrictor opposite the first bearing.
In accordance with another broad aspect of the present invention there is a bearing assembly for use in a drill string to accommodate rotation of the drill bit comprising a first elongate member and a second elongate member, the second elongate member, being telescopically disposed over the first elongate member and the first elongate member being rotatable within the second member and about the long axis of the tool; a flow restrictor disposed between the first elongate member and the second elongate member to restrict fluid flow therebetween; a bearing on each side of the flow restrictor, the bearing assemblies being disposed to act between the first elongate member and the second elongate member.
The first elongate member and the second elongate member can be the mandrel and outer housing of the bearing assembly, respectively.
The bearings are preferably oil-lubricated requiring sealed oil chambers. A sealed, lubricated bearing offers an extended useful life over a mud-lubricated bearing. In a bearing assembly having lubricant-containing sealed bearings, preferably means are provided to balance the seals of the chamber. In one embodiment, at least one fluid flow channel is provided past the upper bearing assembly to provide for balancing the pressures at the seals of the lubricant-filled chamber. In another embodiment, openings are provided through the housing such that fluids at external pressure are in contact with chamber seals.
Preferably, the bearing assembly includes radial and thrust bearings. In one preferred embodiment the thrust bearings include on-bottom bearings for accommodating load in one direction and off-bottom bearings for accommodating load in an opposite direction to the on-bottom bearings. These thrust bearings are positioned on the bearing assembly to be adjusted simultaneously. Preferably, these thrust bearings are contained within the same lubricant-filled chamber.
In a preferred bearing assembly, there are at least three radial bearings spaced along the bearing assembly with, for example, two on one side of the flow restrictor and one on the other side. Preferably, greater radial support is provided between the flow restrictor and the bit end of the bearing assembly where greater lateral and sideways bending loads are experienced. Preferably radial bearings are positioned on either side of the flow restrictor and on either side of the thrust bearings. All radial bearings are preferably selected to maintain the mandrel concentric within the bore of the housing.
In accordance with another aspect of the present invention, there is provided a bearing assembly for use in a drill string to accommodate rotation of the drill bit comprising a first elongate member and a second elongate member, the second elongate member being telescopically disposed over and rotatable about the first elongate member; a flow restrictor disposed between the first elongate member and the second elongate member to restrict fluid flow therebetween; at least one bearing disposed to act between the first elongate member and the second elongate member and a compression nut threadably engaged to the first elongate member and disposed between the first elongate member and the second elongate member, the compression nut abutting against a shoulder on the inner diameter of the second elongate member and supporting the at least one bearing.
Preferably, the bearing is a thrust bearing. In one embodiment, the compression nut is positioned to maintain the second elongate member in telescopic arrangement over the first elongate member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the orientation of FIGS. 1A to 1 D.
FIGS. 1A to 1 D are together a sectional view along the axis of a bearing assembly according to the present invention.
FIG. 2 is a section through an upper bearing along line 2 — 2 of FIG. 1B with the mandrel, Du bearing and floating piston removed.
FIG. 3 is a partial sectional view of another bearing assembly according to the present invention.
FIG. 4 is an enlarged view of a bearing having mounted thereon a compression nut.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures, a bearing assembly 10 is shown. Bearing assembly 10 includes a mandrel 12 , a mandrel adapter 13 secured by a threaded connection to the mandrel and a housing 14 . Housing 14 is telescopically disposed and rotatable about mandrel 12 . Box end 16 of mandrel 12 is adapted for connection directly or indirectly to a drill bit (not shown). Mandrel adapter 13 is adapted for connection to the power section of the mud motor. Holes 13 a engage the motor drive shaft (not shown). Open end 17 of housing 14 is adapted for connection into a drillstring of tubulars (not shown).
In operation, bearing assembly 10 is connected between a drill bit and a drill string of tubulars. Generally, drilling fluid is pumped through the drill string into bore 18 of the housing. Thereafter, the fluid passes into the inner bore 19 of mandrel adapter and then into the inner bore 19 a of the mandrel. This fluid then passes out through the ports in the drill bit and back up the outside of the housing on its way back to surface. Some of the fluid also passes through the annular space 42 between the mandrel and the housing.
The drilling fluid is under pressure as it passes through this route. In particular, in the bores of the housing and the mandrel, fluid is pressurized by hydrostatic pressure as well as pump pressure. Once the fluid passes through the drill bit ports, any pump pressure is dissipated leaving only hydrostatic pressure acting on the drilling fluid. Thus, generally, the fluid inside the bearing assembly is at a greater pressure than the fluid outside the bearing assembly.
A lubricant-filled bearing chamber 20 is disposed between mandrel 12 and housing 14 to support rotation of the mandrel relative to the housing. The lubricant is preferably oil but can be other substitutes such as silicone, grease, etc. Bearing chamber 20 is filled with oil through fill ports 21 that are sealed off before use by metal threaded plugs or welded caps. Bearing chamber 20 is sealed by upper sealing elements 22 a , 22 a ′ on a floating piston 23 and a lower sealing element 22 b . These seals maintain the oil within the chamber about the bearing members contained therein. The sealing elements are for example O-rings or pressure deformable seals such as PolyPac or Kalsi seals. Sealing element 22 a seals between piston 23 and mandrel 12 . Sealing elements 22 a ′ seal between piston 23 and housing 14 . Piston 23 is movable axially through the annular space between the housing and the mandrel to permit expansion and contraction in the chamber volume, as caused by change in external pressure and temperature. A plated surface or a piston housing sleeve 24 , for example formed of chromium iron, is secured to the surface of the housing adjacent piston 23 to provide a smooth durable surface over which the piston can move.
The seals 22 a , 22 a ′ and 22 b at either end of bearing chamber 20 are pressure balanced to improve bearing operation and useful life. In particular, sealing element 22 b is exposed to external pressure and openings 25 are formed through housing 14 to permit communication of fluids at external pressure to sealing elements 22 a and 22 a ′. Bearing chamber 20 is positioned between a flow restrictor 26 and the box end 16 of the mandrel.
Flow restrictor 26 includes a stationary flow restrictor 27 a secured within the housing and a rotatable flow restrictor 27 b on the shaft. A stopper ring 29 supports and retains the rotatable flow restrictor on the shaft. A suitable flow restrictor is one adapted to lose no more than 10% pumping pressure, although other flow restrictors could be used, as desired. Flow restrictor 26 restricts fluid flow therepast in the annular space between the mandrel and the housing. This reduction in flow effectively reduces the differential pressure of the fluid that comes into contact with upper seals 22 a and 22 a ′ of bearing chamber 20 . In particular, fluid jetting against floating piston 23 is substantially eliminated. Thus, flow restrictor 26 tends to substantially equalize the pressures acting against seals 22 a , 22 a ′ and seal 22 b . This increases the useful life of bearing chamber 20 .
Bearing chamber 20 contains two radial bearing surfaces 46 , 48 and axial thrust bearings 49 a , 49 b . Radial bearings 46 , 48 are positioned on either side of the thrust bearings to provide lateral support for them. As will be appreciated, all of these bearings need not be contained in the same oil-filled chamber.
A compression nut 50 is mounted on mandrel 12 and is positioned within bearing chamber 20 . Compression nut 50 includes inner facing threads 51 for threaded engagement with a threaded portion 52 on mandrel 12 . A shoulder 54 is formed on mandrel 12 against which compression nut 50 is torqued. Compression nut 50 is threaded onto mandrel with substantially zero tolerance such that once the compression nut is torqued onto the threaded portion of the mandrel and locked against shoulder 54 , the threads are in tension and load is uniformly distributed along the interface of the threads. Any force applied to the compression nut is directly transmitted into the mandrel without vibration therebetween. Preferably the threaded engagement is through a left-hand thread, when viewed from the top. A left hand thread provides that during use, the rotation of the drill bit and circulation of the drilling fluid will cause the compression nut to be constantly torqued up on the mandrel.
The compression nut when torqued onto the mandrel acts as a part of the mandrel and increases the life span and axial thrust loading capacity of the mandrel. Thrust loading distribution on the bearing mandrel is reduced and the formation of cracks in the mandrel about the nut is prevented. The compression nut acts as a thrust bearing race providing a strong and stable support for dissipation of axial loads from the thrust bearings on either side of the nut including the on bottom 49 a and off bottom 49 b bearing stacks. As such, compression nut 50 provides true axial contact for the thrust bearings eliminating transversal movement and vibration between the nut and the bearing stacks and the mandrel. The compression nut also serves to effectively enlarge the outer diameter of the mandrel such that it is retained in the housing by abutment against shoulder 54 of housing.
On bottom bearing stack 49 a is adjacent off bottom 49 b stack. As such, these bearing stacks beneficially operate under similar pressure conditions. As will be appreciated, when one of these thrust bearings is under load preferably the other is totally free. This arrangement is termed endplay. Adjustment is necessary to accomplish endplay. By positioning the on bottom and off bottom thrust bearings in adjacent position, adjustment of endplay is facilitated. In particular, the width of setting shim 53 is selected and positioned between off bottom bearings 49 b and a shoulder on housing 14 to control the space in which bearings act. Selection of shim 53 controls endplay for both thrust bearings 49 a , 49 b simultaneously.
According to the present invention, the bearing assembly includes a second bearing section 28 positioned between flow restrictor 26 and end 17 of housing 14 . In general, bearing section 28 provides support for radial and end loading of the bearing assembly in drilling applications using drilling mud motors. Bearing 28 also protects the flow restrictors from sideways and bending loads. The components of flow restrictors are very brittle and subject to cracking and failure when subject to such forces. Bearing 28 holds concentric the flow restrictors about the mandrel thereby increasing their useful life.
Bearing 28 can be any radial bearing suitable for downhole use such as for example, a mud lubricated bearing or an oil lubricated bearing. Because of the longer useful life of oil-filled bearings in most downhole conditions, oil-filled bearings are preferred. In one embodiment as shown in FIG. 3, the bearing is a roller bearing 29 in an oil-filled chamber. In the embodiment illustrated in FIGS. 1, a du bearing 30 is used. Du bearing 30 is positioned in a chamber 32 filled with oil through fill ports 34 . Du bearing 30 includes a housing 35 positioned in the annulus between housing 14 and mandrel 12 . Housing 35 includes longitudally extending channels 37 that permit lubricant flow along the radial bearing surface. The chamber is sealed by upper seals 36 a and lower seals 36 b . Upper seals 36 a are carried on a floating piston 38 that moves depending on the fluid pressures and temperatures in which the bearing assembly is operating.
To equalize the pressures acting on upper seals 36 a and lower seals 36 b , and thereby to prevent damage to the seals such as by extrusion thereof, channels 40 are provided for flow of drilling fluid past bearing section 28 . Channels 40 are formed in the outer surface of housing 35 and extend along its length. Thus, chambers 42 , 44 , above and below, respectively, bearing 28 are maintained at substantially equal pressures. While eight channels are shown in FIG. 2, other numbers of channels can be used as desired.
Channels 40 by pass the bearing chamber but do not affect the concentricity of the mandrel within the housing inner bore. In particular, the channels are formed in a spaced apart manner on housing 35 maintaining a maximum outer diameter approximately equal to that of the inner diameter of the housing 14 .
Since turbulence in the drilling fluid can damage the bearing assembly, preferably the channels are formed to minimize turbulence in the drilling fluid passing therethrough. In one embodiment, to reduce the formation of turbulence the channels are preferably oriented substantially parallel to the long axis 10 x of the bearing assembly. By forming substantially axially oriented channels past the second bearing, axial flow of the drilling fluid is maintained. For use in shallow wells, where pressures of drilling fluid are not so great, these channels can be omitted, if desired.
To facilitate assembly the housing and mandrel can be formed in separate parts that are secured together during assembly.
Although preferred embodiments of the present invention have been described in some detail hereinabove, those skilled in the art will recognize that various substitutions and modifications may be made to the invention without departing from the scope and spirit of the appended claims. | A bearing assembly is disclosed for use with a mud motor. The bearing assembly includes at least three radial bearings to protect the flow restrictor of the bearing assembly against harmful sideways and lateral loading. The bearing assembly also includes a compression nut to eliminate cracks on the mandrel at the split ring. | 4 |
FIELD OF THE INVENTION
The instant invention relates to a carrier rack lift assembly for use with pick-up trucks, flat bed trucks and trailers and more particularly to a lift assembly having telescoping support members that can be raised to any desired height within a specified range for supporting and maintaining a wide variety of loads.
BACKGROUND OF THE INVENTION
The well known truck racks are used to increase the usefulness of pick-up trucks, flat bed trucks and trailers. Many of the prior art racks must be permanently fastened to the truck bed and are available at one specific height. Some may be adjustable to two or three preset heights while a few may exhibit a wider range of adjustability. In most of the adjustable prior art racks, any change in the height of the rack must be accomplished when there is no load resting on the upper portion of the rack and require more than one person to effect the change. The prior art racks are, in actuality, merely support frames with limited versatility. They are not designed to be completely height adjustable nor are they designed for adjustability under heavy loads. Changes in height cannot be made by one person. None of the prior art rack assemblies are meant to secure the interior of the truck bed or to provide any other functions.
Hart, in U.S. Pat. No. 2,720,414, describes a rack that is made in sections and is mounted on the body of a pick-up truck. All four sides of the rack are horizontally adjustable to fit a variety of truck bed lengths. Each of the four vertical support posts have one height adjustable member which can raise the upper horizontal supports high enough so that long boards can be extended over the cab of the truck. Both horizontal and vertical adjustments are made possible with outer tubes having multiple openings along their open ends and inner tubes with one opening. The inner tubes are inserted into the outer tubes to the desired distance and secured in place with pins. A load being supported on the rack must be completely removed in order to alter its height and more than one person would be needed to accomplish this. The rack cannot be collapsed and, if not needed, the entire rack must be removed from the truck bed and stored elsewhere.
In U.S. Pat. No. 5,190,337, McDaniel discloses a collapsible rack for use within the bed of a pick-up truck. The rack has four vertical legs, each having two segments connected by a knuckle joint which enables the legs to be folded downward when the rack is not in use. The bottom segments are pivotally mounted to base plates anchored to the truck bed and which run along its horizontal axis. An angled brace extending from mid base plate to the top of each rear leg gives added support to the frame when elevated. There is a side rail on each side of the rack mounted at the top of each pair of legs. A frame extension extends from each side rail over the cab to support long loads. The entire frame collapses flat along the sides of the truck bed when not in use and the parts of the rack fit within channels in the side rails for protection from the elements. The rack can only be used in the one elevated orientation and is stored in the collapsed orientation which takes up space in the truck bed.
An adjustable rack is taught by Berkich in U.S. Pat. No. 5,476,301. The height of the four vertical supports can be adjusted by raising the upper segments having a series of apertures and securing their positions with pins or bolts through corresponding apertures in the lower segments. The height of each support must be adjusted individually making it difficult to do while a load is supported on the rack. There are extensions of upper side rails over the cab that can reach as far as the front bumper, as well as rearward extensions beyond the tailgate. When the vertical supports are in the lowermost positions they rest below the sides of the truck and a cover, cap or camper can be used within the truck bed. This rack is not practical if the height of the rack must be changed with any frequency or with a load in place.
James, in U.S. Pat. No. 5,628,540, discloses another pick-up truck utility rack. The four vertical supports of this rack are mounted on the upper surfaces of the sides of the truck bed. There is a panel attached to the two forward supports which is hinged to pivot downward to form a shelf with a brace to limit the movement to 90°. A movable lower rail is attached to the rear supports and can be lowered to the level of the shelf with which it forms a second level to support a load. An extension can be used over the cab so that long boards can be carried. The vertical supports are of fixed length and once set in place remain stationery. Any load placed at mid-level can only be of the dimensions of the truck bed.
A camper for mounting in the bed of a pick-up truck is taught by Eckman et al. in U.S. Pat. No. 3,743,345. The camper has four telescoping corner support posts, each formed in three tubular sections that are square in cross section and have multiple apertures long their lengths. The supports are raised to the desired height and each segment is secured with a pin that is kept in place by a spring detent. There is a wood reinforced plastic roof that may be used in a horizontal orientation or it may be raised from one side to provide a slanted roof. A notched slotted bracket with a sliding bolt is used to set the angle of the roof. The roof height may be set at many different levels due to the many apertures in the tubular segments, but each post must be set individually. Once the roof is in place, adjustment to a different height may require more than one person. Canvas side flaps form the vertical walls of the camper. Horizontal arms secured to the uppermost sections of the corner support posts may be used to extend the camper space and can be covered by the canvas flaps. The entire camper unit can be removed and used as a tent independent of the truck. The canvas flaps only provide shelter from the elements but do not secure the interior of the camper. There is no way to raise all of the posts at the same time.
A lumber rack-camper as taught by Ingram in U.S. Pat. No. 5,423,587 has a non-adjustable rack frame which can be reversibly attached to the sides of a pick-up truck. There is an over-cab extension for carrying long boards and several cross rafters are supported on the tops of the corner vertical supports and intermediate posts supported on side frame members. A flexible cover is placed over the rafters to enclose the camper. The front of the cover fits over the extension and is supported by angled braces to proved and an air dam so the truck can travel at highway speeds while the camper cover is in place. Each side panel of the cover can be rolled up or down independently, but they do not secure the interior compartment. The corner supports are not adjustable.
Modifications to the side walls of a pick-up truck to provide secure storage compartments are taught by Clare et al. in U.S. Pat. No. 6,033,002. The storage compartments are hidden and built into the side walls. They are accessed through top mounted doors. A carrier rack that can be collapsed into the truck bed is also disclosed. The rack has a swivel mounted cab extension that folds backward for storage. The four supports for the rack may have two or three nesting segments and are adjustable by means of apertures and pins. When collapsed into the truck bed the rack cannot be seen from the outside. All adjustments to the height of the rack must be made one support at a time and only the storage compartments hidden in the side walls provide any security.
Though the prior art describes a variety of carrier racks for use with pick-up trucks, none of the prior art patents disclose a carrier rack lift assembly that can be raised and set at any desired height. Those with a degree of adjustability are limited to being set at specific levels according to the apertures in the support segments. None of the adjustable prior art rack lift means can easily be manipulated by one person. None of the prior art patents disclose an electrically powered carrier rack lift assembly that can be adjusted at the press of a button and raised to any desired height. And none of the prior art patents teach a rack lift assembly whereby any adjustment in height can be made with a full load of cargo in place. There is a need for a carrier rack lift assembly that exhibits all of the above-mentioned features and that is practical for use with all pick-up and flat bed trucks and carriers.
BRIEF SUMMARY OF THE INVENTION
The present invention may provide a carrier rack lift assembly for use with pick-up trucks, flat bed trucks and trailers. The lift assembly of the instant invention may be reversibly secured to the truck bed such that it may be removed when not needed. The essence of the lift assembly may be the four electrically activated support posts which may be completely collapsible to a height of only 13 inches (33 cm) from the truck bed and may be telescoped upward to a height of 65 inches (165 cm) from the truck bed. The support posts may also be set at any desired height in between by merely pushing a button. A roof cover in the form of a traditional cap or other such cover may be used with the lift assembly, and side panels may be added to enclose an interior compartment to make it secure from inclement weather conditions and outside tampering.
It is an object of the present invention to provide a carrier rack lift assembly that can be set at any desired height without the incremental limitations requiring specific openings in the telescoping support posts.
It is another object of the present invention to provide a lift assembly that is reversibly attached to the truck bed such that it can be removed when not needed.
A further object of the present invention is to provide a lift assembly that is operated electrically so that it can be manipulated by the touch of a button.
A still further object of the present invention is to provide a lift assembly that can be operated by one person.
Another object of the present invention is to provide a lift assembly that is adjustable and permits the height to be changed with a full load of cargo in place.
A still further object of the present invention to provide a lift assembly that can support a variety of upper rail systems.
A further object of the present invention is to provide a lift assembly that can support and raise loads of considerable weight at the push of a button.
It is another object of the present invention to provide a lift assembly that can be electrically wired such that the telescoping support posts can be raised simultaneously or in any desired combination or sequence.
Another object of the present invention is to provide a lift assembly that can be used with conventional truck caps or other roof covers.
The present invention is a rack lift assembly, for use with pick-up trucks, flat bed trucks and trailers having a horizontal cargo bed, and being capable of raising and supporting an elevated utility rack. The rack assembly comprises at least four telescoping support legs, each situated at a corner of the cargo bed, and each of the support legs comprising a series of nested rotatable cylindrical segments, an outer first segment and at least one inner second segment, the first segment being smooth on its exterior surface and having at least two threads situated at the bottom of its interior surface, and the second segment being threaded on its exterior surface, having a stop means at the top of its exterior surface and a stop means at the bottom of its exterior surface, and having at least two threads situated at the bottom of its interior surface. The stop means is to prevent the segments from becoming dissociated. There is a canister for containment of the segments; a support frame to support the canister on the cargo bed; a drive shaft to rotate the segments, the drive shaft being positioned axially within the nested segments, being threaded for substantially the upper three fourths of its length, and having a stop means at its top and another stop means situated below the threads, the stop means for preventing the drive shaft from becoming dissociated from said segments. The threads on the segments and the drive shaft are of the same dimensions for cooperation therebetween. There is a means to rotate the drive shaft in a forward direction and in a reverse direction and a top cap to which the rack is affixed. When a utility rack is supported on the four support legs and the rotation means causes the drive shafts to be rotated in the forward direction the segments rotate in the forward direction and move upward such that the support legs telescope upward raising the utility rack, and when the rotation means causes the drive shaft to be rotated in the reverse direction the segments rotate in the reverse direction and are moved downward such that the support legs are collapsed and the utility rack is lowered.
The present invention is also a lift assembly for smoothly raising and lowering a load. The lift assembly comprises a series of nested rotatable cylindrical segments, an outer first segment being smooth on its exterior surface and having at least two threads situated at the bottom of its interior surface, at least one inner second segment being threaded on its exterior surface, having a collar about the top of its exterior surface and a collar about the bottom of its exterior surface and having at least two threads situated at the bottom of its interior surface. There is a canister for containment of the segments, a support frame to support the canister on a horizontal surface, a drive shaft to rotate said segments the drive shaft being positioned axially within the nested segments, being threaded for substantially the upper three fourths of its length, and having a first collar about its top and a second collar situated below the threads. The threads on the segments and the drive shaft being of the same dimensions for cooperation therebetween, and the collars on the segments and the drive shaft being capable of acting as stops to prevent said segments from becoming dissociated. There is a rotation means to rotate the drive shaft in a forward direction and in a reverse direction and a cylindrical top cap on which the load is supported. When the load is supported on the lift assembly and the rotation means causes the drive shaft to be rotated in the forward direction the segments rotate in the forward direction and move upward such that the lift assembly telescopes upward raising the load, and when the rotation means causes the drive shaft to be rotated in the reverse direction the segments rotate in the reverse direction and are moved downward such that the lift assembly is collapsed and the load is lowered.
Other features and advantages of the invention will be seen from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear perspective view of a typical pick-up truck.
FIG. 2 is a rear perspective view of the pick-up truck with the rack of the instant invention raised to the level of the truck cab.
FIG. 3 is a rear perspective view of the pick-up truck with the rack raised to a level above the truck cab.
FIG. 4 is a rear perspective view of the pick-up truck with the rack raised to its full height and with side panels lowered to fully enclose the truck bed.
FIG. 5 is a rear view of the truck of FIG. 3 .
FIG. 6 a schematic cutaway view of the main components of the lifting mechanism;
FIGS. 7-A through 7 -F are schematic cutaway views of six of the threaded segments;
FIGS. 8-A through 8 -D are schematic cutaway scale views of the four innermost segments;
FIG. 9 is a schematic cutaway view of the outermost segment;
FIG. 10 is schematic cutaway view of the support frame;
FIG. 11 is top plan view of the support frame of FIG. 10;
FIG. 12 is a partial cutaway view of the canister;
FIG. 13 is a side view of the drive shaft;
FIG. 14-A is a side view of the large Browning pulley;
FIG. 14-B is a s sectional view through line B—B of FIG. 14-A;
FIG. 15 is a schematic cutaway view of the complete lifting mechanism;
FIG. 16 is top plan view of the complete lifting mechanism;
FIG. 17-A is a top plan view of the bearing plate;
FIG. 17-B is a sectional view through line B—B of FIG. 17-A;
FIG. 18-A is a side partial cutaway view of the complete lifting mechanism in the fully collapsed orientation;
FIG. 18-B is a side partial cutaway view of the complete lifting mechanism in the fully extended orientation;
FIG. 19 is a top plan view of the bed of a pick-up truck with the lifting mechanism in place;
FIG. 20 is partial perspective view of the lifting assembly and brace;
FIG. 21 is a perspective exploded view of the top cap and bearings;
FIG. 22 is a partial cutaway view of the top cap and bearings;
FIG. 23 is a bottom plan view of the top cap without the bearings;
FIG. 24 is a partial cutaway view of the left assembly and brace with the sleeves;
FIG. 25 is a perspective view of a segment of the brace; and
FIG. 26 is a perspective view of the lift assembly being used with a trailer.
DETAILED DESCRIPTION OF THE INVENTION
The carrier rack lift assembly 30 of the instant invention may be collapsible to a height of only 13 inches (33 cm) and may telescope to a height of 65 inches (165 cm) from the supporting surface. The lift assembly 30 may be compatible for use with a typical pick-up truck 35 (FIG. 1) which may have a cab 31 , a flat truck bed 32 , side panels 33 and a tailgate 34 . The lift assembly 30 may just as easily be used with a flat bed truck (not illustrated) or trailer 82 . The lift assembly 30 may be raised or lowered to any desired level from the fully collapsed orientation to the fully extended orientation. When fully extended, the top of the lift assembly with accompanying cargo rails 36 may reach a height of six feet above the truck bed 32 . The fully collapsed lift assembly 30 may not be visible above the side panels 33 of the pick-up truck 35 .
The truck 35 with the lift assembly 30 partially extended so that it may be observed above the side panels 33 may be seen in FIG. 2 . At this level the upper rails 36 situated at the top of the lift assembly 30 may accommodate various loads as long as they do not extend more than a few inches beyond the longitudinal dimensions of the rails 36 to insure that the objects placed on the rails 36 cannot strike the rear window 37 of the cab 31 . The lift assembly 30 may be raised further to levels above the top of the cab 31 , as seen in FIGS. 3 and 5 to accommodate longer loads. The fully extended rack 30 may be seen in FIG. 4 .
The lift assembly 30 may consist of four telescoping support legs 38 which may form the supporting structure for the rails 36 . The support legs 38 may be raised or lowered by means of an electric motor 73 powered by the truck's battery pack (not illustrated). A manual raising means may also be used, but is not illustrated or described herein.
Each support leg 38 may be comprised of a series of nested segments. The number of segments may determine the height of the fully extended support leg 38 . In the preferred embodiment, for use in pick-up trucks, each support leg may consist of seven nested segments 40 - 46 and a central drive shaft 47 contained within a cylindrical canister 39 . See FIG. 15 . (FIG. 6 shows the major parts but only five segments.) The canister 39 may act as a housing for the segments of the support leg 38 . A support frame 48 (FIGS. 10 and 11) may surround substantially three fourths of the circumference of the bottom third of the canister 39 and may serve to support the canister above the truck bed 32 a sufficient distance to allow the necessary moving parts to function properly. There may be three evenly spaced flanges 49 welded to the outside surface of the support frame 48 along its bottom edge. A band 61 may extend from one vertical edge 62 to the other vertical edge 62 of the support frame 48 such that the bottom edge of the support frame 48 that makes contact with the truck bed 32 may form a complete circle and may provide maximum stability to the support leg 38 . The flanges 49 may have openings 50 to accommodate bolts (not shown) used to anchor the support legs 38 to the truck bed 32 . There may be three bolts 51 passing through openings in the wall of the support frame 48 above the flanges 49 which may secure the support frame 48 to the canister 39 .
The seven segments 40 - 46 of the support leg 38 may be cylindrical and successively and incrementally smaller in diameter and longer in length. The outermost segment 40 (FIG. 9) may be the largest in diameter and the shortest in length. The outermost segment 40 may have a smooth outer surface and a smooth inner surface except for the presence of three threads 52 situated at the bottom interior edge. The other six segments 41 - 46 (FIGS. 7-A through 7 -F) may each have threads 53 along their entire exterior surfaces and smooth interior surfaces with the same three threads 52 situated at the bottom interior edges. Each of the six segments 41 - 46 may also have a collar 54 around the top of the exterior surface and another collar 55 around the bottom of the exterior surface. FIGS. 8-A through 8 -D provide slightly different views of four of the segments 43 - 46 .
The drive shaft 47 (FIG. 13) may be axially situated within the innermost segment 46 and may be of solid construction with threads 56 along the upper ¾ of its exterior surface. There may be a collar 57 around the top of the drive shaft 47 and another collar 58 situated below the threads 56 . The lower ¼ of the drive shaft 59 may have a smooth surface and the lower one inch (2.54 cm) of the drive shaft 47 may have a slightly smaller diameter and may be fitted with a vertically mounted flat sided key seat 60 .
The threads on the inner and outer surfaces of all of the segments 40 - 46 and on the drive shaft 47 may all be 5 Acme threads. The collars 54 , 55 on the outer surfaces of the segments 40 - 46 and the collars 57 , 58 on the drive shaft 47 may all be welded to the segments 41 - 46 and drive shaft 47 and may be substantially ¼ inch (0.64 cm) wide and the depth of the threads ( 52 , 53 and 56 ) which are all the same, as noted above.
The cylindrical canister 39 (FIG. 12) may have smooth interior and exterior surfaces and may have a horizontal bearing plate 63 welded to the interior of the canister 39 just above the bottom edge. There may be a central opening 64 in the bearing plate 63 through which the drive shaft 47 may pass, and four evenly spaced smaller openings 65 . (FIGS. 17-A and 17 -B) An upper bearing 67 may be mounted on top of the bearing plate 63 and a lower bearing 68 may be mounted on the underside of the bearing plate 63 . The upper bearing 67 and lower bearing 68 may be secured by bolts 69 passing through the small openings 65 in the bearing plate 63 and secured by nuts 70 . The two bearings may assist in the smooth rotation of the drive shaft 47 . There may be two mounting ferrules 66 welded to the exterior of the canister 39 just above the level of the bearing plate 63 . The two mounting ferrules 66 may be situated within, and in close proximity to, the vertical edges 62 of the support frame 48 .
The lower end of the drive shaft 47 may pass through the upper bearing 67 , the central opening 64 of the bearing plate 63 and extend below the lower bearing 68 to communicate with the central opening 72 of a large Browning pulley 71 which may be disposed below the lower bearing 68 . The large Browning pulley 71 may have a channel 73 through the core extending from the central opening 72 to the perimeter. This channel 73 may be dimensioned to accept the key seat 60 of the drive shaft 47 to insure that there may be no slippage when the drive shaft 47 is rotated by the turning of the pulley 71 , (FIGS. 14-A and 14 -B).
Referring to FIG. 15, the large Browning pulley 71 may be made to turn by a motor 74 contained within a motor housing 75 that may be integral with a motor mount 76 . The motor mount 76 may be secured to the support frame 48 by means of two long threaded studs 77 projecting from the ferrules 66 of the canister 39 . The studs 77 may be bent to conform to the angles necessary to enable them to communicate with channels in the motor mount 76 . Nuts 78 may be located on both sides of the motor mount 76 to hold it securely at a specific distance from the support frame 48 . The nuts 78 may also permit adjustment of the distance of the motor mount 76 to the support frame 48 as described below.
The drive shaft of the motor 74 may be joined to a small Browning pulley 79 by a coupling 80 . The small Browning pulley 79 may be rotated by the action of the motor 74 which may be powered by the truck battery (not illustrated). A Browning belt 81 may cooperate between the large Browning pulley 71 and the small Browning pulley 79 to rotate the drive shaft 47 . The sizes of the large Browning pulley 71 and small Browning pulley 79 may be chosen to provide a 3:1 ratio, but other sizes may be selected to provide different ratios.
The Browning belt 81 may easily be changed or adjusted by loosening the nuts 78 and moving the motor mount 76 as needed along the studs 77 . To change the belt 81 , the motor mount 76 may be moved toward the support frame 48 , the belt 81 loosened and removed and the new belt put in place. The motor mount 76 may thereafter be moved away from the support frame 48 until the new belt is taut and the nuts 78 are tightened. The adjustment of the distance of the motor mount 76 to the support frame 48 may determine the tension on the Browning belt 81 .
In addition to the drive shaft being rotated by Browning pulleys and a Browning belt, the rotation may also be accomplished using a chain and sprocket assembly as well as a straight gear drive assembly consisting of two main gears and an idler gear. Neither the chain and sprocket assembly nor the straight gear drive is illustrated herein.
The support leg 38 may be made to rise as follows: when the motor 74 is activated the small Browning pulley 79 , the Browning belt 81 and thereafter the large Browning pulley 71 may be caused to rotate and with them the drive shaft 47 ; as the drive shaft 47 rotates, all of the nested segments 40 - 46 may rotate with it. Once the drive shaft 47 and the segments 40 - 46 revolve any one of the segments may begin to crawl upward until the lower collar 55 of the rising segment contacts the upper collar 54 of the adjacent concentric segment and it can go no farther. As the segments continue to revolve another segment may begin to move upward with the collars acting as the stops. This action may continue until all of the segments have moved upward to their fullest height and the support leg 38 has reached its full extension. The segments in each leg may not necessarily move in the same sequence but since all of the threads are alike the tops of the support legs 38 may rise at the same rate. Reversing the motor may reverse the process. The motor 74 may be stopped at any point thus enabling the support leg 38 to be raised or lowered to any desired level.
Since the threads on the interior and exterior of all segments 40 - 46 and the drive shaft 47 are the same (Acme 5 threads), the fact that the segments may rise in different sequences in the various support legs 38 will not effect the height attained by each leg 38 as long as the motors for all four of the support legs 38 are activated at the same time. This may be accomplished by the manner of wiring the electrical system which may have all support legs 38 activated by the same switch. The lift assembly 30 may lift a wide variety of loads to any desired height and maintain the loads in the same degree of horizontal orientation. Once the support legs 38 have reached the desired height the switch may be released. The support legs 38 may remain quite stable and retain their load until the height of the support legs 38 is changed by again activating the switch.
FIG. 18-A shows the fully collapsed support leg 38 . Line A-B may represent the width of the base of the leg which may be only 5 inches (12.7 cm) and line C-D may represent the overall height of 13 inches (33 cm). The fully extended support leg 38 may be seen in FIG. 18-B wherein line E-F may represent the fully extended height of 65 inches (165 cm).
The pick-up truck bed 32 may accommodate four support legs 38 , located in each of the four corners as seen in FIGS. 5 and 19. When used in a flat bed truck or trailer 82 (FIG. 26) six or more support legs may be needed.
The dimensions of the essential parts used in the preferred embodiment may be seen in Table I. The nested segments may be made of steel that is 0.625 in (1.588 cm) in thickness. A one horsepower motor may be used, as well as motors providing up to four horsepower. The preferred embodiment may utilize a 1.5 horsepower, 12 volt, 20 amp motor as exemplified by model #540-927-OM manufactured by FASCO. Pulleys having ratios other than 3:1 may provide different rates of rotation of the segments. The three threads 52 on the inside of each segment occupy the bottom ⅝ inch (1.59 cm) of the interior surfaces.
TABLE I
Dimensions of Preferred Embodiment
Part
height (in)
(cm)
exterior diameter (in)
(cm)
Canister 39
9½
24.1
5¾
14.6
Segment 40
7{fraction (9/16)}
19.2
4{fraction (5/16)}
10.9
Segment 41
7{fraction (25/32)}
19.8
3{fraction (15/16)}
10
Segment 42
8{fraction (1/32)}
20.4
3⅜
8.6
Segment 43
8{fraction (5/16)}
21.1
2{fraction (13/16)}
7.1
Segment 44
8½
21.6
2¼
5.7
Segment 45
8{fraction (13/16)}
22.4
1{fraction (11/16)}
4.3
Segment 46
9
22.9
1⅛
2.9
Drive Shaft 47
12{fraction (31/32)}
32.9
¾
1.9
Support Frame 48
5{fraction (9/16)}
14.1
5
12.7
The support legs 38 may require a top cap 83 that will not interfere with the rotation of the segments. The top cap 83 may be in the form of a short cylinder that fits over and rests on top of the largest or outside segment 40 . There may be a flat top 84 on the top cap 83 that may by unadorned or the flat top 84 may accommodate one or more lugs 85 or other connectors. There may be two 0.25 inch (0.63 cm) plate bearings 86 inside the top cap 83 such as D- 35 bearings manufactured by Union Bearings. The inside of the flat top 84 may contain a circular bearing locator 87 which may maintain the bearings 86 in the center of the top cap 83 . The thickness of the bearing locator 87 may be equal to the thickness of the two plate bearings 86 . The lower bearing may rest directly on the segments 40 - 46 and the two bearings 86 may rotate with the segments. The top cap 83 itself may not rotate so that upper rails 36 or other structures supported on the support legs 38 are not disturbed by the rotation of the segments. (See FIGS. 21, 22 and 23 )
The extension of the support legs 38 to a height of 65 inches (165 cm) may produce a degree of flexibility or wobble that may not be desired. To prevent any such effects in the extended legs a simple brace 88 may be set adjacent to each of the support legs 38 . (FIG. 20) The braces 88 may be composed of a series of nested telescoping brace segments 89 . Each brace segment 89 may be made from square metal tubing and may have a vertical slot 90 in one side, a stop knob 91 below the slot 90 and a stop collar 92 around the upper rim. (FIG. 25) The stop knob 91 of each segment may fit into the slot 90 of the larger segment below and may maintain the alignment of the segments as they are telescoped upward. The stop collars 92 may prevent the segments from falling into one another. The brace 88 may be attached to the support leg 38 at its top and at the bottom. There may be a square cap 93 attached to the uppermost and segment 89 of the brace 88 instead of a stop collar 92 . A curved attaching member 94 welded or otherwise affixed to the square cap 93 and also welded to the top cap 83 of the support leg 38 provides the upper attachment and may enable the support brace 88 to be raised simultaneously with the support leg 38 providing the added stability to the extended support leg 38 . There may be another curved attaching member 96 welded or otherwise affixed to the canister 39 and the lowermost brace segment 97 to provide the lower attachment.
The support legs 38 and the support braces 88 may be subject to a variety of weather conditions, road chemicals, dirt and other corrosive materials which may interfere with their smooth operation. To protect these open systems from undesirable outside conditions, protective sleeves 95 may be placed around both of them. The protective sleeves 95 may consist of telescoping rubber or other flexible polymeric sleeves that are folded accordion-style when in the compressed orientation and which easily extend upward when the support leg 38 and brace 88 are raised. The bottom of the sleeve 95 for the support leg 38 may be attached to the support frame 48 or canister 39 and the top may be attached to the top cap 83 so it may be pulled upward as the top cap 83 rises. The sleeve 95 for the support brace 88 may be attached to the lowermost segment of the brace and the brace cap 93 and may be likewise pulled upward as the brace 88 is extended. (See FIG. 24) Such sleeves are manufactured by McMaster Carr # 9421K17 (support leg 38 cover) and #9421K14 (brace 88 cover).
One of the four support legs 38 of the instant invention may be placed at each of the four corners of the bed 32 of a pick-up truck as shown in FIG. 19 . The best positioning of support leg 38 , motor housing 75 and support brace 88 may be as illustrated. For larger pick-up trucks, flat bed trucks and trailers 82 more than four support legs 38 may be utilized. (FIG. 26)
The basic lift assembly of the instant invention may be constructed with a drive shaft, and one segment, but at least two segments are preferable and as many segments as are needed to reach the desired height and perform the desired function may be utilized. The heights and diameters of the segments may also be made to accommodate the needs of the user and are not confined to the dimensions exemplified herein.
The four unit lift assembly may be electrically wired to insure that all support legs are activated simultaneously so that the load resting on the upper rack may be raised horizontally and kept level. Other arrangements of the wiring system may permit the two front support legs to be raised with one activation and t h e rear support legs to be raised with a second activation. This system may provide a dumping function. Another arrangement may enable the two right legs to be raised together and the two left legs to be raised together providing for a slanted roof support. Other combination may also be accomplished according to the sequence in which the support legs are electrically activated.
The lift assembly of the instant invention may be used to raise and support a wide variety of rack systems as well as top caps, covers and any other units used with flat bed trucks.
The support leg unit may itself have many other applications in addition to the uses in pick-up trucks and other truck and trailer beds as described above. An individual unit may be used as a jack and has considerable lifting capacity. A single unit with a ⅝ inch (1.59 cm) drive shaft may have a one ton lifting capacity and a single unit with a ⅜ inch (0.95 cm) drive shaft may have a 500 lb lifting capacity. Units may be made to lift up to three tons. Two support legs may be used to lift heavy items such as boats. Multiple support legs may also be utilized as the supports for temporary structures or variable height enclosures.
While one embodiment of the present invention has been illustrated and described in detail, it is to be understood that this invention is not limited thereto and may be otherwise practiced within the scope of the following claims.
SLOSS PARTS LIST
30
LIFT ASSEMBLY
31
CAB
32
TRUCK BED
33
SIDE PANELS
34
TAILGATE
35
PICK-UP TRUCK
36
UPPER RAILS
37
REAR WINDOW OF CAB
38
SUPPORT LEG
39
CANISTER
40
SEGMENT-OUTER SMOOTH
41
SEGMENT
42
SEGMENT
43
SEGMENT
44
SEGMENT
45
SEGMENT
46
SEGMENT INNER SMALLEST
47
DRIVE SHAFT
48
SUPPORT FRAME
49
FLANGE ON SUPPORT FRAME
50
OPENING IN FLANGE
51
BOLT
52
3 THREADS
53
OUTER SURFACE THREADS
54
TOP COLLOAR
55
BOTTOM COLLAR
56
DRIVE SHAFT THREADS
57
UPPER COLLAR DRIVE SHAFT
58
LOWER CLOOAR DRIVE SHAFT
59
LOWER SMOOTH PORTION
60
KEYSEAT
61
SUPPORT BAND
62
EDGEPF SUPPORT FRAME
63
BEARING PLATE IN CANISTER
64
CENTRAL OPENING BEARING PL.
65
OPENINGS BEARING PLATE
66
MOUNTING FERRULE
67
UPPER BEARING
68
LOWER BEARING
69
BOLTS
70
NUTS
71
LARGE BROWNING PULLEY
72
CENTRAL OPENING IN PULLEY
73
CHANNEL IN PULLEY
74
MOTOR
75
MOTOR HOUSING
76
MOTOR MOUNT
77
THREADED STUDS
78
NUTS
79
SMALL BROWNING PULLEY
80
COUPLING
81
BELT
82
TRAILER
83
TOP CAP
84
TOP PLATE OF TOP CAP
85
LUGS ON TOP CAP
86
PLATE BEARINGS
87
BEARING LOCATOR
88
BRACE
89
BRACE SEGMENT
90
VERTICAL SLOT IN SEGMENT
91
STOP KNOB
92
STOP COLLAR
93
BRACE CAP
94
ATTACHING MEMBER FOR BRACE
95
PROTECTIVE SLEEVE
96
ATTACHING BOTTOM MEMBER
97
LOWERMOST SEGMENT | A lift assembly that can be reversibly installed in the bed of a pick-up truck or other flat bed transport means. At least four telescoping support legs are disposed at the four corners of the truck bed and support the upper rails on which the load is placed. The support legs are made up of a series of nested threaded segments driven by a similarly threaded drive shaft. A reversible motor associated with each support leg enables the segments to rotate in a forward direction to raise the load and to rotate in the reverse direction to lower the load. The motors are activated simultaneously and powered by the truck battery. The raising and lowering motion is smooth and continuous and can be stopped at any desired height. The lift assembly enables the height of the load to be easily changed by one person without any disturbance or shifting of the load. Telescoping braces are available to stabilize the support legs when fully extended and protective sleeves can be used to eliminate damage to the mechanism from environmental contaminants. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a method and to an apparatus for the deployment of a duct within a mass of powder-like material, such as cereal grains.
The present invention in particular permits the creation of an access to the interior of a mass of powder-like material situated, for example, in a geological formation, a ship's hold, a silo, or any other storage unit.
By creating such access it is possible to carry out observations, take samples, or perform a desired treatment.
This is particularly important in the case of grains, so as to be able to inspect them and/or to protect them effectively and lastingly, particularly against parasites.
SUMMARY OF THE PRESENT INVENTION
The subject matter of the present invention is a method for the deployment of a duct within a mass of powder-like material, according to which the duct is deployed from a compact configuration, characterized by the fact that the duct is brought in this compact configuration to a point in the mass of powder-like material and, while one end of the duct is held fixed, the other end is moved toward the exterior of the mass of powder-like material, the deployment of the duct thus being effected.
In a preferred embodiment, the duct is placed in its compact configuration into a container and is provided with a penetrating/anchoring detachable extremity which is temporarily affixed to one end of the duct remains in fixed position in the mass of powder-like material when the container is moved toward the exterior of the powder-like mass to deploy the duct.
According to a preferred embodiment of the invention, the container is moved within the powder-like mass by means of a probe operating by percussion or vibration in one or the other direction.
In one of its preferred applications, the present invention relates to a method of treatment of cereal grains, characterized by the fact that at least one permeable duct is deployed through a mass of cereal grains by the method that has been described above, that a cereal treatment product, such as dry or hot air, is injected to aerate or dry the cereal grains, or that fumigants or gases are injected to combat parasites, and/or that the duct is ventilated or a partial vacuum is produced inside the duct for the purpose of, for example, removing a gas that is in the mass of grain.
The present invention is also directed to an apparatus for the practice of the method that has just been described, this apparatus having a duct adapted to be put into a first, compact configuration and into a second, deployed configuration, characterized by the fact that it comprises a container open at one of its extremities to receive the duct in its compact configuration, a piece preferably shaped to facilitate penetration of the container into the powder-like mass, affixed to one end of the duct and detachably fitted to the open end of the container so as to remain in the powder-like mass when it is deployed.
In a preferred embodiment, the container comprises a retaining means to keep the duct in its compact configuration within the container, when it is deployed.
This means can comprise, for example, a brush that is provided with a series of radially disposed semi-rigid bristles, the ends which thrust against the interior of the duct in its compact configuration, or also a deformable foam, which holds the duct in its compact configuration by exerting a certain pressure against the inside surface of the duct.
The duct is advantageously deployed all the way to the surface of the powder-like material. It thus permits inspections, measurements or sampling to learn the composition or the state of the mass of powder-like material.
The sheath thus permits the powder-like material to be treated by injecting, for example, a chemical product intended to eliminate parasites situated within the mass of grains, or also to be ventilated or to have air or a gas, which was previously injected, extracted.
In its compact configuration, the duct can be folded, pleated, compressed, corrugated, convoluted or in bellows form, on the condition only that it can be deployed by applying axial traction to one of its extremities.
In a first variant of embodiment, the wall of the duct is made of a porous material, such as cloth, so that the duct can be easily traversed by a gas or a liquid.
In a second variant, the wall of the duct has openings for this purpose, which are regularly spaced, for example, on the surface of the duct and the size of which preferably is sufficiently small, so as to prevent significant penetration of the powder-like material into the interior of the duct.
In this case the duct can be made, for example, with the help of a thin aluminum foil, which is girdled to give it the shape of accordion pleats of circular section, so that the duct can be stored in the container in its compact configuration and be deployed later on in accordance with the invention.
Pursuant to the invention, the duct can be given a deformable wall, which preferably is permeable and is supported by an armature comprising, for example, a helical metal or plastic wire, which is located preferably inside the duct.
In this case, after the duct has been used, it can be removed from the powder-like material by exerting traction on the armature.
The device of the present invention is particularly adapted for creating vertical tunnels in a powder-like material.
The invention will be better understood from the description that follows and in connection with the appended drawing, which are given by way of illustration and not by way of limitation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of an embodiment of the inventive apparatus;
FIG. 2 is a diagrammatic view illustrating a vertical penetration of the apparatus of FIG. 1 into a powder-like mass;
FIG. 3 is a diagrammatic view illustrating the removal of the container of FIG. 2 for the deployment of the duct;
FIG. 4 is a diagrammatic view showing the duct placed in the powder-like mass.
FIG. 5 is a diagrammatic view showing the placement of horizontal ducts, and FIGS. 6a, 6b and 6c are diagrammatic views showing the removal of the duct by traction on the spiral armature.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an embodiment of the apparatus of the present invention.
This apparatus comprises a duct 1, which can assume a compact configuration and a deployed configuration. In the compact configuration, represented in FIG. 1, the duct, which has a ringed structure, is compressed axially on itself so as to reduce its length considerably so that it can enter the container 2.
In the preferred variant, represented in FIG. 1, the duct has an armature comprising, for example, a spiral, plastic or metal wire, which sustains the wall 3 of the duct when placed inside of the latter.
To simplify the drawing, this spiral armature is represented in FIG. 1 by parallel lines, which are perpendicular to the axis of the duct except at the ends of the duct, where the wall 3 of the duct as well as the spiral armature 4 can be seen.
The wall 3 of the duct comprises, for example, a woven material or a film of porous plastic material.
An axial compression of the armature 4 permits the compact configuration of the duct 1 to be obtained.
When the duct changes from its compact configuration to its deployed configuration, the pitch of the spiral armature greatly increases, while its diameter decreases and the wall 3 of the duct is deployed to assume a substantially cylindrical shape.
In a variant of the invention, the internal spiral armature is independent or is lightly attached to the wall of the duct so that after deployment of the duct, the armature can be withdrawn simply by traction on its end situated outside of the powder-like mass. In the absence of the armature, the duct flattens and can easily be withdrawn by simple traction.
In another variant, a pull on an armature, which remains affixed to the wall, produces a reduction in the diameter of the latter and thus permits the duct to be withdrawn from the powder-like material after use.
The inside diameter of the duct is generally less than 100 mm. It is, for example, between 25 and 70 mm, and preferably between 50 and 60 mm.
The length of the duct depends on the volume of the mass of powder-like material, in which the duct is to be placed. This length can run to more than 100 meters. It can range, for example, from 10 to 60 meters.
In a variant, the duct has openings on its surface, which can be distributed in any manner. These openings can be obtained simply by perforating the wall of the particular duct, when the latter is made of a thin sheet of aluminum.
According to a preferred embodiment of the invention, the duct is stored in a cartridge-like container 2, which, in the example shown in FIG. 1, is of a substantially cylindrical shape with an open end 5, which can be plugged with a penetrating/anchoring closure end piece 6 of advantageously conical shape to facilitate penetration of the container into the mass of powder-like material.
In the employment of the apparatus, piece 6 is attached to one end of the duct 1 and then is lightly attached to and readily removably associated with the body of the container 2. An anchoring collar 7 is associated with the conical piece 6 as shown in FIG. 1.
While the container 2 is penetrating into the powder-like material, piece 6 is held against the opening 5 of the container by the pressure exerted by the powder-like material.
However, during the deployment of the duct 1, piece 6, which is retained or anchored by its collar 7 in the powder-like mass, detaches itself from the container 2 and remains anchored in the mass.
Conical piece 6 with its collar or anchor plate 7 thus permits one end of the duct 1 to be maintained in the mass of powder-like material.
In the example illustrated in FIG. 1, the container 2 is driven by a vibratory or percussion probe 11 which engages at its front end 8 an opening 9 of the container and is held there by a pin 10, for example.
Such a probe, powered by an electric cable or compressed-air tube 12, is described in French patent application 90.02685 filed on Mar. 5, 1990. It comprises an enclosure containing a striking piston, which acts in one direction on a front anvil zone or in the other direction on a rear anvil zone. The impacts of the striking piston on the front anvil zone cause the probe to advance, and vice versa.
Such vibratory or percussion probes can be driven electrically or pneumatically. They make it possible to propel the container 2 containing the duct 1 in its compact configuration forward into the interior of the mass of powder-like material or backward for the purpose of deploying the duct.
Experiments made by the applicant company have shown that, surprisingly, the presence of the container 2 containing the duct 1 ahead of the probe 11 facilitates the penetration of this assembly into the mass of powder-like material. Thus it is that the probe 11 coupled to the container 2 buries itself more rapidly in the powder-like material than if it were alone.
As it can be seen in FIG. 1, the central body of the container holds axially in its cavity 13 a rod 14 equipped radially with semi-rigid nylon bristles 15, which reach to the vicinity of the inside wall of the cavity 13, forming a brush 16, the head of which is close to the opening 5 of the container.
Due to the flexibility of its bristles 15, the duct 1 can be introduced in compact configuration into the container 2, wherein it is held by the semi-rigid bristles 15 of the brush 16.
FIG. 2 represents the inventive apparatus during its substantially vertical descent into a mass of powder-like material 18.
Under the action of the probe 11, the descent of the container into the powder-like material 18 is made in the direction of the arrow 17 to the desired depth, for example, to near the bottom of a silo or a ship's hold.
By means of an appropriate remote control signal, the probe 11 and container 2 are made to re-ascend in the direction of arrow 19 of FIG. 3, while the brush 16 retains the duct 1 within the container and provides for its regular deployment as the container re-ascends.
The deployed portion of the duct 1, whose bottom end is held in place by anchoring collar piece 7, can be seen at 1a in FIG. 3.
Portion 1a of the duct has been represented in FIG. 4 by an armature composed of a succession of rings 4a. However, it is clear that it is generally easier to make an armature of a spiral shape as described above.
In a variant, the brush 16 can be replaced by a piece of resilient foam, onto which the duct is forced in its compact configuration. The action of the resilient foam prevents the premature deployment of the sheath while the container is being retrieved.
FIG. 4 shows a duct 1 deployed within the mass 18 of powder-like material up to the surface of the latter.
The duct thus constitutes a well, which provides access to the interior of the powder-like mass.
The duct 1 advantageously is permeable or has opening permitting gases or liquids into the powder-like mass, for example for the treatment of the latter. It is also possible to lower data acquisition means through the duct in order to assure, for example, that the grain, which is stored in the hold of a ship, is of good quality and in a good state of preservation.
The duct also permits samples of powder-like material to be taken at different depths.
Furthermore, it permits treatments of the powder-like material, such as aeration or drying, to be carried out and materials, designed to combat parasites, to be injected.
FIG. 5 shows a horizontal employment of the apparatus of the present invention, for example to place a duct through a pile 21 of powder-like material.
In the lower part of FIG. 5, there is an inventive apparatus, which, after having penetrated in the direction of arrow 22 to the middle of the pile, returns in the direction of arrow 23 while deploying the duct 1 from the center to the right side of the pile 21.
It can also be seen in FIG. 5 how it is possible to deploy, in accordance with the invention, a duct 1, which passes all the way through the pile 21 of powder-like material while being deployed in the direction of the arrow 24.
FIGS. 6a, 6b and 6c show how the duct 1 can be extracted from the mass of powder-like material after use, by exerting traction on the spiral armature of the duct.
In FIG. 6a, the duct 1 can be seen in the position of use. Armature 4 of the duct is affixed to the piece 6, which plugs the bottom part of the container 2 due to the fact that the bottom portion of the armature is resiliently engaged in the groove 6a of the piece 6.
FIG. 6b shows how traction in the direction of the arrow deforms the armature 4 by reducing the diameter of the duct, and FIG. 6a shows how the armature is disengaged from the groove 6a, while piece 6 remains in place and the duct is extracted from the top.
It is understood that the examples above are given by way of illustration and not by way of limitation. They can be modified in any way desirable without thereby departing from the scope of the invention. | The subject matter of the present invention is a method for the deployment of a duct within a mass of powder-like material, according to which the duct is deployed from a compact configuration, characterized by the fact that the duct is brought in this compact configuration to a point in the mass of powder-like material and, while one end of the duct is held fixed, the other end is moved toward the exterior of the mass of powder-like material, the deployment of the duct thus being effected. | 0 |
FIELD OF THE INVENTION
This invention relates to a water selecting/dispensing device which can be positioned on the edge of a wash-basin or the like.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide a dispensing device whereby it is possible to select in a reciprocally exclusionary fashion the delivery between at least one source of treated water and mixable sources of hot and cold water, while avoiding possible mixing between the treated water and the hot and cold water. This object is achieved according to the invention by providing a device for dispensing water from at least one delivery outlet, comprising first means for manually controlling the delivery from the outlet of water flowing from first sources, and second means for manually controlling the delivery from the outlet of water flowing from second sources, characterized by the fact that at least the first means are operatively connected to cutoff means inhibiting delivery from the second means when the first means are made to deliver water from their respective sources.
BRIEF DESCRIPTION OF THE DRAWINGS
The innovative principles of this invention and its advantages with respect to the known technique will be more clearly evident from the following description of possible exemplary and non-restrictive embodiments applying such principles, with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic cross-sectional and partially cutaway view of a first tap embodiment made according to this invention;
FIG. 2 is a partially cutaway side elevational view of the tap of FIG. 1 operated;
FIG. 3 is a partially cutaway front view of the device of FIG. 1;
FIG. 4 is a view similar to FIG. 1 of a second embodiment of a tap made according to this invention;
FIG. 5 is a view similar to FIG. 4 of the tap of FIG. 4 operated;
FIG. 6 is a view similar to FIG. 1 of a third embodiment of the tap made according to this invention;
FIG. 7 is a view similar to FIG. 1 of the tap of FIG. 6 operated;
FIG. 8 is a cross-sectional view taken along line VIII--VIII in FIG. 6;
FIG. 9 is a view similar to FIG. 1 of another tap made according to this invention;
FIG. 10 is a schematic cross-sectional view of a selector applicable to the taps mentioned previously;
FIG. 11 is a cross-sectional view taken along line XI--XI of FIG. 10; and
FIG. 12 is a view similar to FIG. 1 of a further embodiment of a tap made according to this invention.
DETAILED DESCRIPTION
With reference to the figures, a tap made according to the invention is shown in FIGS. 1, 2, 3 and is generically indicated by reference 10. The tap comprises a body 11 secured from below to a surface 12, for example the edge of a wash-basin.
The body 11 comprises a housing designed to receive a single-control mixer cartridge 13, of known technique (for example of the type with ceramic disks, well-known by any technician expert in the field). The cartridge has a control pin 21 connected by means of a casing element 50, to an operating lever 14. The lever controls the delivery and adjusts the mixing of the water flowing from two inlets 15, 16 (FIG. 2) typically for hot water and cold water, respectively.
The water is turned on by slanting the lever 14 downward, in the plane of the drawing, (as shown by the broken line 26), while the mixing is regulated by rotating the lever around the axis of the pin 21. The outlet of the cartridge 13 is connected, by means of a duct 17, to a first delivery pipe 18.
In the opposite position with respect to the cartridge 13, the body 11 has a housing for a known screw-type tap 19, which is made to rotate by means of a lever 20 protruding radially from a casing element 27 keyed onto the pin 28 controlling the screw. The screw tap 19 has an inlet duct 22 connected to a source of treated water, for example purified. The outlet of the screw tap is connected, by means of a duct 23, to a delivery pipe 24 advantageously disposed concentric to the pipe 18. The pipes 18 and 24 then lead into a delivery outlet 25. The pipes 18 and 24, which are integral with each other, are preferably connected to the body 11 in a rotatable fashion with respect to their axis, so as to enable the outlet 25 to be oriented in a horizontal plane. The casing element 27 has a cam-shaped surface which acts on the head 30 of a pin 31 in order to push it, against the action of a spring 32, when the screw tap is turned on by shifting the lever 20 (as clearly shown in FIG. 2). As can be more clearly seen in FIG. 3, at its other end the pin 31 supports a "C"-shaped element 33 which constitutes a movable bearing surface for the edge of the casing element 50 integral with the lever 14. When the lever 20 is in the closed position, the element 33 is in the retracted position shown in FIG. 1, and the lever 14 can be freely shifted to operate the mixer cartridge 13. As shown in FIG. 2, when the lever 20 is rotated, the screw tap 19 opens and the cam surface 29 simultaneously pushes the pin 31, so that the element 33 comes to rest against the edge of the casing 50, thus preventing the lever 14 from shifting and consequently opening the mixer. Advantageously, whenever the tap 19 is closed and the mixer 13 is open, the subsequent opening of the tap 19 forces the element 33 to close the mixer. The extension of the C-shaped element 33 ensures interference with the casing 50 belonging to the lever 14. The lever has also been rotated around the axis of pin 21 in order to vary the mixing ratio between the sources 15 and 16.
It is clear, at this point, how the device 10 operates. By operating the lever 14, water flowing from the ducts 15 and 16 can be delivered from the outlet 25 mixed to any desired degree. Likewise, by operating the lever 20, water flowing from the duct 22 can be delivered from the outlet 25. Once the delivery of one of the two flows of water has begun, the presence of the mechanical stop, consisting of the pin 31 and the element 33, prevents the other from simultaneously being delivered. This arrangement, together with the fact that the paths of the two different flows of water fare completely separate, prevents any possibility whatsoever of them becoming mixed together.
In this way, the properties of the treated water (for example its purity) can in no way be altered by the water coming from the other ducts. The impossibility of even small quantities of liquid contained in the ducts of the delivery outlet becoming mixed is useful whenever the sources consist of liquids other than simply water, such as for example, soft drinks.
FIGS. 4 and 5 show a second embodiment of a tap according to the inspiring principles of this invention. This second embodiment 110 is substantially similar in structure to the previous embodiment 10 and maintains the same numbering as the latter preceded by the digit one, for the parts which remain substantially unchanged, and for which reference should be made to the foregoing description. The second embodiment is thus composed of a body 111 with housings designed to receive a mixing cartridge 113, operated by a lever 114 to mix and control the delivery of water flowing from ducts 115 and 116 (for example, hot and cold water ducts, respectively), and a screw-type tap 119, operated by a lever 120 to regulate the incoming flow of treated water (refrigerated, purified, etc.) from a duct 122.
Unlike the previous embodiment, the outlet ducts 117 and 123, from the mixer 113 and from the screw tap 119, respectively, pass through a chamber 150 within which is slidingly and tightly housed a piston 151, which moves against the action of a spring 152 to alternatively close the duct 117 or the duct 123 which penetrate into the chamber 160 on opposites sides of a piston 1616.
As shown in FIG. 4, the spring 162 exerts pressure on piston 161 to close the duct 117. When the screw tap 119 is opened the water flowing from the duct 122 can then flow through the ducts 123 and 124 towards a delivery outlet, not shown since it is essentially similar to the delivery outlet 25 of FIG. 1.
Conversely, when the mixer 113 is turned, on the water flowing from it, as shown in FIG. 5, forces the piston 161 to slide against the action of the spring, so as to open the duct 117 in the direction of the duct 118, which also communicates with the delivery outlet. The sliding movement of the piston simultaneously closes the duct 123, so that when the tap 119 is operated it prevents delivery of the corresponding water.
In this way a hydraulic lock is obtained which prevents the water flowing from the ducts 115, 116 (advantageously normal mains water) from being accidentally mixed with the treated water flowing from the duct 122.
FIGS. 6-8 show a third embodiment applying the innovative principles claimed herein.
This embodiment, which is generically indicated by reference 210, comprises a body 211 with a housing designed to receive a mixing cartridge 213, operated by a lever 214 for mixing and controlling the delivery of water flowing from ducts 215 and 216 (for example, cold and hot water, respectively, from a water supply system), the mixed flow passes through ducts 217 and 224 and is then delivered from a delivery outlet, not shown, identical to the delivery outlet 25 of FIG. 1.
Disposed at the opposite end of the body 211 are a selector 260 and a delivery tap 261.
The selector 260 comprises a first fixed disk 262 having (as is more clearly shown in FIG. 8) a plurality of holes disposed along a circumference concentric to the disk. For example, there can be three holes, indicated in the figures by references 263, 264, 265, communicating by means of ducts 266, 267, 268 with their respective pipes 269, 270, 271 which supply treated water. The treated water can be, for example, purified and refrigerated water, purified water, and water containing carbon dioxide.
Disposed matching with one face of the disk 262 is a second disk 272 coaxial with the first and free to rotate around their common axis. The rotation of the disk 272 is controlled by an external ring nut 273 connected to it by means of a screw 274 sliding within a circumferentially extended slot 275, as can be clearly seen in FIG. 7. The disk 272 is traversed by a hole 276 which, on rotation of the disk is shifted to selectively match with one of the plurality of holes on the fixed disk 262. In this way, the selected duct (269, 270 or 271) communicates, through a chamber 277, with a duct 278 coaxial to the disks and ending in a chamber 279 connected to duct 218 leading to the delivery outlet.
Fitted to slide axially to the duct 278 is a hollow shaft 280 provided at one end with a plug 281 which intercepts the flow through the duct 278.
Sliding within the hollow shaft 280 is a shaft 282 which is divided at one end to simultaneously control a plug 283 which is actuated to close the inlet of the mixer 213 connected, through the duct 285, to the duct 215 and (as shown in FIG. 7) a plug 284 which is actuated to close the inlet of the mixer 213 connected, through a duct 286, to the duct 216.
At the opposite end to the plugs 283 and 284, the shaft 282 carries an element 287 which is made to slide axially, against the action of a spring 290, by the pressure exerted by a cam surface 288 operated by shifting a lever 220.
By compression of a spring 289, the movement of the element 287 is transmitted elastically to the shaft 282. In use, the mixer 213 can be operated by shifting the lever 214, similarly to the mixer 13 of the first embodiment.
When the lever 220 is shifted from the position shown in FIG. 6 to the position shown in FIG. 7, it initially shifts, by means of the spring 289, the shaft 282 so that the plugs 283, 284 cut off the flow of water to the mixer 213.
By continuing the rotational movement of the lever 220 the spring is compressed until the element 287 comes into contact with the hollow shaft 280 and forces it to open the duct 278, thus obtaining delivery of the water flowing from the duct (269, 270 or 271) which is selected by rotating the ring nut 273.
This ensures that, whenever the lever 220 is operated while water is being delivered through the mixer 213, the delivery from the mixer is automatically interrupted before the delivery controlled by the tap 261 begins. At the same time, whenever the tap 261 is open and the mixer 213 is turned on, no water will be delivered from the latter. This makes it impossible for the water coming from the two sets of ducts 215, 216 and 269, 271 to be mixed, even in the case of incorrect manipulation by the user. FIG. 9 shows a further example of a tap according to the invention. In this further embodiment, generically indicated by reference 310, the two sets of water to be kept separate from each other each comprise two sources consisting respectively of ducts 315, 316 and 393, 394. For example, the first can be connected to sources of hot water and cold water from the mains and the second can be connected to sources of purified water and refrigerated purified water.
The sources of the first set can be mixed by means of the mixer 313, by shifting the lever 314, while the sources of the second set can be mixed by means of the mixer 391, by a similar movement of slanting and rotating the lever 392. The outlets of the two mixers are connected to separate delivery ducts, indicated by references 318 and 324, respectively, which lead into a delivery outlet which is similar to the outlet 25 of FIG. 1 and therefore not shown.
When the lever 392 is slanted, to open the mixer 391, it pushes the edge of the casing element 327 against a C-shaped element 395, substantially identical to the element 33 of FIG. 3. In this way, a pin 331 connected to it is made to slide, against the action of a spring 332, so as to in turn push a C-shaped element 333 against the edge of the casing element 350. As a result, if the mixer 314 was open it is closed by the thrust of the element 333. Similarly, if the mixer 313 is opened when the mixer 391 is open, the latter is closed by the thrust of the element 395 against the edge of the casing 327, thus preventing the simultaneous operation of both mixers, which would result in the mixing of their respective flows of water.
In FIG. 12 is shown a further tap made according to the invention, and generically indicated by 410, comprising a body 411 secured from below to a surface 412, for example to edge of a wash-basin. The body 411 in turns comprises a housing designed to receive a single-control mixer cartridge 413, of known technique (for example of the type with ceramic disks, well-known by any technician expert in the field). The cartridge has a control pin 421 connected, by means of a casing element 450, to an operating lever 414. By rotating and slanting the lever 414 with respect to the axis of the cartridge it is thus possible to control the delivery and adjust the mixing of the water flowing from two inlets 415, 416, typically for hot water and cold water, respectively.
In the opposite position with respect to the cartridge 413, the body 411 has a housing for a known screw-type tap 419, which is made to rotate by means of a lever 420 protruding radially from a casing element 427 keyed onto the pin 428 controlling the screw. The screw tap 419 has an inlet duct 422 connected to any known source of treated water, for example purified, and an outlet connected, by means of a duct 423, to a chamber 400 which leads off into a first delivery pipe 418.
An annular diaphragm 402 surrounds the pipe 418 and hermetically separates the chamber 400 from a second chamber 401 which leads off into a tubular element 403 connected to a second pipe 424. A duct 417 connected to the mixed outlet of the cartridge 413 also leads into the chamber 401.
The pipes 424 and 418 are advantageously integrally and concentrically disposed so that their other ends open out into a delivery head 405 and are preferably connected to the body 411 in an axially rotating fashion, so as to enable the head to be oriented in a horizontal plane. The delivery head 405, which is advantageously axially rotatable with respect to the ducts 418 and 424 thanks to an airtight rotary coupling 404, comprises a delivery outlet 425 with a first passage 406 directly connected to the pipe 424. A second passage 407, coaxial to the first, is connected to the pipe 418 by means of a valve unit 408 comprising a piston 409 biased by a spring 454 to tightly close the mouth of the duct 418. The delivery head is advantageously fitted with a liquid crystal thermometer 456 in contact with the water dispensed by the mixer, so as to give an indication of its temperature.
To use, let us assume that the lever 420 is operated so as to open the screw tap 419. The treated water arriving from the duct 422 will begin to flow into the duct 418 until it reaches the valve unit 408. The ratio between the flexibility of the diaphragm and the thrust of the spring is such that the pressure of the water flowing from the screw tap will first flex the diaphragm 402 and then the piston 409 will move against the action of the spring 454. Thus, before the water begins to flow from the outlet 425, the diaphragm flexes and comes to rest tightly against the edge 455 of the element 403 thereby closing the passage between chamber 401 and pipe 424.
If at this point we were to open the mixer tap 413, the delivery of mains water from the ducts 415 and 416 would be prevented because the diaphragm 402 prevents it from flowing between duct 417 and pipe 424. It should be noted that the area of the diaphragm affected by the pressure of the treated water in the chamber 400 is double compared to the area of diaphragm affected by the pressure of the mains water in the chamber 401. Consequently, although the pressure of the different flows of water is the same, the water arriving from the duct 423 will always take precedence in the delivery. Therefore, whenever only the mixer tap 413 is opened the mains water is immediately delivered from the outlet 425, but if then the tap 419 is opened the diaphragm closes the passage between chamber 401 and pipe 424, impeding the flow of mains water, and the treated water is then delivered.
This arrangement, together with the fact that the paths of the different flows of water are completely separate, prevents any possibility whatsoever of them becoming mixed together.
In this way, the properties of the treated water (for example its purity) can in no way be altered by the water coming from the other ducts. The impossibility of even small quantities of liquid contained in the ducts of the delivery out let becoming mixed is useful whenever the sources consist of liquids other than simply water, such as for example, soft drinks.
The operating features described above are obviously identical also when the pressure of the incoming water in the two circuits differs, within certain limits. In fact, in the worst of hypotheses, that is when the inlet pressure of the treated water is lower than the inlet pressure of the mains water, it should be borne in mind that whereas the water flowing through the duct 403 to the outlet encounters practically no resistance, the water flowing through the duct 418 encounters the resistance of opening the valve 408, and to this is added the different area of the diaphragm affected by the pressure of the two sources of water.
Should it be desired to be able to choose from a wider range of sources, FIGS. 10 and 11 show a selector which can be connected to an inlet duct of the previous embodiments and, in particular, to duct 22 or 122 of the embodiments shown in FIGS. 1-3 and 4-5, respectively. This selector, which is generically indicated by reference 34, can be fitted into a surface 35, for example the edge of a wash-basin, and internally comprises a first fixed disk 36 with peripheral holes 37, 38, 39 connected respectively to inlet ducts 40, 41, 42 supplying water from different sources. The fixed disk 36 is also provided with an axial hole 43 connected to an outlet duct 44. Disposed matching with the disk 36 is a second disk 45 which can be rotated on its axis by means of an external control lever 46 which turns a shaft 47 coupled to the disk. The movable disk 45 has a hole 48 coaxial to the central hole 43 of the first disk and a peripheral hole 49 selectively matching with one of the peripheral holes in the fixed six 36.
Thus, by rotating the control lever 46 it is possible to connect one of the sources 40, 41, 42 to the outlet duct 44 which, when connected to the inlet duct of one of the previously described embodiments, supplies it alternatively with water.
It is thus possible, for example with the embodiments of FIGS. 1, 4, 12, for the control 20, 120, 420 to enable delivery from several sources by selection control by means of the device 34.
It will be obvious at this point that the intended object of the invention are achieved by providing a tap-operated dispensing device for delivering water from different sources, while avoiding any possibility of undesirable mixing. The foregoing description of an embodiment applying the innovative principles of this invention is given by way of example in order to illustrate such innovative principles and should not therefore be understood as a limitation to the scope of the invention claimed herein. For example, the taps shown may also differ in shape in order to adapt to particular aesthetical or structural requirements.
Moreover, even though the two delivery pipes are shown concentric, it will be obvious to any technician that it is also possible to obtain an embodiment with pipes disposed side by side or a single pipe divided by a longitudinal internal diaphragm.
If complete separation of the paths for the water flowing from the two sets of sources connected to the two controls on the tap is not required, a single pipe can obviously be used.
It will also be obvious to any technician that it is possible, in the embodiment shown in FIGS. 1-3, to position the pin 31 biased elastically to the right, so that the movement of opening the lever 14 shifts the pin 31 towards the left to engage it in a housing in the element 27 thereby preventing it from rotating. Thus, contrarily, the movement of the lever 20 prevents the pin 31 from engaging in said housing and consequently the lever 14 cannot be slanted, thereby providing a locking device with reciprocal exclusion.
Finally, the types of taps delivering water into the chambers 400 and 401 may differ from those shown. In fact, use may be made, for example, of two simple screw-type taps whenever there are only two sources to be kept separate, or of two mixing taps whenever there are two sets of water to be kept separate, each made up of two freely mixable sources. | A device (10) for dispensing water from at least one delivery outlet (25) has a first tap device (19) for manually controlling the delivery from the outlet (25) of fluid flowing from a first source (22) and a second tap device (13) for manually controlling the delivery from the outlet (25) of fluid flowing from a second source (15, 16). At least the first tap device (19) is operatively connected to a cutoff device (30, 31, 32, 33, 402) for inhibiting delivery of fluid from the second source (15) when the first tap device (19) is operated to deliver fluid from the first source (22). | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. patent application Ser. No. 11/685,807, filed on Mar. 14, 2007, which claims the benefit of U.S. Provisional Application Ser. No. 60/781,727, filed on Mar. 14, 2006.
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to devices and methods for treating intracranial aneurysms. Treatment of various types of intracranial aneurysms, such as wide-neck and vertebrobasilar aneurysms, has been particularly difficult. Current methods for endovascular treatment for such aneurysms include the introduction of coils into the aneurysm to fill or occlude the aneurysm. However, particularly in cases of wide-neck aneurysm, loops of coils may not be contained within the aneurysm and may protrude out into the vessel. A known technique to prevent escape of the coils is a two-catheter technique, in which a microcatheter and a balloon catheter are introduced simultaneously. For example, in one technique, the microcatheter is placed within the aneurysm, and, during coil delivery, a balloon is inflated in the parent vessel adjacent to the aneurysm orifice. The balloon remains inflated during coil delivery and until the configuration of coils is set, after which the balloon is deflated and the catheter is removed. In another technique, two microcatheters are placed in an aneurysm and multiple coils are introduced.
[0003] The use of two devices is cumbersome and can result in wire entanglement, limited pushability and torqueability, increased procedure time and complications.
[0004] An alternative method includes the use of self-expanding stents such as, for example, the Neuroform™ stents manufactured by Boston Scientific Corp. (MA, USA). Specifically, such stents are presented to the site of the aneurysm and deployed, and can help to prevent escape of coils. Self expanding stents are generally used due to their low profile and maneuverability, features which are crucial for small vessels associated with intracranial aneurysms. However, they are prone to positioning problems and are difficult to anchor in place during deployment. Furthermore, the use of stents in general is not always considered optimal, since once the stent is in place, it cannot be removed and may itself present additional problems such as turbulence, thrombosis, or even stenosis in the stented region of the vessel. Moreover, the presence of a stent warrants patient-prescribed anti-coagulation medication, which may be contraindicated for some patients.
[0005] It would thus be advantageous to have a device which could be used to prevent escape of coils during a procedure which is devoid of the above limitations.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention, there is provided a device for providing a coil to an aneurysm. The device includes an access element having an access lumen and a distal end which is pre-shaped at an angle to a longitudinal axis of the device and which may be forcibly aligned with the longitudinal axis, and an occlusion element for occluding an ostium of the aneurysm during delivery of the coil, the occlusion element at least partially attached to the access element.
[0007] According to another aspect of the invention, there is provided a method for treating an aneurysm. The method includes providing a device having an access element and an occlusion element, the access element having a distal end which includes a pre-shaped configuration which is at an angle to a longitudinal axis of the device, providing a guidewire through the access element and a distal connecting element positioned at a distal end of the occlusion element so as to straighten the pre-shaped distal end, introducing the device into a vessel adjacent to the aneurysm; releasing the guidewire from the distal connecting element so as to cause the access element to assume its pre-shaped configuration, occluding an ostium of the aneurysm the said occlusion element, and delivering a coil through the access element and into the aneurysm.
[0008] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above and further advantages of the present invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
[0010] FIGS. 1A and 1B are schematic illustrations of a device in accordance with embodiments of the present invention, shown in a deployed state and a pre-deployed state, respectively;
[0011] FIGS. 1C , 1 D and 1 E are cross-sectional illustrations of the device of FIGS. 1A and 1B , showing an access lumen, an inflation lumen and a core wire, in accordance with several configurations;
[0012] FIGS. 1F and 1G are illustrations of a distal portion of the device of FIGS. 1A and 1B in accordance with additional embodiments of the present invention;
[0013] FIGS. 2A and 2B are schematic illustrations of a device in accordance with further embodiments of the present invention, shown in a deployed state and a pre-deployed state, respectively;
[0014] FIG. 2C is a cross-section illustration of the device of FIGS. 2A and 2B , showing an access lumen, an inflation lumen coaxial to the access lumen, and a core wire;
[0015] FIGS. 3A and 3B are schematic illustrations of a device in accordance with further embodiments of the present invention, shown in a deployed state and a pre-deployed state, respectively;
[0016] FIG. 3C is a cross-section illustration of the device of FIGS. 3A and 3B , showing an access lumen, a shaft and a core wire;
[0017] FIGS. 4A and 4B are schematic illustrations of a device in accordance with further embodiments of the present invention, shown in a pre-deployed state and in a deployed state, respectively;
[0018] FIGS. 5A-5D are schematic illustrations of a device in accordance with yet further embodiments of the present invention, shown in deployed states in FIGS. 5A and 5C and in pre-deployed states in FIGS. 5B and 5D ;
[0019] FIGS. 6A-6D are schematic illustrations of the steps of a method of using the devices of FIGS. 1A-1G or FIGS. 2A-2C , in accordance with embodiments of the present invention;
[0020] FIGS. 7A-7D are schematic illustrations of the steps of a method of using the devices of FIGS. 3A-3C , in accordance with embodiments of the present invention;
[0021] FIGS. 8A-8D are schematic illustrations of the steps of a method of using the devices of FIGS. 5A-5D , in accordance with embodiments of the present invention;
[0022] FIGS. 9A-9C are schematic illustrations of the steps of a method of using the devices of the present application to treat an aneurysm at a Y-bifurcation;
[0023] FIGS. 10A-10C are schematic illustrations of the steps of a method of using the device of FIGS. 4A and 4B to treat an aneurysm at a Y-bifurcation; and
[0024] FIGS. 11A-11C are schematic illustrations of views of marker positions in accordance with several different positions of the devices of the present invention.
[0025] It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn accurately or to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. Moreover, some of the blocks depicted in the drawings may be combined into a single function.
DETAILED DESCRIPTION
[0026] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be understood by those of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components and structures may not have been described in detail so as not to obscure the present invention.
[0027] Reference is now made to FIGS. 1A and 1B , which are schematic illustrations of a device 100 in accordance with embodiments of the present invention, shown in a deployed state and in a pre-deployed state, respectively. Device 100 includes a shaft 103 having a proximal end 102 and a distal portion 104 . Shaft 103 is comprised of an access element 106 for accessing an area of an aneurysm, and an occlusion element 110 , for providing occlusion means to the ostium of the aneurysm. Distal portion 104 of shaft 103 includes an access element distal portion 107 and an occlusion element distal portion 140 , wherein occlusion element distal portion 140 includes a balloon 116 having a balloon proximal end 142 and a balloon distal end 144 . In the embodiment shown in FIGS. 1A and 1B , access element 106 is an elongated element extending from proximal end 102 of shaft 103 to distal portion 104 of shaft 103 , and includes an access lumen 108 therethrough. Proximal end 102 of shaft 103 includes an access hub 117 for introduction of a material or object through access lumen 108 . Distal portion 107 of access element 106 extends distally past balloon proximal end 142 , and is comprised of a soft elastomeric or polymeric material such as a urethane, silicone rubber, latex, nylon, any copolymers thereof, or any other suitable material. Alternatively, distal portion 107 of access element 106 includes a spring-element that provides pre-shaping. A radiopaque access marker 125 is positioned on distal portion 107 of access element 106 . Occlusion element 110 is also an elongated element positioned alongside access element 106 and extending from proximal end 102 of shaft 103 to distal portion 104 of shaft 103 . Occlusion element 110 has a balloon 116 at a distal end thereof. Balloon 116 is shown in an inflated state in FIG. 1A and in a deflated state in FIG. 1B . An inflation lumen 112 provides fluid communication between an inflation port 115 at proximal end 102 of shaft 103 and balloon 116 . Additional radiopaque markers 124 are positioned along occlusion element 110 and/or shaft 103 .
[0028] A distal connecting element 114 is positioned at the distal end of device 100 , and may be attached to balloon 116 . Alternatively, distal connecting element 114 may be attached to a distal tip 119 , distal to balloon 116 , as shown in FIGS. 1F and 1G , in the inflated and deflated states, respectively. In this embodiment, a radiopaque marker 124 may be positioned on distal connecting element 114 . As shown in FIG. 1A , distal portion 107 of access element 106 is pre-shaped at an angle to a longitudinal axis 146 of device 100 , wherein longitudinal axis 146 is defined by an imaginary line connecting distal portion 104 and proximal end 102 of shaft 103 . The angle can be in a range of 0 to 90 degrees, and in most cases is in a range of 20-70 degrees.
[0029] As shown in FIG. 1B , pre-shaped access element 106 can be forcibly aligned with longitudinal axis 146 of device 100 by placing a guidewire 118 therethrough and further positioning guidewire 118 through distal connecting element 114 . This relatively straight configuration results in a reduced profile which is suitable for introduction and advancement through blood vessels. In one embodiment, access element 106 acts as a microcatheter for providing treatment coils. In an alternative embodiment, access element 106 acts as a conduit for a separate microcatheter placed therein.
[0030] Reference is now made to FIG. 1C , which is a cross-section illustration of section A-A, showing access lumen 108 and inflation lumen 112 . Inflation lumen 112 may be smaller than access lumen 108 , and may assume various shapes and configurations, provided that there is sufficient area for introduction of an inflation fluid. The cross-sectional shape of shaft 103 may be approximately circular, as shown in FIG. 1C , elliptical, as shown in FIG. 1D , may assume a figure-eight configuration, as shown in FIG. 1E , or may be any other suitable shape or configuration. In some embodiments, a core wire 122 is positioned through device 100 to provide stiffness and enhance pushability and trackability. Additionally, stiffness of proximal end 102 of shaft 103 may be provided by braiding or by other methods known in the art. Stiffness improves overall pushability and torqueability.
[0031] Reference is now made to FIGS. 2A and 2B , which are schematic illustrations of a device 200 in accordance with alternative embodiments of the present invention, shown in a deployed state and in a pre-deployed state, respectively. Device 200 includes a shaft 203 having a proximal end 202 and a distal end 204 . Device 200 includes an access element 206 for accessing an area of an aneurysm, and an occlusion element 210 , for providing occlusion means to the ostium of the aneurysm. Distal end 204 of shaft 203 includes an access element distal portion 207 and an occlusion element distal portion 240 , wherein occlusion element distal portion 240 includes a balloon 216 having a balloon proximal end 242 and a balloon distal end 244 . In the embodiment shown in FIGS. 2A and 2B , access element 206 is an elongated element extending from proximal end 202 of shaft 203 to distal end 204 of shaft 203 , and includes an access lumen 208 therethrough. Proximal end 202 of shaft 203 includes an access hub 217 for introduction of a material or object through access lumen 208 . Distal portion 207 of access element 206 extends distally past balloon proximal end 242 and is comprised of an elastomeric or polymeric material such as a urethane, silicone rubber, latex, nylon, any copolymers thereof, or any other suitable material. Alternatively, distal portion 207 of access element 206 includes a spring-element that provides pre-shaping. A radiopaque access marker 225 is positioned on distal portion 207 of access element 206 . Occlusion element 210 is also an elongated element positioned coaxial to access element 206 and extending from proximal end 202 of shaft 203 to distal end 204 of shaft 203 . Occlusion element 210 has a balloon 216 at a distal end thereof. Balloon 216 is shown in an inflated state in FIG. 2A and in a deflated state in FIG. 2B . An inflation lumen 212 provides fluid communication between an inflation port 215 at proximal end 202 of shaft 203 and balloon 216 . Distal portion 207 of access element 206 protrudes through a portion of balloon 216 . Additional radiopaque markers 224 are positioned along occlusion element 210 and/or shaft 203 .
[0032] A distal connecting element 214 is positioned at a distal end of device 200 , and may be attached to balloon 216 . Alternatively, distal connecting element 214 may be attached to a distal tip, distal to balloon 216 . As shown in FIG. 2A , distal portion 207 of access element 206 is pre-shaped at an angle to a longitudinal axis 246 of device 200 , wherein longitudinal axis 246 is defined by an imaginary line connecting distal end 204 and proximal end 202 of shaft 203 . The angle can be in a range of 0 to 90 degrees, and in most cases is in a range of 20-70 degrees.
[0033] As shown in FIG. 2B , pre-shaped access element 206 can be forcibly aligned with longitudinal axis 246 of device 200 by placing a guidewire 218 therethrough and further positioning guidewire 218 through distal connecting element 214 . This relatively straight configuration results in a reduced profile which is suitable for introduction and advancement through blood vessels. In one embodiment, access element 206 acts as a microcatheter for providing treatment coils. In an alternative embodiment, access element 206 acts as a conduit for a separate microcatheter placed therein.
[0034] Reference is now made to FIG. 2C , which is a cross-section illustration of section B-B, showing access lumen 208 and inflation lumen 212 in a position which is coaxial to access lumen 208 . The cross-sectional shape of shaft 203 may be approximately circular, as shown in FIG. 2C , or may be elliptical, may assume a figure-eight configuration, or may be any other suitable shape or configuration. In some embodiments, a core wire 222 is positioned through device 200 and alongside access element 206 to provide stiffness. Additionally, stiffness of proximal end 202 of shaft 203 may be provided by braiding or by other methods known in the art. Stiffness improves overall pushability and torqueability.
[0035] Reference is now made to FIGS. 3A and 3B , which are schematic illustrations of a device 300 in accordance with embodiments of the present invention, shown in a deployed state and in a pre-deployed state, respectively. Device 300 includes a shaft 303 having a proximal end 302 and a distal end 304 . Device 300 includes an access element 306 for accessing an area of an aneurysm, and an occlusion element 310 , for providing occlusion means to the ostium of the aneurysm. Distal end 304 of device 300 includes an access element distal portion 307 and an occlusion element distal portion 340 , wherein occlusion element distal portion 340 includes a balloon 316 having a balloon proximal end 342 and a balloon distal end 344 . In the embodiment shown in FIGS. 3A and 3B , access element 306 is an elongated element extending distally past balloon proximal end 342 , and includes an access lumen 308 therethrough. Access element 306 is comprised of an elastomeric or polymeric material such as a urethane, silicone rubber, latex, nylon, any copolymers thereof, or any other suitable material. Alternatively, distal portion 207 of access element 206 includes a spring-element that provides pre-shaping. A radiopaque access marker 325 is positioned on distal portion 307 of access element 306 . Proximal end 302 of shaft 303 has a larger diameter than distal portion 304 of shaft 303 and than access element 306 . Occlusion element 310 is a balloon 316 positioned at distal end 304 of shaft 303 . Both access lumen 308 and balloon 316 are in communication with shaft 303 , and may be accessed via a shared hub 317 . Balloon 316 is shown in an inflated state in FIG. 3A and in a deflated state in FIG. 3B . In one embodiment, a divider 309 partially separates balloon 316 from shaft 303 , allowing fluid flow but not allowing transfer of denser materials. This configuration allows for a microcatheter having an outer diameter which is approximately equal to an inner diameter of access element 306 to be introduced through access lumen 308 , effectively sealing access element 306 . Once the microcatheter is in place in the aneurysm, inflation fluid can be introduced through shaft 303 , and will flow directly into balloon 316 . Additional radiopaque markers 324 are positioned along occlusion element 310 and/or shaft 303 .
[0036] A distal connecting element 314 is positioned at a distal end of device 300 , and may be attached to balloon 316 . Alternatively, distal connecting element 314 may be attached to a distal tip, distal to balloon 316 . As shown in FIG. 3A , access element 306 is pre-shaped at an angle to a longitudinal axis 346 of device 300 , wherein longitudinal axis 346 is defined by an imaginary line connecting distal end 304 and proximal end 302 of shaft 303 . The angle can be in a range of 0 to 90 degrees, and in most cases is in a range of 20-70 degrees.
[0037] As shown in FIG. 3B , pre-shaped access element 306 can be forcibly aligned with longitudinal axis 346 of device 300 by placing a guidewire 318 therethrough and further positioning guidewire 318 through distal connecting element 314 . This relatively straight configuration results in a reduced profile which is suitable for introduction and advancement through blood vessels. In one embodiment, access element 306 acts as a microcatheter for providing treatment coils. In an alternative embodiment, access element 306 acts as a conduit for a separate microcatheter placed therein.
[0038] Reference is now made to FIG. 3C , which is a cross-section illustration of section C-C showing access lumen 308 and shaft 303 . The cross-sectional shape of shaft 303 may be approximately circular, as shown in FIG. 3C , or may be elliptical, may assume a figure-eight configuration, or may be any other suitable shape or configuration. In some embodiments, a core wire 322 is positioned through device 300 to provide stiffness. Additionally, stiffness of proximal end 302 of shaft 303 may be provided by braiding or by other methods known in the art. Stiffness improves overall pushability and torqueability.
[0039] Reference is now made to FIGS. 4A and 4B , which are schematic illustrations of a device 400 in accordance with embodiments of the present invention, shown in a pre-deployed state and in a deployed state, respectively. Device 400 includes a shaft 403 having a proximal end 402 and a distal end 404 . Device 400 includes an access element 406 for accessing an area of an aneurysm, and an occlusion element 410 , for providing occlusion means to the ostium of the aneurysm. In the embodiment shown in FIGS. 4A and 4B , access element 406 is an elongated element extending from an access port 411 along a body of device 400 to distal end 404 of shaft 403 , and includes an access lumen 408 therethrough. A radiopaque access marker 425 is positioned on a distal portion of access element 406 . Occlusion element 410 is an elongated element extending from proximal end 402 of shaft 403 to a location proximal to distal end 404 of shaft 403 . Occlusion element 410 includes a balloon 416 having a distal portion 417 and a proximal portion 418 . Distal portion 417 has a different compliance than proximal portion 418 . The difference in compliance may be provided by the use of different materials for distal portion 417 and proximal portion 418 . Alternatively, the same material may be used, but with different durometers or thicknesses. Any other known method of providing an object with two different compliances may be used. In a preferred embodiment, distal portion 417 has a lower compliance than proximal portion 418 . In other embodiments, distal portion 417 has a higher compliance than proximal portion 418 . Balloon 416 is shown in a deflated state in FIG. 4A and in an inflated state in FIG. 4B . An inflation lumen 412 provides fluid communication between an inflation port 415 at proximal end 402 of shaft 403 and balloon 416 .
[0040] While generally not recommended for endovascular aneurysm treatment, there may be some cases where the use of a stent may be beneficial. It should be readily apparent that a stent may be positioned at a distal end of any of the devices described above, and that balloon 116 , 216 or 316 may be used to deploy the stent.
[0041] In some embodiments, a fixed wire is added to the distal end of balloon 116 , 216 , 316 or to a distal tip of the device. This wire can aid in rotation of the device and can enhance torqueability.
[0042] Reference is now made to FIGS. 5A , 5 B, 5 C and 5 D, which are schematic illustrations of a device 500 in accordance with embodiments of the present invention. In a first embodiment, shown in FIG. 5A in a deployed state and in FIG. 5B in a pre-deployed state, device 500 includes a shaft 503 having a proximal end 502 and a distal portion 504 . Device 500 includes an access element 506 for accessing an area of an aneurysm, and an occlusion element 510 , for providing occlusion means to the aneurysm. Access element 506 is an elongated element extending from proximal end 502 of shaft 503 to distal portion 504 of shaft 503 , and includes an access lumen 508 therethrough. A distal portion 507 of access element 506 is comprised of a soft elastomeric or polymeric material such as a urethane, silicone rubber, latex, nylon, any copolymers thereof, or any other suitable material. Alternatively, distal portion 507 of access element 506 includes a spring-element that provides pre-shaping.
[0043] A radiopaque access marker 525 is positioned on distal portion 507 of access element 506 . Occlusion element 510 is also an elongated element positioned alongside and attached to access element 506 , and extending from proximal end 502 of shaft 503 to distal portion 504 of shaft 503 . Occlusion element 510 includes an occlusion lumen 512 for introduction of occlusion material, such as a coil, therethrough. A distal portion 513 of occlusion element 510 is comprised of a soft elastomeric or polymeric material such as a urethane, silicone rubber, latex, nylon, any copolymers thereof, or any other suitable material. Alternatively, distal portion 513 of occlusion element 510 includes a spring-element that provides pre-shaping. Additional radiopaque markers 524 may be positioned along occlusion element 510 . In one embodiment, shaft 503 is a dual lumen shaft having an access lumen 508 and an occlusion lumen 512 .
[0044] Distal portions 507 and 513 are pre-shaped at an angle to a longitudinal axis of device 500 , wherein the longitudinal axis is defined by an imaginary line connecting distal portion 504 and proximal end 502 of shaft 503 . The angle can be in a range of 0 to 90 degrees, and in most cases is in a range of 20-70 degrees. Proximal end 502 of shaft 503 includes an access hub 517 for introduction of a material or object through access lumen 508 , and an occlusion hub 519 for introduction of a material or object through occlusion lumen 512 .
[0045] Device 500 is shown in a pre-deployed position in FIG. 5B , wherein a guidewire 518 positioned through occlusion lumen 512 forcibly aligns distal portions 507 and 513 with the longitudinal axis of device 500 . Alternatively, guidewire 518 may be positioned through access lumen 508 . This relatively straight configuration results in a reduced profile which is suitable for introduction and advancement through blood vessels. Upon removal of guidewire 518 , distal ends 507 and 513 assume their pre-shaped configuration.
[0046] In an alternative embodiment, shown in FIGS. 5C and 5D , a distal connecting element 514 is positioned at distal end of occlusion element 510 . In this embodiment, an additional radiopaque marker 524 may be positioned on distal connecting element 514 . In this embodiment, pre-shaped access element 506 and pre-shaped occlusion element 510 can be forcibly aligned with the longitudinal axis of device 500 by placing a guidewire 518 through access lumen 508 and further positioning guidewire 518 through distal connecting element 514 .
[0047] Reference is now made to FIGS. 6A-6D , which are schematic illustrations of the steps of a method of using device 100 to treat an aneurysm. Although the figures are shown and described with respect to device 100 , the method for using device 200 may be the same as for device 100 . As shown in FIG. 6A , device 100 is introduced over a guidewire 118 into a main vessel 132 to an area of an aneurysm 134 . Device 100 is in its unexpanded state, with distal portion 107 of access element 106 held in an aligned position with device 100 via guidewire 118 placed through access element 106 and distal connecting element 114 . As shown in FIG. 6B , guidewire 118 is retracted proximally, releasing guidewire 118 from distal connecting element 114 , and causing distal portion 107 of access element 106 to assume its pre-shaped configuration. Distal portion 107 of access element 106 is positioned within aneurysm 134 . Markers 124 and 125 are used for positioning, as will be described in further detail hereinbelow. As shown in FIG. 6C , access element 106 is positioned within aneurysm 134 , and balloon 116 is expanded—blocking the neck or ostium of aneurysm 134 . As shown in FIG. 6D , a coil 136 is then introduced through access lumen 108 and into aneurysm 134 , in accordance with methods known in the art. Alternatively, a microcatheter is then introduced through access lumen 108 , and coil 136 is delivered through the microcatheter. Balloon 116 can be inflated and deflated several times during the procedure so as to alternate between allowing normal blood passage through main vessel 132 , and keeping the ostium of aneurysm 134 blocked until coil 136 is set. Once coil 136 is set, balloon 116 is deflated, and device 100 is removed from the vessel.
[0048] Reference is now made to FIGS. 7A-7D , which are schematic illustrations of the steps of a method of using device 300 to treat an aneurysm. As shown in FIG. 7A , device 300 is introduced over a guidewire 318 into a main vessel 132 to an area of an aneurysm 134 . Device 300 is in its unexpanded state, with access element 306 held in an aligned position with device 300 via guidewire 318 placed through access element 306 and distal connecting element 314 . As shown in FIG. 7B , guidewire 318 is retracted proximally, releasing guidewire 318 from distal connecting element 314 , and causing distal portion 307 of access element 306 to assume its pre-shaped configuration. Distal portion 307 of access element 306 is positioned within aneurysm 134 . Markers are used for positioning, as will be described in further detail hereinbelow. As shown in FIG. 7C , distal portion 307 of access element 306 is positioned within aneurysm 134 . Microcatheter 320 is then positioned in access lumen 308 . Microcatheter 320 effectively seals access element 306 , allowing for inflation fluid to reach balloon 316 . Balloon 316 is then expanded, blocking the neck or ostium of aneurysm 134 . As shown in FIG. 7D , a coil 336 is then introduced through microcatheter 320 and into aneurysm 134 , in accordance with methods known in the art. Balloon 316 can be inflated and deflated several times during the procedure so as to alternate between allowing normal blood passage through main vessel 132 , and keeping the ostium of aneurysm 134 blocked until coil 336 is set. Once coil 336 is set, balloon 316 is deflated, and device 300 is removed from the vessel.
[0049] Reference is now made to FIGS. 8A-8D , which are schematic illustrations of the steps of a method of using device 500 to treat an aneurysm. Although the figures are shown and described with respect to one embodiment of device 500 , the method for using other embodiments of device 500 may be the same as the method depicted in FIGS. 8A-8D . As shown in FIG. 8A , device 500 is introduced over a guidewire 518 into a main vessel 132 to an area of an aneurysm 134 . Device 500 is in its undeployed state, with access element 506 and occlusion element 510 held in an aligned position via guidewire 518 placed through access element 506 and distal connecting element 514 . As shown in FIG. 8B , guidewire 518 is retracted proximally, releasing guidewire 518 from distal connecting element 514 , and causing distal portion 507 of access element 506 and distal portion 513 of occlusion element 510 to assume their pre-shaped configurations. Distal portion 507 of access element 506 and distal portion 513 of occlusion element 510 are positioned within aneurysm 134 . Markers 524 and 525 are used for positioning, as will be described in further detail hereinbelow. As shown in FIG. 8C , a blocking coil 535 is introduced through occlusion lumen 512 and into aneurysm 134 —blocking the neck or ostium of aneurysm 134 . As shown in FIG. 8D , one or more coils 136 are then introduced through access lumen 508 and into aneurysm 134 , in accordance with methods known in the art. After coils 136 are delivered into aneurysm 134 and detached, and satisfactory filling of the aneurysm is confirmed, blocking coil 535 is detached. Detachment of coils 136 and blocking coil 535 is achieved in accordance with methods known in the art. Alternatively, a microcatheter is introduced through occlusion lumen 512 to deliver blocking coil 535 , and a microcatheter is introduced through access lumen 108 to deliver coils 136 . This method alleviates the long occlusion time or potential vessel damage sometimes associated with the use of balloons for occlusion.
[0050] Reference is now made to FIGS. 9A-9C , which are schematic illustrations of a method of using device 100 to treat an aneurysm at a Y-bifurcation, such as a vertebrobasilar junction. In this type of vessel, an aneurysm 234 may be positioned just opposite a main vessel 232 , and must be accessed head-on rather than from an angle. Although the method is shown for device 100 , it should be readily apparent that any of the devices in accordance with the various embodiments may be similarly used. As shown in FIG. 9A , device 100 is introduced over a guidewire 118 through main vessel 232 . As shown in FIG. 9B , access element 106 is positioned in aneurysm 134 . Balloon 116 is then inflated, as shown in FIG. 9C . In some instances, balloon 116 is compliant enough to block the ostium on its own. In other instances, it may be useful to introduce a second device with balloon 116 positioned over the remainder of ostium 134 . Once the ostium is blocked, coil 136 is introduced into aneurysm 134 , as described above with respect to FIGS. 6A-6D , 7 A- 7 D and 8 A- 8 D.
[0051] Reference is now made to FIGS. 10A-10C , which are schematic illustrations of a method of using device 400 to treat an aneurysm at a Y-bifurcation, such as a vertebrobasilar junction. In this type of vessel, an aneurysm 234 may be positioned just opposite a main vessel 232 , and must be accessed head-on rather than from an angle. As shown in FIG. 10A , device 400 is introduced over a guidewire 419 through main vessel 232 . As shown in FIG. 10B , access element 406 is positioned in aneurysm 134 , and balloon 416 is inflated. The high compliance of proximal portion 418 causes proximal portion 417 to be inflated over a wide area, causing the ostium to be substantially blocked. The low compliance of distal portion 417 prevents balloon 416 from expanding into aneurysm 234 . Once the ostium is blocked, coil 136 is introduced into aneurysm 234 , as described above with respect to FIGS. 6A-6D , 7 A- 7 D, 8 A- 8 D, and 9 A- 9 D.
[0052] Reference is now made to FIGS. 11A , 11 B and 11 C, which are illustrations of several views of marker positioning. Marker 125 , positioned on distal portion 107 of access element 106 , and markers 124 , positioned along the longitudinal axis of device 100 , together provide an indication of positioning and location. It should be readily apparent that similar configurations are provided in the alternative embodiments of device 200 , 300 , 400 , and 500 . In a first view, shown in FIG. 11A , markers 124 form a relatively straight line, while marker 125 is slightly off the line formed by markers 124 . This indicates translational positioning of device 100 prior to deployment. When the distal portion 107 of access element 106 of device 100 is released, it assumes its pre-shaped configuration, and marker 125 moves to a position which is further off the line formed by markers 124 , as shown in FIG. 11B . If positioning is inaccurate, marker 125 appears at a side opposite the aneurysm, as shown in FIG. 11C . Thus, if a user views the view shown in FIG. 11C or a similar view, the user can then rotate device 100 until it is in the correct position as indicated by the position of markers 124 and 125 as shown in FIG. 11B . This specific configuration of markers allows for proper alignment and positioning within the vessel.
[0053] In additional embodiments of the invention, access element 106 , 206 , 306 , 406 or 506 may include multiple access lumens. Moreover, points of attachment of access element 106 , 206 , 306 or 506 to occlusion element 110 , 210 , 310 or 510 , respectively, may vary. In one embodiment, the access element is attached at a midpoint of the balloon. In other embodiments, the access element is attached at a proximal end of the balloon, at a distal end of the balloon, or at any point in between.
[0054] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | Devices and methods for treating an aneurysm include a single unit having an access element and an occlusion element, the access element providing access to the aneurysm for introducing treatment objects such as coils therethrough while the occlusion element blocks the treatment objects from protruding into the vessel. The access element is an elongated element having an access lumen for direct introduction of coils or for introduction of coils via a microcatheter. The occlusion element is a balloon or an elongated element for introduction of blocking objects such as coils therethrough. In embodiments of the present invention, a distal end of the access element is preshaped at an angle to a longitudinal axis of the device, wherein upon introduction of the device into the vessel, the access element is aligned with the longitudinal axis and at placement of the device adjacent the aneurysm, the access element assumes its pre-shaped configuration. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a broadly applicable method of protecting plants or crop against pests and diseases, by successive foliar sprays of plant nutrients in aqueous solutions of extreme pH values, without employing toxic organic materials.
BACKGROUND OF THE INVENTION
[0002] The intensive use of pesticides in agriculture lowers the quality of environment and endangers human health. Many toxic chemicals have been used as pesticides, some have been banned, while others are still in use. Pesticides have broad and often unexpected effects on the environment. The most of sprayed pesticides reach other than the intended targets; damaging pollinators, for example, causes losses on crop, whereas reducing the bird populations may indirectly help the pests. Some pesticides remain in soil, an may end up in drinking water and food. Some pesticides resist degradation, remain in the environment for years, and may travel great distances through the atmosphere to become deposited in remote regions. Pesticides may bioaccumulate, and increase their concentrations many times in certain organisms and organs. In humans, reported was the increased risk of cancer; neurobehavioral disorders, infertility, immune disorders, and others. Chronic effects can be hardly assessed. Another serious problem is resistance to pesticides which often evolves in the pests. There has been a long felt need for less invasive pest control. Kolodziej et al. showed a protective effect of foliar fertilization applied on a medicinal herb, American ginseng, when a phosphate exhibiting very high pH was used [Kolodziej B. et al.: Proc. 1 st IC on Culinary Herbs, Eds.: K. Turgut et al., Acta Hort. 826, ISHS 2009]. Fertilizers are usually added to the soil, but it is known that the plants can absorb nutrition which is applied directly onto the leaves. EP 1386897 describes a phosphorus containing foliar fertilizer, the composition being buffered to maintain the pH values between 6.5 and 8.5. It is an object of this invention to provide a method for protecting plants against pests, comprising a foliar fertilizer.
[0003] It is another object of this invention to provide a universally applicable method for protecting a broad variety of plants important for agriculture and industry against various types of pests.
[0004] It is still another object of this invention to provide an efficient method of protecting plants against pests, which method would be environmentally-friendly.
[0005] It is a further object of this invention to provide, by successive foliar sprays, nutrients to plants while reducing the pest infestation.
[0006] Other objects and advantages of present invention will appear as description proceeds.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method of controlling plant pests and diseases comprising a plurality of sequential applications of foliar liquid fertilizers having extreme pH values. Where extreme pH is mentioned, intended is a pH value lower than 4.0 or higher than 9.0. Said sequential applications may comprise alternating applications of acidic/alkaline fertilizers, or alkaline/acidic fertilizers, or repeating applications of acidic/acidic fertilizers or alkaline/alkaline fertilizers. Any combination of alternating and repeating applications may be employed, without limitation, during the crop cycle of life. Of course, the plant or crop should not be damaged by the spray. In a preferred embodiment of the method for protecting plants against pests and diseases, said fertilizers are derived from potassium and phosphate fully soluble sources. Said sequential applications preferably follow each other in the intervals of about 2 up to 20 days. The intervals of application vary according to the field intensity of the pests infestation or diseases. In some applications, a sequence of sprayings is repeated for increasing the treatment efficiency; the same sequence of certain sprayings may be repeated once or more times, forming a series of the same sequences. In a preferred embodiment, the sprayings employ concentrations of the fertilizers of from 0.2 wt % to 2.0 wt %.
[0008] The invention provides a kit for protecting plants against pests and diseases, comprising instructions and two foliar solid-soluble or already liquid fertilizers for sequential application onto said plants having extreme pH values differing at least by 5 pH units. Said kit consists of foliar fertilizers which provide extreme pH when dissolved in water, the fertilizers are pre-weighed in bags. Preferably, in one set of bags there are well-denoted bags, each corresponding to one spraying; the volumes of water to which the bags are dissolved are well described, as well as the time intervals between the sprayings. Alternatively, the fertilizers for the kit are in the liquid form in bottles or other adequate container for liquid fertilizers.
DETAILED DESCRIPTION OF THE INVENTION
[0009] It has now been found that spraying crop with a sequence of sprays greatly differing in their pH is surprisingly effective in clearing the crop from pests and diseases infestation. The invention employs aqueous compositions for foliar spraying, comprising soluble or liquid fertilizers having extreme pH values, to be sequentially applied onto the plant, so creating unfriendly environment for pests and diseases. “Extreme pH” means usually a pH less than pH 4 or greater than pH 9. These types of fertilizers can be used for nearly every crop. The frequency of the application should be preferably performed in intervals of from 2 days to up to 20 days during the crop growth period. The composition comprises components that are soluble plants nutrients, and further foliar additives improving the efficiency of the foliar application, and facilitating the handling of the products. In the most preferred aspect of the instant technology, two compositions exhibiting two different extreme pH values are applied, preferably one having extremely basic pH and the other having extremely acidic pH. The basic and acidic compositions are applied sequentially, in at least two spray actions. Usually, three spray actions are sequentially employed, but sequences of more spraying actions may be used. In a preferred embodiment of the invention, two compositions are applied alternately, ach new spray changing the pH of the environment, the change occurring preferably more times. In another embodiment, one composition may be used repeatedly. The first spray changes the ambient pH from normal, approximately neutral value, the second spray changes the pH value again, and so on. In one embodiment, two different compositions achieve two pH changes in two spraying actions. In other embodiment, two different compositions achieve three pH changes in three spraying actions. In still another embodiment, three different compositions achieve three pH changes in three spraying actions. The term “pesticide” as used herein relates to agrochemicals protecting against any pests and diseases that attack plants; usually the term includes insects, fungi, or bacteria, but other pests may be included. The term pathogen is sometimes used interchangeably with the term pest. The pesticides used in agriculture are used mostly at a slightly acidic pH, usually in a narrow range of 4.5-6.5, to get the best action against the pests and diseases. Many pesticides undergo alkaline hydrolysis at pH higher than about 7 and lose their efficiency. The instant invention relates to pesticidal effects at pH far from neutral. Furthermore, the compositions according to the invention add fertilizing value, beside the pesticidal effects. In a preferred embodiment, the invention achieves extreme pH changes by means of potassium and phosphates. Many available fertilizers include nutrients, for example various micronutrient, which can cause overdose and may be toxic if applied repeatedly during the crop grow cycle. On the other hand, the use of macronutrients like P/K (phosphorus/potassium) usually does not lead to overdose, and when applied as foliar fertilizer, they complement the P/K coming from soil. The pH effect occurs in solution, but not in dry phase. The materials may be used, for example, in a concentration of about 1%. The effect is maintained while the leaves stay wet and humid; therefore, it is preferable to slow the evaporation process as much as possible, for example by spraying the plant at the end of the day to keep the pH effect by for long hours during the night and even at beginning of the next morning.
[0010] Sometimes, after drying the solution, the acidic or basic material may work again when the dew of the next day provides water. Often, a few hours of wet environment comprising an extreme pH on the plant surface is enough to at least inhibit the normal development of plant pests, for example, by interfering with some stages of insects development, such as the development from egg to larva and to the next stages. The high difference between the inner pH of the pathogen and the outer pH in the environment inhibits the body processes and may even disrupt the cell membrane by influx or efflux of protons. Most pathogens do not tolerate a difference higher than about two pH units across cell or organelles membranes lasting more than a few hours. It is believed that when several pH changes occur sequentially, the interference is synergistically stronger. When, for example, in one embodiment of the invention, the pH on the plant leaves is changed from the normal pH close to neutral to very acidic and/or to very alkaline within a few days, the shock may irreversibly damage the pest development, or at least inhibit its normal development and the reproduction capacity—at least to such a degree that the pest cannot anymore afflict practical damages. The extreme pH sprays are applied repeatedly until the infestation intensity of the pests and diseases decreases. Still more preferably, additional sprays and pH changes represent a shock, precluding any tentative adaptation of pest agents. Such a spray sequence is an efficient new strategy in combating a variety of pests, even adaptable pests. Often, it is not necessary to change the pH to an extreme value at every stage, enough is to make the pH jump in the environment. In one aspect, the invention aims at controlling plant pests by sequential applications of foliar liquid fertilizers having extreme pH values, either by repeating applications of acidic products or alkaline products, or by alternating acidic and alkaline products differing by at least 5 pH units. Repeatedly applied sprays causing the pH changes provides an effective, cheap, and environmentally friendly way of fighting plant pests.
[0011] The invention provides a kit comprising several bags with solids to be dissolved in water, or several solution for spraying, including acidic and alkaline fertilizers. The selection of the type of acid or base, their concentrations, and the intervals between the sprays depend on the type of pest to combat, the plant or crop to be protected, the plant age, the degree of infestation, weather, etc. In some cases, the information about the pest sensitivity can be obtained and can be utilized in optimizing the working parameters. The invention enables to efficiently treat a plant even without prior knowledge about pest sensitivity. A universally efficient first spray is initially applied, and its effects on the pests are evaluated, enabling to better choose a second spray. The foliar fertilizers are applied in aqueous solutions at a concentration of from about 0.2 wt % to about 2.0 wt %. The lower concentration is recommended to young plants and some vegetables that are very sensitive, while the solution concentration can increase for adult plants and for strong plants. A skilled person will easily calculate fertilizers weights and water volumes to be used for the foliar applications. The optimization may include minimizing the amounts of used agrochemicals, in some cases. In other cases, higher amounts of the used agrochemicals are not avoided. In some cases, the weather may influence practical decisions in regard to the amounts and intervals. The rain, for example, washes off the residues of the last spray.
[0012] The preferred material exhibit suitable pH, solubility, easy handling, and is rich in P/K. According to the kind of crop and the phytosanitary status, additional sprays can be necessary to get effective pest and disease control, more in case of perennial plants than for the annual crops or vegetables of short life cycle.
[0013] The pH on the leaves after spraying gradually returns from the extreme value toward neutrality in few hours. In some cases, the same product (providing the same extreme pH as before) may be applied, and the repeated shock will be efficient against the pest, even though the extreme pH will have the same value in two successive sprayings. In many cases, the successive spray has different pH, which is usually more efficient and also precludes eventual adaptation by the pathogen to a specific pH. Repeated spraying, including a sequence of sprays or series of sequences, destroys more reliably even the residues of the pathogens, and further prevents or complicates to the pathogens their eventual migration from adjacent fields. The treatment according to the invention is universally very effective. An example of plants to be protected includes, for example, apples, tomatoes, soybeans, cotton, and others.
[0014] The invention will be further described and illustrated in the following examples.
EXAMPLE
Materials
[0015] Two blends based on phosphate and potassium, prepared from fully soluble and clean raw materials, were dissolved in water to the concentration of 1 wt %; the pH of the solution was less than 4 for the acid blend and higher than 9 for the alkaline one.
Method
[0016] Two melon plots, strongly infested by leaf miner ( Liriomyza ssp.), were treated against leaf miner pest (Mossoro in Brazil, November 2009). The leaf miner fly had been the main pest problem in the area. The first field was sprayed every third day by a classical pesticide, more types of pesticides were applied. The second plot was treated in accordance with the method of the invention. The treatment according to the invention included a sequence of nine spraying prepared as described above. Each spraying employed between 600-1000 liters/hectare, the intervals between the sprayings in the sequence were 4-5 days, for the 3 first sprays; then after 12 days followed 3 sprays in 4-5 days intervals; finally, after 10 days, the last 3 sprays followed again in 4-5 days intervals. During all the growth period, the melon leaves were cleaner from leaf miner in the plot treated according to the invention when compared with the plot treated with the regular pesticides.
[0017] It was surprising to find that classical insecticide did not stop the infestation; despite the treatment, galleries were formed in the leaves, and finally even larvae of Liriomyza appeared. As for the treatment according to the invention, it was observed that the pH changes inhibited the insect development at the larval stage. The 1% concentration of the spray solution and the high volume increasing according to the crop age from 600 up to 1000 liters/hectare was very good for covering the foliage. The treatment according to the invention stopped the pests intensity, and usual galleries carved in the leaves by the pest were not observed at all or only slight presence was perceptible, without economic damage for the crop.
[0018] While this invention has been described in terms of some specific examples, many modifications and variations are possible. It is therefore understood that within the scope of the appended claims, the invention may be realized otherwise than as specifically described. | Provided is an environmentally friendly and broadly applicable method for protecting plants or crop against pests and diseases by successive foliar sprays with aqueous liquids exhibiting high acidity or basicity. The sprays provide protection, and further supply the plant with phosphorus and potassium. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority to U.S. Provisional Application No. 60/817,162, filed Jun. 29, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Often it is desirable to carry or stow needed equipment, food, beverages or personal belongings in a lockable portable container and to be locked or unlocked by the owner, as needed or required
SUMMARY OF THE INVENTION
This invention discloses and claims portable locker apparatus which may be further described as portable locker apparatus and is an assembly of three components which includes a lockable locker body, a slidable tray fitting inside of the lockable locker body for canned food or beverages loaded on to the slidable tray and the loaded slidable tray fitting inside of the lockable locker body and this whole assembly may be placed in a refrigerator and the door of the lockable locker body locked, and further the whole assembly of the loaded slidable tray fitting inside of the locked locker body placed in a refrigerator and locked onto a tray of the refrigerator as a first embodiment, by inserting a cable loop through a double slot at the rear floor of the locker and the ends of the cable loop locked together with a padlock, and the third component being a fabric carrying bag and placing the assembly of the locked portable locker body containing the loaded slidable tray fitting into the fabric carrying bag, and the carrying bag having an opening for the cable loop extending from the rear floor of the portable locker through the opening of the carrying bag and the cable loop extending further to lock the total three component portable locker assembly to a suitable anchor to prevent pilferage of the total assembly. The second embodiment to omit slots, cable and padlock, for locking the portable locker apparatus.
The portable locker body apparatus and slidable tray assembly have many vents to hasten the cooling of the contents of food or beverages when the assembly is placed in a refrigerator. There is room in this portable locker apparatus to include cold ice bags as needed, and as an alternate, this apparatus of a portable locker may be used for warm foods if so desired.
The fabric carrying bag may include insulation to keep the contents cool, or to keep the contents warm if so desired
BACKGROUND ART
Background art is listed below, and it is to be pointed out that none of the cited patents, individually would anticipate, or collectively make obvious this present invention.
U.S. Pat. No. 4,030,426 for TRAV-L-SAFE
U.S. Pat. No. 4,539,828 for SECURITY LOCK BOX
U.S. Pat. No. 4,664,041 for BEACH LOCKER
U.S. Pat. No. 4,799,370 for VIDEOCASSETTE LOCK BOX
U.S. Pat. No. 5,235,920 for SECURITY LOCK BOX
U.S. Pat. No. 5,884,989 for HANDGUN SECURITY LOCK BOX
U.S. Pat. No. 5,934,499 for LOCKER BOX
U.S. Pat. No. 6,490,893 for PORTABLE LOCK BOX
FIG. NO.
DESCRIPTION
1.
Front elevation view of portable locker apparatus
2.
Elevation view of left side of portable locker apparatus.
3.
Elevation view of rear side of portable locker, apparatus.
4.
Elevation view of right side of portable locker apparatus
5.
Plan view of bottom of portable locker apparatus
6.
Plan view of top of portable locker apparatus
7.
Enlarged elevation view of door flap extending
over lock pin slot.
8.
Isometric view of portable locker apparatus
9.
Isometric view of locker with door open.
10.
Front end elevation view of removable tray fitting
in portable locker.
11.
Cross section view of tray.
12.
Plan view of removable tray.
13.
Side elevation view of tray.
14.
Plan view of tray bottom outer surface.
15.
Isometric view of locker carry bag, showing lock
and cable with front door flap open.
16.
Isometric view of locker carry bag with door flap
open.
17.
Front elevation view of locker in carrying bag with
front flap open.
18.
Front elevation view of locker in carrying bag with
front flap zippered shut.
19.
Portable locker apparatus attached to shelf wires of
refrigerator
20
Elevation view of rear side of locker apparatus.
21
Plan view of bottom of portable locker apparatus
22
Isometric view of portable locker apparatus carry bag.
LEGEND NO.
DESCRIPTION
1.
Portable locker apparatus body.
2, 2′.
Vents in door of locker.
3.
Combination dial for door lock.
4.
Vents in door of locker.
5.
Vents in top edge of rear of locker.
6, 6′, 6′′, 6′′′
Slots in edges of rear side of portable locker.
7, 7′
Segments between slots 6, 6′ and 6′′, 6′′′
8.
Door of portable locker body.
9.
Door flap over slot 10 in portable locker body.
10.
Slot for combination lock bolt.
11.
Hinge for door of portable lockerbody.
12.
Perforated vent area in bottom of beverage holding
tray.
13, 13′
Inner/outer ridge on door 8 of portable locker body.
14.
Wave form ridges on tray for holding beverage cans.
15.
Cable for locking or anchoring portable locker.
16.
Beverage cans loaded on tray for holding cans.
17.
Beverage holding tray.
18.
Padlock for locking cable eyes together.
19.
Runners on underside bottom of beverage tray
20.
Closure flap at rear panel of carrying bag.
21.
Velcro loops.
22.
Velcro hooks.
23.
Zipper on front panel of carrying bag.
24.
Rear panel of locker carrying bag.
25.
Carrying bag for locker.
26.
Handle straps attached to carrying bag.
27.
Carrying bag closing flap panel.
28, 28′
Eyes in cable ends.
29
Refrigerator wire shelf.
30
Door lock bolt.
31
Portable locker apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Portable locker apparatus is useful for carrying hot or cold food. cold beverages or other items to job sites, work sites or fun sites and the locker to be locked to prevent pilferage, and further the locker to be locked on to the site to prevent theft of the portable locker.
The portable locker apparatus body 1 , shown in FIG. 8 in isometric view, and FIG. 1 is a front elevation view of the portable locker apparatus body 1 , showing the door 8 of the portable locker body 1 , and the door 8 hung on hinge 11 and combination dial 3 for door lock, vents 2 , 2 ′ in top edge and bottom edge door of locker. Vents 4 are shown adjacent to the combination dial 3 for the door lock FIG. 2 is elevation view of left side of the portable locker body 1 , showing hinge 11 for mounting of door 8 of the portable locker body 1 . FIG. 3 is an elevation view of rear or back side of portable locker apparatus body 1 , and vent slots 5 in door 1 on front of the portable locker apparatus body 1 , and slots 6 , 6 ′ in bottom of rear wall of the portable locker 1 , with a segment 7 between the slots 6 , 6 ′ for threading cable 15 through slots 6 , 6 ′ and around segment 7 between the slots 6 , 6 ′ with a padlock 18 attached to the eyes 28 , 28 ′ in the cable ends. (see FIG. 19 ). Further reference is made to FIG. 19 , to show alternate location for locking the portable locker apparatus 31 showing slots 6 ″, 6 ′″ slots in top rim of the rear of the portable locker, and segment 7 ′ between slots 6 ″ and 6 ′″.
FIG. 4 is an elevation view of right side of portable locker apparatus body 1 , showing door edge 9 over slot 10 which receives the locking bolt of the door lock activated by combination dial 3 . The door edge 9 is perpendicular to door 8 of the portable locker apparatus body 1 . Also shown in this FIG. 4 is inner door edge 13 extending inside the edges of the portable locker 1 opening. This is to reinforce the edges of the opening of the portable locker apparatus 1 , and work in conjunction with the edge of the door 8 of the portable locker apparatus body 1 , which edge overlaps the outside edges of the front opening of the portable locker apparatus 1 .
FIG. 3 is an elevation view of the back or rear side of the portable locker apparatus body body 1 , showing slots 6 , 6 ′ for threading cable 15 for locking the portable locker apparatus 1 , and these slots extend over into the bottom of the portable locker as shown in FIG. 5 .
FIG. 6 is a top plan view of the portable locker apparatus 1 , showing the door 8 , hinge 11 for door of the portable locker 1 and rim 13 extending around the inner periphery of the door edge and the edge of the opening of the portable locker apparatus 1 , edge.
FIG. 7 is an enlarged section of FIG. 4 , showing combination dial 3 for the door lock and door edge ear 9 extending over slot 10 in portable locker apparatus body 31 . The slot 10 is shown in FIGS. 4 and 7 by phantom lines with legend 13 showing edge of the door 8 extending over the outer edge of the open end of the portable locker, and inner ridge 13 of door 8 extending over the inner edges of the open end edges of the portable locker apparatus body 31 . Door lock bolt 30 , is shown in FIG. 9 .
FIG. 8 is isometric view of portable locker apparatus 31 , with the door 8 of locker in closed position. FIG. 9 is isometric view of portable locker apparatus body 31 , and portable locker apparatus 1 with door 8 of locker in open position.
The whole assembly of the portable locker apparatus 1 is to include portable locker apparatus body 31 , a tray, or beverage holding tray 17 shown in FIG. 10 , which is a front elevation view thereof and showing phantom wave form ridges in the tray 17 , and extending the length of the tray as shown in FIG. 12 . FIG. 11 is a cross section view of FIG. 10 showing wave form ridges 14 in the beverage tray 17 , and runners 19 on the under side bottom of the beverage tray 17 , and perforated area 12 , extending the length of tray 17 .
The wave form may be further described as a crest and trough.
FIG. 12 is a plan view of the tray 17 , showing the wave form ridges 14 extending length wise in the tray 17 and a beverage can 16 loaded on a trough, and perforations 12 on the bottom of and extending the length of tray 17 .
FIG. 13 is a side elevation view of tray 17 , showing wave form ridges 14 in the tray 17 for holding beverage cans 16 , shown loaded in a double layer.
FIG. 14 is a bottom plan view showing runners 19 on underside bottom of beverage tray 17 and perforated vent area 12 in the bottom of tray 17 .
FIG. 15 is a flexible cloth insulating carrying bag 25 for portable locker apparatus 31 , and having handle straps 26 on the bag, a carrying bag closing flap 27 , with zippers 23 on the closing flap 27 and the zipper 23 meshing with zipper 23 ′ on the opening of the carrying bag. At the rear of the carrying bag 25 is panel 24 , of portable locker carrying bag 25 having a carrying bag closing flap 20 , there is a lock opening flap 20 , having a Velcro hooks 22 , to mesh with Velcro loops 21 mounted on the rear panel bottom of the carrying bag 25 . This opening and closing flap 20 allows attaching the cable 15 for locking the portable locker 1 in the carrying bag 25 and a padlock 18 attached to the eyes 28 , 28 ′ in the cable ends.
FIG. 16 shows the carrying bag 25 , and rear panel 24 , of carrying bag 25 , with rear lock opening/closing flap 20 in closed position.
FIG. 17 is a front perspective view showing in particular the portable locker apparatus 31 in carrying bag 25 , and carrying bag opening/closing flap 27 in open position
FIG. 18 is a perspective view of the portable locker apparatus 31 in the closed carrying bag 25 .
FIG. 19 is a pictorial of portable locker 31 , in a refrigerator, and the locker locked onto the wire shelf 29 of the refrigerator via the cable 15 , and the eyes 28 , 28 ′ of the cable connected by a padlock 18 .
The second embodiment of this invention is shown in FIGS. 20 , 21 , and 22 , wherein FIG. 20 is an elevation view of the rear side of portable locker apparatus showing an alternate to FIG. 3 , wherein slots 6 , 6 ′ as shown in FIG. 3 are deleted. FIG. 21 is a plan view of bottom of portable locker apparatus 31 , derived from FIG. 5 , but slots 6 , 6 ′ are omitted from the plan view of bottom of portable locker apparatus and is an alternate to FIG. 5 , and is a second embodiment. FIG. 22 is an isometric view of portable locker apparatus carrying bag, derived from FIG. 16 , but deleting closure flap 20 at the rear of carrying bag 25 , for portable locker apparatus 31 . The first embodiment of this invention discloses and claims provisions for locking the portable locker apparatus by having slots 6 , 6 ′, 6 ″, 6 ′″ in the portable locker apparatus, and closure flap 20 at the rear of carrying bag 25 . On referring to the above FIG. 21 , this is a compressed version of FIG. 5 , to show deletion of slots 6 , 6 ′, 6 ″ and 6 ′″ in edges of rear side of portable locker apparatus body 1 , as the second embodiment of this invention.
The portable locker apparatus body 1 , door 8 of portable locker apparatus 31 , and beverage holder tray 17 of this invention, apart from the carrying bag, are formed of plastic, selected from polyethylene, polystyrene, nylon, polyvinyl, polycarbonate or ABS, and preferably including reinforcing fibers such as glass fibers for added rigidity.
The carrying bag 25 is of fabric, and may include insulation to be an insulated carrying bag to help maintain either cold or heat in the portable locker apparatus 31 , enclosed in the carrying bag 25 .
The first embodiment of this invention includes FIGS. 3 , 5 , 15 , 16 , and 19 , and includes legends 6 , 6 ′, 7 , 15 , 18 , 20 , 21 , 22 , 28 , and 28 ′, while the second embodiment is shown in FIGS. 20 , 21 , and 22 . FIG. 3 , the, first embodiment, shows legends 6 , 6 ′, 7 and FIG. 20 , the second embodiment, without the legends 6 , 6 ′, and 7 is derived from FIG. 3 . FIG. 5 , the first embodiment, shows legends 6 , 6 ′, and 7 , and FIG. 21 , the second embodiment, without the legends, is derived from first embodiment FIG. 5 . FIG. 15 , the first embodiment, shows legends 15 , 18 20 , 21 , 22 , 28 , and 28 ′ and FIG. 22 , the second embodiment, is derived from FIG. 15 . | Portable locker apparatus is disclosed comprising three parts or components which includes a locker body formed of plastic material a tray for holding beverage cans placed horizontally on wave form ridges in the tray, and a carrying bag fitting around the portable locker apparatus, and in this first embodiment a cable fitting in slots in the portable locker apparatus with a padlock connecting eyelets on the cable ends and to anchor the whole assembly as needed. The second embodiment excludes the cable and slots but includes all other components of the portable locker apparatus, beverage tray and carrying bag. | 4 |
BACKGROUND
This invention relates to apparatus for mounting the actuator and trim on a valve and is particularly suitable for undersea applications.
It is often desirable in the production of oil and gas from subsea wells to provide flow control valves at the wellhead at the sea floor. Such valves are usually operated, maintained or repaired manually or with submersible vehicles that have limited capability.
For example, in one embodiment a four inch cage and plug type valve body is mounted in piping at a subsea wellhead. The "trim" or operating mechanism within the valve body is replaceable so that leakage or wear problems can be rectified. A valve actuator or operator is commonly connected to the trim so that the valve can either be operated from a remote location or it can be operated manually with relatively little effort. In such an arrangement the valve trim and actuator are ordinarily removable from the valve as a unit for return to the tender or platform for maintenance. In an exemplary embodiment the dry weight of the trim and actuator is about 335 kilograms. This heavy assembly must be secured to the valve body by divers or submersibles.
Previous arrangements for making this connection have not been entirely satisfactory. The actuator and trim may be connected to the valve body by flanges which requires the assembly and tightening of a large number of bolts. The bolts must be removed when the valve is disassembled for maintenance. In another arrangement the valve body is threaded and a "hammer nut" is used to secure the trim in the valve body. As suggested by its name, the nut is tightened or loosened by hammering.
There are clear shortcomings to either of these approaches and it is therefore desirable to provide a means for reliably and easily connecting the trim and actuator to a subsea valve. It is desirable that this be simple so that a single diver can perform the operation quickly and with minimum effort.
BRIEF SUMMARY OF THE INVENTION
There is, therefore, provided in practice of this invention a valve and actuator assembly comprising a valve body having a threaded open end in which the valve operating trim is inserted. An actuator is connected to the trim for adjusting the valve for controlling flow through the valve. A nut captured between the actuator and trim, and free to rotate relative thereto, connects to the threaded open end of the valve body. A ring gear secured to the nut is driven by a spur gear on a shaft mounted on the actuator. Such a shaft can be readily rotated manually to provide a substantial mechanical advantage for threading the nut onto the valve body.
DRAWINGS
These and other features and advantages of the present invention will be appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 illustrates in side view and partial longitudinal cross section a valve and actuator assembly constructed according to principles of this invention;
FIG. 2 is a top view of the actuator and valve assembly; and
FIG. 3 is a fragmentary cross section at line 3--3 of FIG. 1.
DESCRIPTION
In the illustrated embodiment only a fragment of the open end of the body 10 of a conventional valve is shown. In an exemplary embodiment the valve is a plug and cage valve and since the internal structure of the valve is unimportant for understanding, only the end of the cage 11 of the valve trim is illustrated. Typically, the balance of the valve body is a roughly cylindrical casting having fittings on each side for connection in a piping system. The details of the valve body are unimportant for an understanding of this invention.
The end of the shaft 12 of the plug is also shown in FIG. 1. In the jargon of the art the plug and cage are referred to as the "valve trim". Although this particular embodiment happens to be a plug and cage valve, the trim could be for a needle valve or a multiple orifice valve, for example. The feature of the valve of significance in practice of this invention is that there are threads 13 at the open end of the valve body.
A valve actuator assembly 14 is bolted to the end of the valve cage 11 by a spool piece 16 which is rigidly connected to the case for the actuator. In the drawings only the exterior of the actuator case is illustrated since the conventional internal gearing and the like for operating the valve trim is not material to practice of this invention. In the illustrated embodiment the actuator is driven by a crank operated shaft 17 at the far end from the valve. Internal gearing within the actuator causes the shaft 12 of the plug to shift longitudinally in response to rotation of the actuator shaft 17. The plug shaft is kept from rotating by keys 18 secured to the plug shaft by a dowel 19 for sliding in slots 21 in the spool piece. The internal gearing also operates a pointer 22 adjacent indicia 23 on the cover of the actuator assembly. A different actuator might be used for a needle valve or multiple orifice valve.
A bonnet nut 26 is threaded onto the threads 13 at the open end of the valve body. The nut is captive between the end of the cage 11 and the spool piece 16, but is free to rotate relative to the trim and spool piece. When secured on the valve body the nut tightly engages a shoulder 27 at the end of the cage. This secures the cage tightly in its proper position in the valve body. The nut is sealed against the shoulder by an O-ring 28. The nut is also sealed against, but does not tightly engage, a shoulder 29 on the valve body by an O-ring 31. A grease fitting and plug 32 is provided on the nut so that grease can be squeezed into the space between the nut and cage and into the threads between the nut and valve body. Trapped seawater and grease can extrude past the seal ring 31 adjacent the valve body shoulder 29. The grease inhibits corrosion in the threads that might make it difficult to disassemble the valve.
An internal ring gear 33 is securely bolted to the bonnet nut. A smaller spur gear 34 engages the teeth of the ring gear. The spur gear is mounted on the end of a drive shaft 36 mounted on the side of the housing of the actuator 14. One end of the shaft is supported in a bearing bushing 37 held in place by a pillow block 38 fastened to the actuator housing by bolts 39. Nearer its other end the gear shaft is supported by a bearing bushing 41 held in a hole in the flange 42 of the actuator housing by a snap ring 43. The end of the shaft has a square lug 44 for receiving a wrench. A smaller driving gear and larger driven gear are used to give a mechanical advantage for tightening the bonnet nut or loosening a stubborn nut if it should be too tight.
To disassemble the valve, the gear shaft 36 is rotated by a ratchet wrench or the like. The resultant rotation of the spur gear 34 drives the ring gear 33, thereby rotating the bonnet nut 26. This causes the nut to disengage from the valve body. A guide (not shown) on the actuator engages a guide on the valve body to prevent the actuator from rotating relative to the body so that as the shaft is rotated, only the bonnet nut rotates. Since the nut is between the spool piece 16 and cage 11, this also gradually withdraws the trim from the valve body. By the time the nut is completely disengaged from the threads on the body the trim is pulled out to the extent that it can freely be removed from the body. The actuator and trim assembly can be pulled from the body by a handle 46 and if desired the weight can be supported by a cable on a side bracket 47.
To reassemble the valve is essentially the reverse of the disassembly. The trim is inserted in the valve body until the bonnet nut reaches a location where it can engage the threads on the valve body. The gear shaft 36 is then rotated to engage the threads and draw the valve trim tightly into the valve body. A torque wrench can be used to provide the proper degree of tightening to assure a good seal without compromising ease of disassembly. It will be noted that the nut secured between the cage and spool piece also serves to approximately center the trim in the body.
Although one embodiment of valve and actuator assembly has been described and illustrated herein, various modifications and variations will be apparent to one skilled in the art. For example, if desired, the gear shaft 36 can be motorized or driven by a motorized wrench. A number of ways of mounting such a shaft on the actuator will also be apparent. If one desires a larger mechanical advantage than obtained by the large ring gear and small gear, an additional gear reduction can be provided between the shaft and nut.
In the preferred embodiment, the valve body has an external thread and the nut fits over it. It will be apparent that a valve body with an internal thread can be used with the nut fitting partly into the valve body. One may also use a large spur gear on the nut and a smaller spur gear on the shaft for driving the nut. In another arrangement, bevel or spiral gears can be used on the bonnet nut and to drive the bonnet nut so that the gear axes do not need to be parallel. The illustrated arrangement is preferred since the gears are relatively shielded and non-hazardous to a diver and the valve operator 17 and nut driving shafts are both at the end of the valve so that there is less concern about working clearance.
Many other details can be modified as desired. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | An actuator is mounted on a valve body by a threaded nut. A ring gear on the nut is engaged by a manually operated spur gear for threading the nut on or off the valve body with a mechanical advantage. | 4 |
FIELD OF THE INVENTION
[0001] This present invention relates generally to data security, and, in particular, to securing data within a system such that the data cannot be contaminated, lost, or leaked from the system even when data storage devices such as disk drives are removed from or added to the system.
BACKGROUND OF THE INVENTION
[0002] Storage systems are utilized to process and store sensitive data. This sensitive data includes medical records, financial data and even details of weapons simulations. Such data must be securely managed so that it is not contaminated, lost, or improperly leaked. Currently, such data is stored on data storage devices (e.g., disk drives) which tend to be readily replaceable to facilitate repair, failure, and migration to faster, cheaper and larger devices.
[0003] The ability to remove devices from the system means that data in the system could become vulnerable when a device is removed. This vulnerability could increase the risk of privacy law violations and/or increase the likelihood that sensitive data will be released.
[0004] Furthermore, when storage devices are removed improperly, data stored in the system could be lost. For example, if two disks are removed from a RAID-5 disk array, the data stored in the array will be lost. The removal could be done out of malice or human error. In either case the resulting cost can be enormous. A typical ten hour restore from backup could cost millions of dollars, and cause serious harm to a company.
[0005] Moreover, inserting devices into a system could introduce contamination such as foreign data and even viruses. For example, in a system that enforces the WORM (Write Once Read Many) property on rewritable disks, allowing the disks to be removed and inserted back into the system could circumvent the enforcement of the WORM property and cause the system to become contaminated with rewritten data.
SUMMARY OF THE INVENTION
[0006] According to the present invention, there is provided a system for securing data with a storage system. The system includes at least one storage device. In addition, the system includes a security mechanism for recognizing an attempt to insert or remove the storage device. Moreover, the system includes a management unit to control the insertion and removal of the storage device.
[0007] Also, according to the present invention, there is provided a method for securing data within a storage system. The method includes recognizing an attempt to insert or remove a storage device from a storage system. In addition, the method includes controlling the insertion and removal of the storage device form the storage system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a storage system
[0009] FIG. 2 is a flowchart illustrating a method of attempting to insert storage device into storage system
[0010] FIG. 3 is a flowchart illustrating a method of attempting to remove storage device from storage system.
DETAILED DESCRIPTION
[0011] The invention will be described primarily as a system and method for securing data within a storage system. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
[0012] Those skilled in the art will recognize that an apparatus, such as a data processing system, including a CPU, memory, I/O, program storage, a connecting bus and other appropriate components could be programmed or otherwise designed to facilitate the practice of the invention. Such a system would include appropriate program means for executing the operations of the invention.
[0013] An article of manufacture, such as a pre-recorded disk or other similar computer program product for use with a data processing system, could include a storage medium and program means recorded thereon for directing the data processing system to facilitate the practice of the method of the invention. Such apparatus and articles of manufacture also fall within the spirit and scope of the invention.
[0014] Referring initially to FIG. 1 , a storage system 10 is shown. Storage system 10 can include a plurality of storage devices 12 . In one embodiment, storage device 12 is a disk drive. Each storage device 12 is associated with a locking mechanism 14 . Storage system 10 includes storage management controller 16 . Storage management controller 16 includes security monitoring unit 18 , data monitoring unit 20 , and initialization unit 22 .
[0015] Storage management controller 16 is responsible for controlling the insertion and removal of storage device 12 . Security monitoring unit 18 is responsible for recognizing and attempt to insert or remove a storage device 12 from storage system 10 .
[0016] Storage system 10 includes storage device slots 23 , where each storage device slot 23 houses one storage device 12 . In the exemplary embodiment, storage device 12 is a disk drive.
[0017] In an alternate embodiment, storage management controller 16 includes a failure and prediction unit. The failure and prediction unit determines the impact on storage system 10 if storage device 12 is removed. The failure and prediction unit prevents the removal of storage device 12 if it determines that the removal would have a negative impact on storage system 10 , where negative impact includes imminent failure of hardware components or software within the storage system.
[0018] FIG. 2 is a flowchart illustrating a method 24 of attempting to insert storage device 12 into storage system 10 . At block 26 , method 24 begins.
[0019] At block 28 , an attempt to insert storage device 12 into storage system 10 is recognized. The attempt is recognized by security monitoring unit 16 .
[0020] At block 30 , storage device 12 is locked into position. Storage device 12 is locked into position by locking mechanism 14 . Locking mechanisms are associated with each of the storage device slots 23 . Locking mechanism 14 is moved into position after storage device 12 has been inserted into storage device slot 23 , to prevent removal of storage device 12 . In the exemplary embodiment, locking mechanism 14 is automatically engaged upon the insertion of storage device 12 .
[0021] At block 32 , storage device 12 is initialized. Storage device 12 is not accessible for reading or writing until it has been initialized. In the exemplary embodiment, initializing the storage device comprises removing all existing data resident on storage device 12 and filling storage device 12 with a predetermined bit pattern. In an alternate embodiment, initializing storage device 12 includes resetting the state of storage device 12 to its initial factory value. In a further alternate embodiment, initializing storage device 12 includes populating storage device 12 with legitimate data currently stored in storage system 10 . For example, if a storage device 12 is inserted to replace another storage device 12 in a RAID-5 array, it s initialization would include rebuilding the appropriate data on the inserted storage device 12 .
[0022] At block 34 , storage device 12 is made available for reading and writing.
[0023] At block 36 , method 24 ends.
[0024] FIG. 3 is a flowchart illustrating a method 38 of attempting to remove storage device 12 from storage system 10 . At block 40 , method 38 begins.
[0025] At block 42 an attempt to remove storage device 12 from storage system 10 is recognized.
[0026] At block 44 a determination is made as to whether permission to remove storage device 12 has been granted. If no, then at block 45 permission is denied. In one embodiment, a password is required before permission to remove storage device 12 is granted.
[0027] At block 48 , a determination is made as to whether a copy of data contained within storage device 12 will remain in storage system 10 , if storage device 12 is removed. If no, then at block 50 a copy of the data is made and stored within storage system 10 . If yes, then at block 52 , storage device 12 is initialized.
[0028] At block 54 , locking mechanism 14 associated with storage device 12 is disengaged to allow for the removal of storage device 12 .
[0029] At block 56 , method 38 ends.
[0030] In an alternative embodiment, storage device 12 may not be removed unless the resulting degree of fault tolerance in storage system 10 remains the same.
[0031] While the invention has been described using a disk drive as a sample data storage device, it should be apparent that the invention applies to other types of storage devices and to combinations of these devices. These devices include but are not limited to tapes, CDs, DVDs, flash memory, Smart Cards, etc. It should also be apparent that different mechanisms can be used to prevent a device from being removed from the system. | According to the present invention, there is provided a system for securing data with a storage system. The system includes at least one storage device. In addition, the system includes a security mechanism for recognizing an attempt to insert or remove the storage device. Moreover, the system includes a management unit to control the insertion and removal of the storage device. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/889,032, filed Feb. 9, 2007, the details of which are incorporated by reference.
TECHNICAL FIELD
[0002] This application relates generally to warewasher systems which are used in commercial applications such as cafeterias and restaurants and, more particularly, to such a warewash system with associated door construction.
BACKGROUND
[0003] Commercial warewashers commonly include a housing area which defines the washing and rinsing area for dishes, pots pans and other wares. Liquid is typically pumped from a tank through a pump intake and delivered to lower and/or upper wash arms that direct the liquid onto the wares. In some embodiments, the warewashers may include access doors for gaining access to components of the warewasher. For example, it may be desirable to gain access to the housing area to remove the wash arms from the warewasher to clean them.
SUMMARY
[0004] In an aspect, a warewasher for washing wares including a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a lower sealing portion that mates with an upper surface of the shelf to provide a lower seal extending laterally along a width of the access door, and an inner sealing portion that cooperates with an inner edge the shelf to provide an inner seal extending laterally along the width of the access door. The inner seal located nearer the spray zone than the lower seal.
[0005] In another aspect, a warewasher for washing wares includes a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf having a groove therein. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The vertically hinged connection permits some vertical movement of the access door along its hinge axis. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a downwardly extending rib that locates within the groove to provide a lower seal extending laterally along a width of the access door. During opening of the access door, the rib rides upward along the shelf and out of the groove causing the door to move vertically upward.
[0006] In another aspect, a warewasher for washing wares includes a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf having a groove therein. A liquid delivery system provides a spray of liquid within the spray zone. A tank is located beneath the spray zone, the tank including the lower shelf. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The vertically hinged connection permits some vertical movement of the access door along its hinge axis. A labyrinth seal assembly extends vertically along a vertically oriented edge of the access door. The labyrinth seal assembly including a channel extending along a height of the access door. The channel is in communication with the spray zone so that liquid entering the channel along a leak path formed between the access door and the labyrinth seal assembly with the access door in its closed configuration drains down into the tank.
[0007] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagrammatic side, section view of an embodiment of a warewash system;
[0009] FIG. 2 is a partial, perspective view of an embodiment of a warewash section for use with the warewash system of FIG. 1 ;
[0010] FIG. 3 is a section, detail view of the warewash section of FIG. 2 with a door in its closed configuration;
[0011] FIG. 4 is a partial, front view of the warewash section of FIG. 2 highlighting locations of pivot pins;
[0012] FIG. 5 is a section, detail view of the warewash section of FIG. 2 with the door in its open configuration;
[0013] FIG. 6 is a detail, section view of the warewash section along line 6 - 6 of FIG. 2 with the door in its closed configuration;
[0014] FIG. 7 is a detail, section view of the warewash section along line 6 - 6 of FIG. 2 with the door being opened;
[0015] FIG. 8 illustrates the warewash section of FIG. 2 with the door being openable in a reverse direction;
[0016] FIG. 8A is a side, detail view of an embodiment of a hinge pin connection arrangement;
[0017] FIGS. 9-12 are various views of another embodiment of a warewash section including a double door configuration; and
[0018] FIG. 13 is a section, detail view of another threshold seal member embodiment with a door in its closed configuration.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , an exemplary conveyor-type warewash system, generally designated 10 , is shown. Warewash system 10 can receive racks 12 of soiled wares 14 from an operator side 16 which are moved through tunnel-like chambers from the operator side toward a dryer unit 18 at an opposite end of the warewash system by a suitable conveyor mechanism 20 . Either continuously or intermittently moving conveyor mechanisms or combinations thereof may be used, depending, for example, on the style, model and size of the warewash system 10 . The racks 12 of soiled wares 14 enter the warewash system 10 through a flexible curtain 22 into a pre-wash chamber 24 where sprays of liquid from upper and lower pre-wash manifolds 26 and 28 above and below the racks, respectively, function to flush heavier soil from the wares. The liquid for this purpose comes from a tank 30 via a pump 32 and supply conduit 34 .
[0020] The racks proceed next to a curtain 38 into the main wash chamber 40 , where the wares are subject to sprays of cleansing liquid from upper and lower wash manifolds 42 and 44 , respectively, these sprays being supplied through a supply conduit 46 by a pump 48 , which draws from a main tank 50 . A heater 58 , such as an electrical immersion heater provided with suitable thermostatic controls (not shown), maintains the temperature of the cleansing liquid in the tank 50 at a suitable level. Not shown, but which may be included, is a device for adding a cleansing detergent to the liquid in tank 50 . During normal operation, pumps 32 and 48 are continuously driven, usually by separate motors, once the warewash system 10 is started for a period of time.
[0021] The warewash system 10 may optionally include a power rinse chamber (not shown) that is substantially identical to main wash chamber 40 . In such an instance, racks of wares proceed from the wash chamber 40 into the power rinse chamber, within which heated rinse water is sprayed onto the wares from upper and lower manifolds.
[0022] The racks 12 of wares 14 exit the main wash chamber 40 through a curtain 52 into the final rinse chamber 54 . The final rinse chamber 54 is provided with upper and lower spray heads or arms 56 , 58 that are supplied with a flow of fresh hot water via pipe 60 under the control of solenoid valve 62 . A rack detector 64 is actuated when rack 12 of wares 14 is positioned in the final rinse chamber 54 and through suitable electrical controls, the detector causes actuation of the solenoid valve 62 to open and admit the hot rinse water to the spray heads 56 , 58 . The water then drains from the wares into tank 50 . The rinsed rack 12 of wares 14 then exit the final rinse chamber 54 through curtain 66 , moving into dryer unit 18 . Although not shown in FIG. 1 , any of the various sections of the warewash system 10 may include a side access door that provides access to the respective chamber. The access door can provide for user access to various components within the chamber and will be described in greater detail below.
[0023] Referring now to FIG. 2 , warewash system 10 includes warewash section 70 which may, for example, be associated with any of the pre-wash chamber 24 , main wash chamber 40 , final rinse chamber 54 , etc. The warewash section 70 includes a frame 72 and a side access door 74 . Hinge pins 76 and 78 pivotally connect the door 74 to the frame 72 , providing a pivot axis P so that the door is openable relative to the frame between closed (as shown) and opened configurations. A handle 80 is provided on the door 74 that can be grasped and pulled by an operator to open the door.
[0024] Referring to FIG. 3 , the door 74 and frame 72 are shown in end view in the closed configuration. Door 74 includes a threshold seal member 82 (e.g., formed of hard rubber, plastic, etc.) that is connected to a bottom 84 of the door. Threshold seal member 82 includes an embossment 85 (e.g., a downward extended rib) that is sized and arranged to mate with a groove or recess 86 that is formed by tank shelf 87 to form an embossment seal and an edge seal member 88 that is sized and arranged to mate with an upper edge 90 of tank shelf 87 to form a tank edge seal. As can be appreciated, the embossment seal forms an outer seal that is spaced furthest away from the tank 92 and the edge seal forms an inner seal that is closest to the tank. The seals inhibit water and steam from escaping the chamber during use. Additionally, the mating between the groove 86 and the embossment 85 acts as a latch that inhibits unintended opening of the door 74 .
[0025] Because threshold member 82 mates with the tank shelf 87 , vertical movement of the door 74 in the direction of arrow 96 is desired in order to open the door. Referring to FIG. 4 , hinge pins 76 and 78 and pin receiving openings in the door 74 are sized and positioned to allow for vertical movement of the door so that the embossment seal and tank edge seal can disengage. Referring to FIG. 5 , the embossment 85 and edge seal member 88 rest against surface 98 with the door 74 in the open configuration. When the door 74 is placed back in the closed configuration as shown by FIG. 3 , the door moves down once the embossment 85 is aligned with the groove 86 and the edge seal member 88 is aligned with the upper edge 90 of the tank shelf 87 , forming the inner and outer seals.
[0026] Referring now to FIG. 6 , warewash section 70 further includes a labyrinth seal assembly 100 located along the left and right sides of the door. Labyrinth seal assembly 100 includes an elongated channel 102 that is formed by an exterior wall 104 , interior walls 106 and 108 and a lip or flange 107 extending inwardly of the door 74 when the door is in the closed orientation. The channel 102 extends along the height H ( FIG. 2 ) of the door 74 , is in communication with the chamber of the warewash section 70 and includes an opening 110 between the interior wall 108 and the door 74 . In some embodiments, the walls 104 , 106 , 108 are formed using stainless steel, however other materials may be used. A similar labyrinth arrangement could be located at the top of the door.
[0027] Arrows 112 illustrate a tortuous steam and water leak path during use. Steam entering the channel 102 along the path condenses therein and drains down into the chamber of the warewash section 70 . Labyrinth seal assembly 100 inhibits the escape of steam and water from the warewash section 70 , which can allow for elimination of temporary rubber/plastic seals that may eventually break down and need replacement. In some embodiments, rubber and/or plastic seals may also be used with the labyrinth seal assembly 100 . Referring to FIG. 7 , the labyrinth seal assembly 100 is sized and arranged so that it does not interfere with opening of the door 74 .
[0028] Referring back to FIG. 2 , in some embodiments, pivot axis P may be moved from the configuration illustrated to the configuration illustrated in FIG. 8 . In other words, the configuration of the door 74 may be changed so that it can be opened in a reverse direction. In order to accomplish this, hinge pins 76 and 78 are removable from their locations in FIG. 2 to the locations in FIG. 8 . Door 74 includes a second set of pin receiving openings 112 that are located at an opposite edge of the door from pin receiving openings 114 . Handle 80 may also be made removable so that it can be repositioned at door edge 116 that is furthest from the pivot axis P. Alternatively, the hinge pins may be moved and the orientation of the door changed by simply rotating the door 180 degrees to place the handle at the opposite side, in which case the threshold member could also be moved.
[0029] Referring to FIG. 8A , the pin receiving openings 112 , 114 are formed through the door 74 and the frame 72 . A frame opening 89 can be hex-shaped (or another shape) to match the shape of a nut 91 that is fit with in the frame opening. The hex-shape of the frame opening 89 prevents the nut 91 from turning when tightening the hinge pin 76 . This allows for hinge pin adjustment from outside the chamber.
[0030] Referring to FIG. 9 , an alternative warewash section 120 includes two doors 74 a and 74 b (shown in their open configurations). Each door 74 a and 74 b may include one, all or any combination of the features described above including the threshold member 82 that mates with the tank shelf 87 , a hinged connection (e.g., using hinge pins 76 and 78 ) that allow for vertical movement of the door and the labyrinth seal 100 .
[0031] FIG. 10 illustrates a threshold member arrangement where the threshold members 82 a and 82 b overlap each other when the doors 74 a and 74 b are placed in their closed positions. The threshold members 82 a , 82 b include overlap portions 121 a and 121 b that overlap each other in a side-by-side arrangement, which creates a somewhat tortuous leak path for liquid to pass therebetween.
[0032] Referring now to FIG. 11 , in some embodiments, the warewash section 120 includes a steam deflector 122 that inhibits passage of steam and liquid from the warewash section during use and with the doors 74 closed. The steam deflector 122 is arranged and configured to abut the inside surface of the doors 74 with the doors in their closed positions.
[0033] Referring also to FIG. 12 , the steam deflector 122 is an L-shaped member (e.g., formed of stainless steel or other suitable material) including a vertical component 124 and a horizontal component 126 . The horizontal component 126 is the part of the steam deflector 122 that abuts the doors when they are closed.
[0034] Because the doors 74 include the threshold members 82 with embossment 85 (e.g., a downward extended rib) that is sized and arranged to mate with the groove or recess 86 that is formed by tank shelf 87 and the edge seal member 88 that is sized and arranged to mate with the upper edge 90 of tank shelf 87 ( FIG. 3 ), the steam deflector 122 is made adjustable in order to accommodate the sealing engagements between the threshold members 82 of the doors 74 . In the illustrated embodiment, the steam deflector 122 includes an array of slots 128 that are sized and arranged to receive fasteners for fastening the steam deflector in the position shown. The slots 128 are elongated to allow for forward and rearward adjustment of the threshold member 122 in the direction of arrow 130 ( FIG. 12 ) to ensure that the steam deflector engages the doors 74 with the threshold members 82 properly mated with the tank shelf 87 .
[0035] Referring back to FIG. 11 , the steam deflector 122 is illustrated as a single, continuous member. However, as represented by the dotted lines, the steam deflector 122 may include two separate members 122 a and 122 b , where member 122 a is associated with door 74 a and member 122 b is associated with door 74 b . Providing two separate members 122 a and 122 b allows for independent adjustment of the members based on the closed position of the respective doors. Use of the steam deflector 122 can be used to replace a rubber or plastic upper seal, which can wear over time.
[0036] It is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible. For example, the above-described door construction may be used in non-conveyor type warewash machines such as box-type machines. Referring to FIG. 13 , an alternative arrangement is shown where threshold seal member 140 includes a groove or recess 142 that is sized and arranged to mate with an embossment 144 (e.g., a rib) that is formed by tank shelf 87 to form an embossment seal. Accordingly, other embodiments are contemplated and modifications and changes could be made without departing from the scope of this application. | A warewasher for washing wares including a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a lower sealing portion that mates with an upper surface of the shelf to provide a lower seal extending laterally along a width of the access door, and an inner sealing portion that cooperates with an inner edge the shelf to provide an inner seal extending laterally along the width of the access door. The inner seal located nearer the spray zone than the lower seal. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority from U.S. Provisional Application No. 60/627,893, filed Nov. 16, 2004, entitled STRIPED WETSUIT. The entirety of the contents of that application are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to shark repelling apparel.
BACKGROUND
[0003] Shark attacks are a problem for surfers, divers, kite surfers, triathletes, water skiers, recreational ocean swimmers, sailors, persons lost at sea and those engaged in aquatic activities generally.
[0004] Numerous techniques have been attempted and suggested to protect those engaged in such activities from attack by sharks. Exemplary include chemical repellants, fixed barriers such as cages, electromagnetic repellants, and wearable metal barriers.
[0005] U.S. Pat. Nos. 5,616,333 and 4,602,384 are directed to and contain a discussion of chemical repellants. United States Patent Application Publication No. US2003/0233694 is directed to and contains a discussion of electromagnetic repellants. U.S. Pat. No. 4,833,729 is directed to a wearable metal barrier composed of metal spikes integrated into a rubber or rubber-like suit.
[0006] U.S. Pat. No. 4,494,245 discloses a wetsuit for repelling predatory marine animals that uses aposematic, or protective, coloration. As disclosed in that patent, aposematic coloration is a defense mechanism that certain organisms, animals and plants alike, use to ward off predators. These organisms have bright colors that make them readily identifiable by the predator. They are also are very dangerous to the predator, for example they can be poisonous, so the predator readily learns to avoid them. Other organisms that are not dangerous to the predator also employ similar protective coloration, and this survival strategy is called mimicry. The '245 patent teaches the employment of this mimicry strategy in a method of repelling predatory animals by wearing a wetsuit having a coloration pattern that mimics that of the aposematic animal or its mimic, such as the sea snake Pelamis platurus, or the coral snake, which are known to elicit an avoidance responses in sharks. Taken as a whole, the '245 patent teaches that coloration is a key factor and that two or more colors should be employed, preferably chosen from yellow, black and red, in a pattern that reproduces the pattern of an organism known to be aposematic, or a mimic of an aposematic, for that predator.
SUMMARY OF THE INVENTION
[0007] The invention is based on the surprising discovery that it is the pattern, rather than the color alone or the combination of color and pattern, that is the critical element in repelling sharks. Specifically, it has been determined that a striped pattern is necessary and most effective in repelling sharks.
[0008] Accordingly, in one embodiment, the invention provides water apparel, for example, a wetsuit, having a striped pattern on its exterior surface. The striped pattern should be completely visible to a human eye having 20/20 vision from a distance of at least one yard. The striped pattern can be made by applying a plurality of bands of a contrasting color to the exterior of a solidly colored wetsuit or the wetsuit can be made such that the plurality of bands are an integral part of the wetsuit. The bands may be straight or may form a wavy, drawn-out pattern similar to tiger or zebra stripping. In the latter case, the bands should preferably form arc-like, flowing curves.
[0009] With regard to the upright axis of the wetsuit, the bands can be arranged and disposed horizontally, vertically or diagonally. The horizontal, vertical or diagonal bands can be disposed in a substantially parallel arrangement to each other. The bands can be included in only a portion of the wetsuit or be included in or on the entire wetsuit. Further, the bands can be uniform or can vary in width and length. Additionally, a combination of bands, for example, vertical bands and diagonal bands, can be employed in or on the same suit of varying or of uniform widths, the vertical bands being disposed substantially parallel to each other and the diagonal bands being disposed substantially parallel to each other, but of course, not to the vertical bands.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an illustration of the frontal view of a wetsuit having a plurality of horizontal bands of varying widths throughout the entire wetsuit.
[0011] FIG. 2 is an illustration of the frontal view of a wetsuit having a plurality of vertical bands of uniform width throughout the entire wetsuit.
[0012] FIG. 3 is an illustration of the frontal view of a wetsuit having a combination of horizontal, vertical and diagonal bands of varying widths.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , there is shown a wetsuit, 10 , as is typically used by divers, surfers and the like, in an aquatic environment. Wetsuit 10 can be composed of one piece or of more than one pieces. As shown in FIG. 1 , it is composed of one integral piece including a hood portion, 11 , a torso portion, 12 , including arms, and a bottom portion, 13 , including legs. Alternatively, hood portion 11 could be formed as a separate and removable hood, torso portion 12 could be formed as a separate and removable top and bottom portion 13 could be formed as a separate and removable pair of pants. Further torso portion 1 2 can be sleeveless, short sleeve or long sleeve and likewise, bottom portion 13 can be thigh length or longer, to ankle length.
[0014] Wetsuit 10 in FIG. 1 is illustrated with a plurality of white bands, 15 , on a black background, 16 . Whites bands 15 are horizontally disposed and arranged on background 16 in relation to the upright axis of wetsuit 10 . Horizontal white bands 15 have varying widths, narrow widths at the top of head portion 11 , becoming wider in torso portion 12 and becoming narrower again in bottom portion 13 .
[0015] In FIG. 2 , there is illustrated another embodiment of the invention in which a plurality of bands are disposed and arranged on a background, 26 , vertically in relation to the upright axis of the wetsuit, 20 . As shown, vertical white bands 25 are of uniform width and length on black background 26 in this embodiment, in which the wetsuit, 20 , is composed of hood portion 21 , torso portion 22 and bottom portion 23 .
[0016] FIG. 3 illustrates yet another embodiment of the invention in which the wetsuit, 30 , composed of hood portion 31 , torso portion 32 and bottom portion 33 , has combinations of white bands, disposed and arranged in relation to the upright axis of wetsuit 30 horizontally, 15 , vertically, 25 , and diagonally, 35 , on black background 36 .
[0017] It will be appreciated that the white bands and black background employed here are for illustration purposes only. The invention includes aquatic apparel having any combination of colors or hues, as long as the bands are composed of a color or hue that is divergent and distinct from the other colors or hues. For example, a suit of blue, green, violet or black may have a plurality of white, orange, red or yellow bands, or a combination of white, orange, red and yellow bands. A suit of white, orange, red or yellow may have a plurality of blue, green, violet or black, or a combination of blue, green, violet and black bands. A suit of lime green may have a plurality of violet, bright red, bright yellow or bright orange bands. What is important is that the colors selected be divergent and distinct from each other, such that the visual change from one color to another color is definitive and sudden or abrupt and the bands readily “stand-out” against a “background”. The striped pattern should be completely visible to a human eye having 20/20 vision from a distance of at least one yard. Accordingly, combinations of highly saturated, ruminant, colors or hues are preferred.
[0018] Many different color combinations may be employed and their selection will depend on their hue and intensity. The skilled artisan will be able to readily select appropriate combinations and hues and intensities meeting these characteristics. Thus, in addition to the white and black combination exemplified, various combinations of highly saturated, ruminant, colors may be employed to create the divergent and distinct stripped pattern.
[0019] It will also be appreciated that while the invention is described in terms of wetsuits, which are specialized aquatic garments typically composed of neoprene or other kinds of synthetic rubbers that have insulating characteristics, it may be employed for any kind of water apparel, for example boardshorts, rash and U.V. skins, whether full body, or tops and bottoms, swim tops, swim shorts and bathing suits. Likewise, while the invention is described in terms of hoods, it is equally applicable to gloves and boots.
[0020] Thus, although the invention has been described with respect to specific examples and embodiments, it is not intended that such specific references be considered limitations upon the scope of the invention, which is set forth in the following claims. | Water apparel for repelling sharks is provided comprising a garment having a plurality of divergent and distinct bands forming a striped pattern. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of International Application No. PCT/US2013/027982, filed Feb. 27, 2013, which claims the benefit of U.S. Provisional Application No. 61/666,835, entitled “A Beverage Mixing System and Process,” filed on Jun. 30, 2012, and of U.S. Provisional Application No. 61/604,410, entitled “A Trainable Nutraceutical Beverage System and Method of Operating the Same,” filed on Feb. 28, 2012, all of which are incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a trainable nutraceutical beverage mixing system and method for operating the same. More particularly, the present invention relates to a customizable supplement beverage system, and method for personalizing the same to a particular user and for tracking of the same. The invention also relates to multi-compartment pods or containers for use with the trainable beverage mixing system.
2. Description of the Related Art
Industrial applications of trainable computer systems are known in the art, and typically include user-preference memorization. Also known are customized nutritional food and beverage dispensing systems, such as the one in U.S. Pat. No. 7,762,181 (Boland et al.), the entire contents of which are incorporated by reference.
As discussed in detail in Boland '181 a highly complex ingredient processor blends, cooks and prepares in an individual dose system requiring continuous update and complex operational steps. Unfortunately, this reference processor blends, cooks and prepares in an individual dose system requiring continuous update and complex operational steps. Unfortunately, this reference fails to identify the trainable operation desired of the present invention, system and method. Also detriment to '181 is a substantially high cost requirement for a dispensing system which prohibits individual-use systems.
Accordingly, there is a need for an improved trainable nutraceutical beverage mixing system and method of operating the same. Further, there is also a need to improve process efficiencies in tracking, identifying, dispensing and monitoring individually customizable supplement programs matched with a user's needs. There is also a need for portable beverage mixing system including multi-component containers for use therewith.
ASPECTS AND SUMMARY OF THE INVENTION
In response, the present invention provides a trainable nutraceutical beverage system. Provided is a customizable supplement beverage system, and method for personalizing and operating the same to a particular user and for operative tracking. Proposed additionally is an operative system for receiving and individually identifying a concentrate or supplement combinations, for mixing the same prior to a use, and for dispensing the same for use, and for tracking control factors relating to the same. Also proposed is a personalized supplement program that is beverage based for user convenience.
Also proposed are various portable mixing systems with safety controls according to the preferred embodiment of the present invention with the system. Preferably, the systems comprise a housing body having a pod or container receiving portion with a slip resistant bottom surface. Alternatively, bottom surface may be a type of key-in surface to lock or otherwise secure the pod or container in place during operation. The preferred pods or containers for use with the invention will be discussed in greater detail below. Optionally, the mixing system may have safety controls to alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical being used or the size or amount being used. A user access code, fingerprint scan, retina scan or other known type of safety control mechanisms that are difficult to bypass, including software safety control, may be employed with the system, especially for the consumption of quantity-sensitive materials (i.e., Iron, etc.) to prevent accidental overdose. The mixing system further comprises a movable mixing head comprising a back head movably connected to a front mixing head which includes a stirrer or mixer.
During operation, after the pod or container is positioned securely on the surface, the mixing head is lowered such that the mixer or stirrer is engaged with an upper component of the pod or container. The user then selects the appropriate control for the desired frequency or speed of the mixing. Optionally, the front mixing head, which is connected to the back head via one or more movable arms such that the mixing arm moves about within the pod or container. Similarly, the mixing head may also optionally partially rotate (e.g., approximately 45%, 60%, 75%, etc.) again to move the mixing arm around within container or pod. Optionally, the mixing or agitation may additionally involve varying the depth of the engagement between the mixing paddle and the beverage, varying the duration of the mixing or agitation, reversing and/or oscillating the direction of the mixing (i.e., clockwise, counterclockwise, clockwise, etc.), and/or oscillating the depth of the engagement between the mixing paddle and the beverage (i.e., up, down, up, down, etc.).
Preferably, internal (not shown) to the mixing system is an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. As will be understood by those of skill in the system operational arts, during any use, system may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with the delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, the system may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Also proposed are various embodiments for two compartment mixing pods or containers and some of their components that may be employed with the various mixing systems discussed above. For example, a first embodiment of a pod or container for use with the mixing systems previously described, illustrates a two part pod, a nutritional supplement part and a housing part for containing filtered water, with a mixing paddle having radially projecting blades or fans and a upwardly projecting stem for interfacing with the disclosed mixing systems. Preferably, an upper part of the pod has a sealing cap having a sealing membrane or protective label there on. Optionally, a protective label may contain a 2 D or 3 D barcode thereon for the mixing system to read, store and/or transmit information about the product being used. Also optionally, a lid or cap is secured onto an upper portion of the housing part in a tamper resistant manner such that if the seal is broken the average user would notice.
Preferably, the pod or portion pack is made substantially of recyclable materials. Also, the multiple parts of the pod or pack are preferably embodied as an assembly all of which are molded of the same material (e.g., polyethylene, etc.) which can be disposed of and recycled as an assembly. This is advantageous because it simplifies the waste stream through eliminating the identification and separation of unlike materials.
During operation, once the pod or container is positioned securely into the mixing system, a mixing head will lower the mixing arm or stirrer down onto the upper portion or protective label of the pod or container. The mixing system will continue to move mixing arm downward until the lower end of the mixing arm connects or otherwise engages with the upper end of a stem of the paddle such that when the mixing arm spins, the paddle will rotate at the same speed and/or frequency. The mixing arm continues to apply downward pressure on the stem until a lower tip of the paddle punctures the sealing membrane which had been maintaining the nutritional supplement or vitamin away from the water. Once the sealing membrane is punctured the nutritional supplement or vitamin spills into the water and the mixing arm continues to apply downward pressure on the stem until the paddle is sufficiently submerged to a distance within the water to adequately and completely mix the water and nutritional supplement as described above with respect to any of the mixing systems disclosed herein. Once sufficiently mixed, the mixing arm rises out from within the container so that the container may be removed from the mixing system. Optionally, the mixing arm and/or stem may comprise a mechanism or may be configured in such a way that they become securely engaged and that when the mixing arm is removed from container, it removes the paddle as well. Optionally, the paddle may remain within the container and be disposed of along with the container once all of the liquid mixture is gone.
The above and other aspects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the present invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated preferred embodiment is merely exemplary of methods, structures and compositions for carrying out the present invention, both the organization and method of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.
For a more complete understanding of the present invention, reference is now made to the following drawings in which:
FIG. 1 is a descriptive illustration of one alternative embodiment of the proposed system;
FIG. 2 is an illustrative flow chart of one alternative method according to one embodiment of the proposed invention;
FIG. 3A is a front plan view of the portable mixing system with safety controls according to the preferred embodiment of the present invention with the system in the raised or open position;
FIG. 3B is a top plan view of the mixing system shown in FIG. 3A ;
FIG. 3C is a side view of the mixing system shown in FIG. 3A ;
FIG. 4A is a front plan view of the portable mixing system shown in FIG. 3A with the system in the lowered or closed position;
FIG. 4B is a side view of the mixing system shown in FIG. 4A ;
FIG. 5A is a front plan view of the portable mixing system with safety controls according to an alternate embodiment of the present invention;
FIG. 5B is a top plan view of the mixing system shown in FIG. 5A ;
FIG. 5C is a side view of the mixing system shown in FIG. 5A ;
FIG. 6A is a front plan view of the portable mixing system with safety controls according to another alternate embodiment of the present invention;
FIG. 6B is a side view of the mixing system shown in FIG. 6A ;
FIG. 7A is a front plan view of the portable mixing system with safety controls according to another alternate embodiment of the present invention;
FIG. 7B is a side view of the mixing system shown in FIG. 7A ;
FIG. 8A is a front plan view of the portable mixing system with safety controls according to another alternate embodiment of the present invention;
FIG. 8B is a side view of the mixing system shown in FIG. 8A ;
FIG. 9A is a closed front plan view of the preferred embodiment for a two part pod with a mixing paddle therein for use with the mixing system according to the invention;
FIG. 9B is an exposed cross-sectional view of the two part pod shown in FIG. 9A further showing the mixing paddle;
FIG. 9C is an exposed cross-sectional view of the two part pod shown in FIG. 9A further showing the mixing paddle;
FIG. 9D is a top plan view of the cap or lid for use with the two part pod shown in FIGS. 9A-C ;
FIG. 10 is an exposed cross-sectional view of an alternative embodiment for a two part pod for use with the mixing system according to the invention;
FIG. 11A is a descriptive illustration of phase one of a bi-pod filtration process used with the system according to one aspect of the invention;
FIG. 11B is a descriptive illustration of phase two of a bi-pod filtration process used with the system according to one aspect of the invention;
FIG. 12 is an exploded perspective view of an alternative embodiment for a two part spin pod for use with the mixing system in accordance with the invention;
FIG. 13A is a perspective view of a first embodiment for a stir pod spinning mechanism in the closed position for use in mixing the contents of the spin pod during operation of the mixing system;
FIG. 13B is a perspective view of the stir pod spinning mechanism shown in FIG. 13A but shown in the open position;
FIG. 14A is a perspective view of a second embodiment for a stir pod spinning mechanism in the closed position having three blades for use in mixing the contents of the spin pod during operation of the mixing system;
FIG. 14B is a perspective view of the stir pod spinning mechanism shown in FIG. 14A but shown in the open position;
FIG. 14C is a perspective view of the stir pod spinning mechanism shown in FIG. 14A but shown in the open position and having only two stirring blades;
FIG. 15A is a perspective view of a third embodiment for a stir pod spinning mechanism for use in mixing the contents of the spin pod during operation of the mixing system;
FIG. 15B is a perspective view of the stir pod spinning mechanism shown in FIG. 15A further indicating the flow of liquid during spinning in order to mix the contents of the spin pod;
FIG. 16 is a perspective view of one embodiment of how the stir pods may be packaged for proper sealing and safety;
FIG. 17A is a front plan view of yet another alternative embodiment for a two part pod for use with the mixing system in accordance with the invention;
FIG. 17B is an exposed cross-sectional view of the two part pod shown in FIG. 17A further showing the membrane piercing component upon compression of the two part pod;
FIG. 17C is a perspective view of one embodiment of the membrane piercing component for use with the invention;
FIG. 17D is a perspective view of an alternate embodiment of the two part pod shown in
FIGS. 17A-B ;
FIG. 18A is a front plan view of yet another alternative embodiment for a two part pod for use with the mixing system in accordance with the invention;
FIG. 18B is an exposed cross-sectional view of the two part pod shown in FIG. 18A further showing multiple membrane piercing component upon compression of the two part pod;
FIG. 18C is a perspective view of an alternate embodiment of the two part pod shown in FIGS. 18A-B ;
FIG. 19 is a front plan view of still another alternative embodiment for a two part pod or compartment for use with the mixing system in accordance with the invention; and
Appendix A provides an illustrative summary of operative concepts of the proposed system and method, but the proposed system and method is not limited to the Appendix.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, a detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, systems, compositions and operating structures in accordance with the present invention may be embodied in a wide variety of sizes, shapes, forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention.
Reference will now be made in detail to embodiments of the invention. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. The word ‘couple’ and similar terms do not necessarily denote direct and immediate connections, but also include connections through intermediate elements or devices. For purposes of convenience and clarity only, directional (up/down, etc.) or motional (forward/back, etc.) terms may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope in any manner. It will also be understood that other embodiments may be utilized without departing from the scope of the present invention, and that the detailed description is not to be taken in a limiting sense, and that elements may be differently positioned, or otherwise noted as in the appended claims without requirements of the written description being required thereto.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.
Referring now to FIG. 1 , the proposed system 100 includes an operable process control system and operable data tables 102 that is in communication with a delivery and supply system 101 for management of system 100 as will be discussed. As will be understood from the exemplary illustration an optional data communication loop is provided by illustrated arrows, but this will be understood by those of skill in the art to be operable over any known telecommunication process for receipt, manipulation, and delivery of information, and for tracking physical delivery of later described items.
Within system 100 there is provided a user-unit operable for receipt of a concentrate or supplement container 1 and a supply of a dilutant (e.g., water, coffee, tea, milk, carbonated beverages, any hot or cold fluid, or any other suitable fluid) 2 , with operable power input access 3 (at rear of unit) and a control system 4 containing suitable controls for achieving the goals of the proposed system (including but not limited to on/off, volume control, temp, control, mixing proportions, optional weight-stage for dispensing tracking etc.). Both container 1 and dilutant 2 may be in multi-use, continuous, or single-use sizes.
Additionally noted s a dispensing station unit 5 for supporting a volume to receive a mixture of dilutant 1 and concentrate 2 under mixing conditions controlled by control system 4 . An individual tracking identification or bar code 6 is provided on each concentrate/supplement container 1 and there is positioned an associated reader 7 for receiving identification/use information from code 6 during an installation and use of container 1 . Internal (not shown) to the location unit is an internal process controller unit 8 (including suitable memory and processing units) linked with an optional external communication control system 9 . As will be understood by those of skill in the system operational arts, during any use, system 100 will be able to track individual uses, dispensments, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the end unit and communication control system 9 will be able to communicate externally to process control system and data tables 102 and with delivery supply system 101 , thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 100 will be able to optionally re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Regarding process control system and data tables 102 , it will be understood that these include a comprehensive process control units to receive, track, organize, and select from informational data bases involving comprehensive user identifications, complete medical and query information and user goals, a complete selection with all parameters of dilutants and also all supplements, minerals, pharmaceuticals etc. that may be selected based upon user-parameters.
Referring now to FIG. 2 wherein an operative and optional method of the proposed system is illustrated. In a first step 201 an initial determination is provided of user preferences and needs and includes (in each step noted hereafter) links with process and data control unit and system 102 containing operative communication links 102 A. Such determination step may include questionnaires (multiple) following family history, health concerns, health history, desired outcomes (weight loss, muscle gain, medical treatment support (e.g., diabetes, wound healing, cancer treatment support, etc. without limitations thereto).
Following initial questionnaire and detail information for each individualized users an initial recommended user-unique supplement determination is made in a step 202 linked with a unique identification step 203 and via process and data control system 102 , a supplement concentrate product is created, packaged, and shipped in a combined step 204 to a user for installation in a device 205 . Device system 100 recognizes the unique identification and conducts local controls and monitoring as discussed elsewhere through continuous use steps 206 for a designated period of time (user determined, medically determined etc.) until a desire to conduct a secondary determination step 207 is reached.
In step 207 a link with the unique identification is made via path 210 to process control 102 and the historic data is stored in data tables therewith. Additional steps in a rebalancing step 208 are conducted that would include modifying the initial supplement determination step 202 and crafting a replacement or secondary supplement via a path 209 shown also linked with process control 102 . In this matter, during a rebalancing step a new individually identifiable supplement is packaged, shipped, delivered, linked with the system and dispensed therefrom.
It will be recognized that this process of initial determination and later rebalancing may be repeated without limit so as to provide a continual trainable process unique to each user's needs.
Further, it will be understood that the entire contents of the incorporated-by-reference U.S. Pat. No. 7,762,181 is available to access for enabling content upon question by one of skill in the art. Additionally, it will be understood that this application will incorporate the currently known highest skill in the communication, data management, shipping, user-identification and product-identification technologies in the art. Thus, for a non-limiting example where data is *sent” or ‘recorded’ this will be understood to incorporate all known ways (wired, wireless, encrypted, open, random-access memory, bubble-memory, cloud-based etc.). For example, the current process control system and data tables could be cloud-based, or located on a proprietary enterprise type system with server modules. Finally, it will be understood that the full health, medical, vitamin, pharmaceutical, and nutrition data available and is used to guide supplement or concentrate and dilutant determination.
It will be understood that the phrase dilutant supply or dilutant may be any fluid material that is not the nutraceutical concentration, thereby allowing a dilution of the concentration during a use dispensment. The dilutant may be any suitable fluid for human consumption, and by way of non-limiting example the dilutant may be water or another combination of components (e.g., coffee, tea, milk, pharmaceutical combinations etc., without limitation).
It will be understood that the phrase nutraceutical, indicates a portmanteau of the words “nutrition” and “pharmaceutical”, and as used herein is a food or food product that reportedly provides health and medical benefits, including the prevention and treatment of disease, and that this food or food product may be of any kind, but is preferably in the form of a fluid concentrate intended for combination with water prior to ingestion by an end user. Nothing herein will limit the interpretation to requiring a pharmaceutical product. It will also be understood that nutraceutical may additionally include those compounds, vitamins, flavorings, minerals, drugs, or pharmaceutical compositions (without limit to any) that are believed to have a physiological benefit or provide protection against chronic disease. With recent developments in cellular-level nutraceutical agents the proposed use will be understood as non-limiting and is to be broadly interpreted to include any complementary and alternative therapies now known or later developed.
Turning next to FIGS. 3A-C and 4 A- 4 B, shown are the portable mixing system with safety controls according to the preferred embodiment of the present invention with the system in the raised or open position ( FIGS. 3A-C ) and in the lowered or closed position ( FIGS. 4A-B ). Preferably, the system comprises a housing body 318 having a pod or container receiving portion 312 with a slip resistant bottom surface 310 . Alternatively, bottom surface 310 may be a type of key-in surface to lock or otherwise secure the pod or container 316 in place during operation. The preferred pods or containers 316 for use with the invention will be discussed in greater detail below. Optionally, the mixing system 300 may have safety controls 314 to alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical being used or the size or amount being used. Mixing system 300 further comprises movable mixing head 320 comprising back head 302 movably connected to front mixing head 304 which includes stirrer or mixer 306 .
During operation, after pod or container 316 is positioned securely on surface 310 , mixing head 320 is lowered (see FIGS. 4A-B ) such that mixer or stirrer 306 is inserted into the contents of the pod or container 316 . The user then selects the appropriate control 314 for the desired frequency or speed of the mixing. Optionally, front mixing head, which is connected to back head 302 via movable arms 308 such that mixing arm 306 moves about within pod or container 316 . Similarly, the mixing head 320 may also optionally partially rotate (e.g., approximately 45% or 60%) again to move mixing arm 306 around within container or pod 316 .
Preferably, internal (not shown) to the mixing system 300 is an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. As will be understood by those of skill in the system operational arts, during any use, system 300 may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 300 may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Referring next to FIGS. 5A-C , shown is the portable mixing system with safety controls according to an alternate embodiment of the present invention. Preferably, the system comprises a housing body 418 having a pod or container receiving portion 412 with a slip resistant bottom surface 410 . Alternatively, bottom surface 410 may be a type of key-in surface to lock or otherwise secure the pod or container in place during operation. The preferred pods or containers for use with the invention will be discussed in greater detail below. Optionally, the mixing system 400 may have power control switch 422 and safety controls 414 (e.g., one for mom, one for dad, and one for child) to identify for or alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical or other health product being used or the size or amount being used. Optionally, a user access code, fingerprint scan, retina scan or other known type of safety control mechanisms that are difficult to bypass, including software safety control, may be employed with the system, especially for the consumption of quantity-sensitive materials (i.e., Iron, etc.) to prevent accidental overdose. Mixing system 400 further comprises movable mixing head 420 movably connected within housing 418 and is connected on its bottom surface to stirrer or mixing arm 406 .
During operation, after a pod or container is positioned securely on surface 410 , mixing head 420 is lowered such that mixing arm or stirrer 406 is inserted into the contents of the pod or container. The user then selects the appropriate control 414 for the desired frequency or speed of the mixing. As will be discussed further below, the mixing arm 406 may optionally have fans or blades which extend radially from mixing arm 406 to aid in the mixing process. Optionally, the mixing head 420 may also move up and down as well as partially rotate within housing 418 (e.g., approximately 45% or 60%) again to move mixing arm 406 around within the container or pod.
As discussed above, internal (not shown) to the mixing system 400 is preferably an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. In addition, a barcode reader or scanner 404 may be included to read and transmit information from the product being used to the internal process controller unit. As will be understood by those of skill in the system operational arts, during any use, system 400 may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with the delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 400 may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Turning next to FIGS. 6A-B , shown is the portable mixing system 500 with safety controls according to yet another alternate embodiment of the present invention. Preferably, the system comprises a housing body 518 having a pod or container receiving portion 512 with a slip resistant bottom surface 510 . Alternatively, bottom surface 510 may be a type of key-in surface to lock or otherwise secure the pod or container in place during operation. The preferred pods or containers for use with the invention will be discussed in greater detail below. Optionally, the mixing system 500 may have a power control switch and safety controls 514 (e.g., one for mom, one for dad, and one for child) to identify for or alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical or other health product being used or the size or amount being used. Alternatively, an LED or other touch based electronic screen 504 may be employed to provide all the control menus and options for the user of the system. Mixing system 500 further comprises mixing head 520 connected to housing 518 directly above container receiving portion 512 and is connected to stirrer or mixing arm 506 .
During operation, after a pod or container is positioned securely on surface 510 , mixing head 520 lowers mixing arm or stirrer 506 into the contents of the pod or container. The user then selects the appropriate control 514 (or using other control pad 504 ) for the desired frequency or speed of the mixing. As will be discussed further below, the mixing arm 506 may optionally have fans or blades which extend radially from mixing arm 506 to aid in the mixing process. Optionally, the mixing head 520 may also move up and down as well as partially rotate within housing 518 (e.g., approximately 45% or 60%) again to move mixing arm 506 around within the container or pod.
As discussed above with the other embodiments, internal (not shown) to the mixing system 500 is preferably an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. In addition, a barcode reader or scanner 508 may be included to read and transmit information from the product being used to the internal process controller unit. As will be understood by those of skill in the system operational arts, during any use, system 500 may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 500 may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Turning next to FIGS. 7A-B , shown is the portable mixing system 600 with safety controls according to still yet another alternate embodiment of the present invention. Preferably, the system comprises a housing body 618 having a pod or container receiving portion 612 with a slip resistant bottom surface 610 . Alternatively, bottom surface 610 may be a type of key-in surface to lock or otherwise secure the pod or container in place during operation. The preferred pods or containers for use with the invention will be discussed in greater detail below. Optionally, the mixing system 600 may have a power control switch 622 and safety controls 614 (e.g., one for mom, one for dad, and one for child) to identify for or alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical or other health product being used or the size or amount being used. Alternatively, an LED or other touch based electronic screen 604 may be employed to provide all the control menus and options for the user of the system. Mixing system 600 further comprises mixing head 620 , in this embodiment a ball-shaped head, connected to housing 618 directly above container receiving portion 612 and is connected to stirrer or mixing arm 606 .
Again, during operation, after a pod or container is positioned securely on surface 610 , mixing head 620 lowers mixing arm or stirrer 606 into the contents of the pod or container. The user then selects the appropriate control 614 (or using other control pad 604 ) for the desired frequency or speed of the mixing. Mixing system 600 may optionally employ a locking mechanism or child safety lock to prevent a child from accidentally selecting an adult size or speed. As will be discussed further below, the mixing arm 606 may optionally have fans or blades which extend radially from mixing arm 606 to aid in the mixing process. Optionally, the mixing head 620 may also move up and down as well as partially rotate within housing 618 (e.g., approximately 45% or 60%) again to move mixing arm 606 around within the container or pod.
As discussed above with the other embodiments, internal (not shown) to the mixing system 600 is preferably an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. In addition, a barcode reader or scanner 508 may be included to read and transmit information from the product being used to the internal process controller unit. As will be understood by those of skill in the system operational arts, during any use, system 600 may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 600 may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Referring now to FIGS. 8A-B , shown is the portable mixing system 700 with safety controls according to still another alternate embodiment of the present invention. Preferably, the system comprises a housing body 718 having a pod or container receiving portion 712 with a slip resistant bottom surface 710 . Alternatively, bottom surface 710 may be a type of key-in surface to lock or otherwise secure the pod or container in place during operation. The preferred pods or containers for use with the invention will be discussed in greater detail below. Optionally, the mixing system 700 may have a power control switches 722 and safety controls 714 (e.g., one for mom, one for dad, and one for child) to identify for or alert the user to a particular speed or frequency of the mixing based upon the type of nutraceutical or other health product being used or the size or amount being used. Alternatively, an LED or other touch based electronic screen 704 may be employed to provide all the control menus and options for the user of the system. Mixing system 700 further comprises a mixing head (not seen) within the upper portion of housing 718 connected to directly above container receiving portion 712 and which is connected to or integral with stirrer or mixing arm 706 (also not seen).
During operation, after a pod or container is positioned securely on surface 710 , mixing head lowers mixing arm or stirrer 706 into the contents of the pod or container. The user then selects the appropriate control 714 (or using other control pad 704 ) for the desired frequency or speed of the mixing. Mixing system 700 may optionally employ a locking mechanism or child safety lock to prevent a child from accidentally selecting an adult size or speed. As will be discussed further below, the mixing arm 706 may optionally have fans or blades which extend radially from mixing arm 706 to aid in the mixing process. Optionally, the mixing head may also move up and down as well as partially rotate within housing 718 (e.g., approximately 45%, 60%, 75%, etc.) again to move mixing arm 706 around within the container or pod.
As discussed above with the other embodiments, internal (not shown) to the mixing system 700 is preferably an internal process controller unit (including suitable memory and processing units) optionally linked with an external communication control system. In addition, a barcode reader or scanner 708 may be included to read and transmit information from the product being used to the internal process controller unit. As will be understood by those of skill in the system operational arts, during any use, system 700 may be able to track individual uses, dispensements, particular mixing proportions, total supplement delivery and other operations. Additionally, in an optional embodiment, the communication control system may be able to communicate externally to process control system and data tables and with delivery supply system, thereby permitting comprehensive benefit, use, and adaptation tracking for a user's health benefit. Additionally, system 700 may be able to re-order, and operate commercial transactions on behalf of a user based upon designated user preferences.
Turning our attention now to FIGS. 9 through 19 , shown are various embodiment for pods or containers and some of their components that may be employed with the various mixing systems discussed above with respect to FIGS. 3 through 8 . Referring first to FIGS. 9A-9D , show is a first embodiment of a pod or container 800 for use with the mixing systems previously described, illustrating a two part pod 800 ( 802 , 804 ), a nutritional supplement part 810 and a housing part 804 for containing filtered water 814 , with a mixing paddle 806 having radially projecting blades or fans and a upwardly projecting stem 808 for interfacing with the disclosed mixing systems. The nutritional supplement or vitamin supplement contained within nutritional supplement part 810 for any of the embodiments disclosed herein may be in the form of powder, liquid, dissolvable capsules or tablets, microcapsules, or other known form.
Preferably, upper part 810 of pod 800 has a sealing cap 802 having a sealing membrane or protective label 816 there on. Optionally, protective label 816 contains a 2 D or 3 D barcode thereon as seen in FIG. 9D for the mixing system to read, store and/or transmit information about the product being used. Also optionally, lid or cap 802 is secured onto an upper portion of housing part 804 in a tamper resistant manner such that if the seal is broken the average user would notice. Any of the known tamper resistant mechanisms for bottles or containers may be employed.
During operation, once pod or container 800 is positioned securely into the mixing system, a mixing head lowers will lower the mixing arm or stirrer down onto the upper portion or protective label 816 of pod or container 800 . The mixing system will continue to move mixing arm downward until the lower end of the mixing arm connects or otherwise engages with the upper end of stem 808 of paddle 806 such that when mixing arm spins, paddle 806 will rotate at the same speed and/or frequency. Mixing arm continues to apply downward pressure on stem 808 until a lower tip 807 of paddle 806 punctures sealing membrane 812 which had been maintaining nutritional supplement or vitamin 810 away from water 814 . Once sealing membrane 812 is punctured nutritional supplement or vitamin 810 spills into water 814 and mixing arm continue to apply downward pressure on stem 808 until paddle 806 is sufficiently submerged to a distance within water 814 to adequately and completely mix the water and nutritional supplement as described above with respect to any of the mixing systems disclosed herein. Once sufficiently mixed, the mixing arm rises out from within container 800 so that container 800 may be removed from the mixing system. Optionally, mixing arm (see any of FIGS. 3 through 8 ) and/or stem 808 may comprise a mechanism or may be configured in such a way that they become securely engaged and that when the mixing arm is removed from container 800 , it removes paddle 806 as well. Optionally, paddle may remain with container and be disposed of along with container once all the liquid mixture is gone.
Turning next to FIG. 10 , shown is an exposed cross-sectional view of an alternative embodiment for a two part pod or container 820 for use with the mixing systems in accordance with the invention. In this embodiment, two part pod or container 820 comprises outer container 828 housing liquid (e.g., 3 or 4 ounces of water) and inner container or baggie 826 housing the nutritional supplement blend or vitamins 836 . Inner container 826 is preferably heat-sealed on its upper end to the upper end of outer container 828 . Outer container 828 may preferably be a blow molded polyurethane (PE) bottle or any other suitable container material for foods. An injection molded PE cap 832 is preferably affixed on the outer side of upper end of outer container 828 and includes an injection molded lance 830 through it top surface such that lance 830 has a lowere bladed end within baggie 826 and an upper end extending outwardly through cap 832 . Adjacent the outer top side of cap 832 is preferably positioned a compression spring 822 which is surrounded by a film 824 heat sealed to cap and covering spring 822 . Compression spring 822 is configured such that it maintains lance 830 in position until a downward force is applied during use.
As previously discussed, during operation, once pod or container 820 is positioned securely into the mixing system, a mixing head will lower the mixing arm or stirrer down onto the upper portion directly above spring 22 pod or container 820 . The mixing system will continue to move its mixing arm downward until the lower end of the mixing arm connects or otherwise engages with the upper end of lance 830 . The mixing arm continues to apply downward pressure on upper end of lance 830 until a lower tip of lance 830 punctures the lower end of baggie 826 . Once broken, nutritional supplement or vitamin 836 spills into water 834 and mixing arm continue to apply downward pressure on lance 830 until sufficiently submerged to a distance within water 834 to adequately and completely mix the water and nutritional supplement as described above with respect to any of the mixing systems disclosed herein. Once sufficiently mixed, the mixing arm rises out from within container 820 so that container 820 may be removed from the mixing system. Optionally, mixing arm (see any of FIGS. 3 through 8 ) and/or lance 830 may comprise a mechanism or may be configured in such a way that they become securely engaged and that when the mixing arm is removed from container 820 , it removes lance 830 as well. Optionally, lance 830 may remain with container and be disposed of along with container once all the liquid mixture is gone.
Referring next to FIGS. 11A-B , shown are descriptive illustration of phase one and phase two of a bi-pod filtration process used with the system according to one aspect of the invention.
Looking now at FIG. 12 , shown is an exploded perspective view of another alternative embodiment for a two part spin pod for use with the mixing system in accordance with the invention. As shown, two part pod 840 comprises housing or container 848 for hold liquid, and stir pod 845 comprising upper shaft 842 (preferably of a hex shape or some other shape such that secure interface may be made with the lower end of a mixing arm), side portions 844 and mixing paddle 846 . During operation, once pod or container 840 is positioned securely into the mixing system, a mixing head will lower the mixing arm or stirrer down onto the upper portion directly above and engages upper shaft 842 without applying too much pressure. The mixing system will then begin rotation of the mixing arm thereby rotating stir pod 845 .
Depicted in FIGS. 13 through 15 are alternative embodiments for the stir pod used in conjunction with the spin pod 840 shown in FIG. 12 . For example, FIGS. 13A-B shows stir pod 850 in its closed ( FIG. 13A ) and its open ( FIG. 13B ) positions. During use, the centrifugal force from rotation of stir pod 850 from engaging the mixing arm of one of the above described mixing systems generates sufficient centrifugal force to open blades 852 thereby spilling the nutritional supplement blend therefrom and into the liquid in the container below. Blades 852 are then used to mix the water and nutritional supplement. Similarly, FIGS. 14A-C shows stir pods 854 , 860 (stir pod 860 only having two blades) in closed ( FIG. 14A ) and open ( FIG. 14B-C ) positions. During use, pressure applied to tabs 856 during rotation of stir pods 854 , 860 open blades 858 , 862 thereby spilling the nutritional supplement blend therefrom and into the liquid in the container below. Blades 858 , 862 are then used to mix the water and nutritional supplement. Looking at FIGS. 15A-B shown is another alternate embodiment for a stir pod for use with the invention. That is, stir pod 864 comprises veins or inwardly opening blades 866 such that with rotation thereof water flows into the stir pod 864 and out through an opening 868 on a bottom end of stir pod 864 . During use, the centrifugal force from rotation of stir pod 884 from engaging the mixing arm of one of the above described mixing systems generates sufficient force to open blades 866 inwardly or allow water to break through a seal of some kind to mix with the nutritional supplement within stir pod 864 and flow out through its bottom thereby spilling the combined water-nutritional supplement blend from the stir pod 864 . Briefly, FIG. 16 shows a perspective view of one embodiment of how any of the spinning pods may be packaged for proper sealing and safe handling.
As an alternative embodiment to the portable electronic mixing systems disclosed above, shown in FIGS. 17A-C , 18 A-C and 19 describe various embodiments for a portable and disposable two part pod mixing system in accordance with the invention.
Referring first to FIGS. 17A-D , shown is a first embodiment of a pod or container 900 . As illustrated, mixing container 900 preferably comprises a blow molded (P.P. or PET) housing 904 , which is heat sealed on its lower end 906 with a PP or foil membrane to a blow molded PP lower compressible container 910 . Preferably, housing 904 contains liquid (i.e., approximately 3 ounces of water) while lower collapsible container 910 contains the desired nutritional supplement. On its upper end, housing 904 is removably closed with a cap, such as the cap for an ordinary water bottle or soda bottle. Also optionally, lid or cap 902 is secured onto an upper portion of housing part 904 in a tamper resistant manner such that if the seal is broken the average user would notice. Any of the known tamper resistant mechanisms for bottles or containers may be employed. Of course, a larger lid configuration of container having a large lid such as container 901 may be used.
Also, within lower collapsible container 910 is positioned, preferably affixed to the bottom surface thereof, a foil or membrane piercing divider 914 . Upon shaking or vigorous up and down motion of the container 900 , piercing divider 914 punctures ( 912 ) foil or membrane 908 thereby allowing the nutritional supplement in lower container 910 to mix with the water in housing 904 upon continued shaking. Accordingly, while it is preferred that piercing divider 914 be configured as shown, i.e., in the shape of a pyramid, any shape divider which has a sharp enough apex would suffice.
Turning to FIGS. 18A-B , shown is a second embodiment of a two compartment mixing pod or container 9200 . As illustrated, mixing container 920 here preferably comprises a blow molded (P.P. or PET) housing 904 , which is heat sealed on its lower end with a PP or foil membrane to a blow molded PP lower compressible container 930 . Preferably, housing 924 contains liquid (i.e., approximately 3 ounces of water) while lower collapsible container 930 contains the desired nutritional supplement. On its upper end, housing 924 is removably closed with a tamper resistant heat sealed pull off lid 922 , such as the pull off lid for a container of yogurt.
Also, within lower collapsible container 930 is positioned, preferably affixed to the bottom surface thereof, a foil or membrane piercing divider 934 . Upon shaking or vigorous up and down motion of the container 920 , piercing divider 934 punctures the foil or membrane thereby allowing the nutritional supplement in lower container 930 to mix with the water in housing 924 upon continued shaking. Accordingly, while it is preferred that piercing divider 914 be configured as shown, i.e., in the shape of a pyramid, any shape divider which has a sharp enough apex would suffice. Moreover, while two piercing dividers are shown, other numbers of dividers may be used with the invention.
As seen in FIG. 18C , yet another alternate embodiment of the two part mixing pod is shown. Here, pod 920 comprises on its lower end an expandable lower region 926 which on its lower end is heat sealed to lower collapsible compartment 928 . In this embodiment, upon shaking or vigorous up and down motion of the container 920 , a piercing divider, much like divider 934 seen in FIG. 18B punctures the foil or membrane thereby allowing the nutritional supplement in lower container 928 to mix with the water in housing 924 upon continued shaking. Preferably, upon puncture of the membrane, lower compartment 928 compresses or collapses while at the same time or close to the same time expanding region 926 of pod 920 expands to allow for extra space with housing 924 upon entry of the nutritional supplement.
Similar to the embodiment just described with respect to FIG. 18C , yet another alternate embodiment of the two part mixing pod is shown in FIG. 19 , which is similar to the two compartment pods shown in FIGS. 17A-B but with the added expandable region 946 . Here, pod 940 comprises on its lower end an expandable lower region 946 which on its lower end is heat sealed 938 to lower collapsible compartment 948 . In this embodiment, upon shaking or vigorous up and down motion of the container 940 , a piercing divider, much like divider 934 seen in FIG. 18B , punctures the foil or membrane thereby allowing the nutritional supplement in lower container 948 to mix with the water in housing 944 upon continued shaking. Preferably, upon puncture of the membrane, lower compartment 948 compresses or collapses while at the same time or close to the same time expanding region 946 of pod 940 expands to allow for extra space within housing 944 for entry of the nutritional supplement. Alternatively, pod 940 may be held by a machine at 950 . The machine would compress lower compartment 948 , then shaking pod 940 such that expanding region 946 expands.
In the claims, means or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skilled in the art that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. The scope of the invention, therefore, shall be defined solely by the following claims. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics. | The present invention relates to a system and process for a nutraceutical beverage mixing system. Provided is a customizable supplement beverage system and method for personalizing and operating the same to a particular user and optionally for operative tracking. Proposed additionally is an operative system for receiving and individually identifying a concentrate or supplement combinations, for mixing the same prior to a use, and for dispensing the same for use, and for tracking control factors relating to the same. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a stretched, rough electrical insulating film of polypropylene, comprising zones having different degrees of roughness which lie side by side and form fine channels between each other. The film is particularly suitable for the fabrication of impregnated capacitors and for the sheathing of cables. The present invention relates also to a process for the manufacture of such film.
The materials presently used in the construction of impregnated capacitors are normally combinations of paper-aluminum, paper-polypropylene film-aluminum, or paper-metallized polypropylene film. The capacitors prepared from such material combinations are, however, relatively voluminous. In view of the constantly decreasing dimensions of electrical components, development tends toward capacitors which are constructed of polypropylene films and aluminum or of metallized polypropylene films only and which are called "all-film capacitors".
As compared with the hitherto used insulating paper, polypropylene films have an excellent insulation resistance and outstanding dielectric properties. Conventional polypropylene films, however, are very smooth and tend to cling to each other. In a capacitor wound from such a film, the air entrapped between the film layers cannot be expelled or can be expelled only incompletely by impregnation. A capacitor of this kind is useless because, even at low voltages, short circuits and punctures will occur in the non-impregnated areas.
In order to improve the impregnatability of capacitors comprising polypropylene films, processes have been developed, wherein these films are roughened by systematically influencing the morphology (β-α conversion of crystallites). Such processes are described in German Offenlegungsschriften Nos. 2,553,693, 2,601,810 and 2,722,087. Although it has been possible to improve the impregnation of capacitors produced from films manufactured according to these processes, non-impregnated areas cannot be completely eliminated and, as a consequence, the above-described disadvantages experienced with smooth films will still occur. This is due to the fact that these films have completely irregular surface structures over their entire surfaces. During impregnation, the flow paths for the impregnating medium develop purely accidentally, so that non-impregnated areas and thus air pockets cannot be excluded with certainty.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved, rough, biaxially stretched polypropylene film for use in the field of electrical insulation. It is a further object of the invention to provide such a film which, in the wound or folded condition, can be completely and rapidly filled with an impregnating agent, without leaving air pockets between the film layers and which, therefore, does not have the disadvantages of the prior art films.
A still further object of the invention resides in the provision of an improved process for manufacturing such a film product.
Another object of the invention is the provision of an improved capacitor and an improved sheathed cable manufactured with the improved film according to the invention.
In accomplishing the foregoing objects, there has been provided in accordance with the present invention a film for use in the field of electrical insulation, comprising a biaxially stretched, rough polypropylene film, comprising a plurality of zones having different degrees of roughness. The zones of different roughness adjoin each other in a pattern wherein higher-roughness zones are adjacent to lower-roughness zones and the adjacent zones form fine channels between each other. In one embodiment the film further comprises a layer of metal on one surface thereof.
In accordance with another aspect of the invention, there has been provided a process for manufacturing a film of the above-described type, comprising the steps of extruding a pre-film of polypropylene; cooling the extruded pre-film to a temperature which is sufficient to produce β-crystallites in the pre-film; causing different temperatures in a plurality of first zones and in a plurality of second zones; stretching the pre-film both transversely and longitudinally at a temperature which is sufficient to produce α-crystallites in the resulting stretched film; and heat setting the film. In one embodiment, the extruded pre-film is cooled on a take-up roll, and the step of causing different temperatures in first and second zones comprises differently cooling these zones while the pre-film is on the take-up roll. In another embodiment, the step of causing different temperatures in first and second zones comprises differently heating these zones prior to the stretching step.
In accordance with another aspect of the present invention, there has been provided a capacitor, comprising alternating layers of a dielectric material and a metallic conductive material, wherein the dielectric material comprises the film as defined above.
Further objects, features and advantages of the present invention will become apparent from the detailed description of preferred embodiments which follows, when considered in light of the attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
In the drawings:
FIG. 1 represents a surface profile roughness measurement of a film according to the invention.
FIG. 2 shows two polypropylene films A which are metallized on one side.
FIG. 3 depicts a capacitor manufactured with the films of FIG. 2.
FIG. 4 shows two polypropylene films C and two aluminum foils B.
FIG. 5 represents a capacitor manufactured with layers B and C.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention provides a biaxially stretched, rough polypropylene film for use in the field of electrical insulation, which has the characterizing feature that it comprises zones having different degrees of roughness which adjoin each other so that higher-roughness zones are adjacent to lower-roughness zones, and the adjacent zones form fine channels between each other. The fine channels extending between the rougher and less rough zones produce a kind of wick effect when capacitors or cable sheaths are impregnated, and as a result, a complete and rapid impregnation is obtained. The differences in roughness between the zones of higher and lower roughness preferably range between the factors of about 1.5 and 5.0. Although it is also possible to have smaller zones, the different zones preferably have a dimension of about ≧0.1 mm 2 .
In practice, it has been found that films in which the higher-roughness zones predominate can be impregnated particularly well. The preferred films have mean roughness heights R z ranging between about 1.0 μm and about 4.0 μm in the higher-roughness zones and between about 0.1 μm and about 1.0 μm in the lower-roughness zones. It is, however, not intended to exclude different roughness values.
Since the films are usually slit after manufacture in the longitudinal direction to give narrow strips which are then, for example, wound into capacitors which are impregnated from their end faces, films are preferred wherein the fine channels run chiefly in the transverse direction with respect to the longitudinal extension of the film web.
Film which are metallized on one surface are especially useful because in that case the capacitor need not be wound or folded from two different webs, i.e., metal and film.
The two surfaces of the films may naturally exhibit different degrees of roughness and roughness ratios, but the roughness height must, on the whole, be low enough to prevent the occurrence of an embossing effect in the first stretching step of the stretching procedure, since this would impair the mechanical strength of the films and is, therfore, to be regarded as a disadvantage.
The invention relates also to a process for the manufacture of the above-defined film, in which the conventional stretching processes for flat films are employed, i.e., transverse-longitudinal stretching, simultaneous stretching or longitudinal-transverse stretching. Depending upon the intended use of the film, re-stretching may be performed in the known manner in the transverse or longitudinal direction or simultaneously, in order to optimize the desired mechanical properties, for example, tensile strength, elongation at break, modulus of elasticity etc.
The process of the invention comprises extruding the poly-propylene through a slot die, cooling it on a take-up roll, stretching the pre-film longitudinally-transversely, or transversely-longitudinally, simultaneously, optionally re-stretching, heat-setting, optionally metallizing and winding up the film. The process is characterized by the features: (1) that the take-up roll is maintained at a temperature which is high enough to produce β-crystallites in the film, (2) that the pre-film is differently cooled in adjacent zones while it is on the take-up roll and/or is differently heated in adjacent zones prior to the first stretching operation, and (3) that the temperature during stretching is adjusted to such a level that the β-crystallites are converted into α-crystallites.
The process may be carried out in such a way that the take-up roll is systematically textured. This may, for example, be done by sandblasting, subsequent chrome-plating and grinding to a defined roughness, or by systematically chrome-plating a partial area of the surface only or by covering partial areas (engraved roll).
By differently cooling the melt on the textured roll, different numbers of β-crystallites are generated in contiguous zones, which lead to different degrees of roughness in the following conversion to α-crystallites. This way of running the process is particularly suitable if the film is subsequently simultaneously stretched in both axis directions.
Alternatively, a correspondingly textured heated roll may also be installed, which procedes the first stretching operation and which, due to its surface texture, causes a different heating up of the pre-film. In the longitudinal-transverse stretching process, preferably the first stretching roll is textured, i.e., designed as an engraved roll. It is, however, also possible to combine the two processes.
The polypropylene is extruded at a temperature of from about 240° to 300° C., preferably from about 250° to 270° C. The first stretching step is carried out at a temperature ranging from about 120° to 160° C., preferably from about 135° to 150° C. The ratio of longitudinal stretching is from about 1:4.0 to 1:6.5, preferably from about 1:4.5 to 1:6.0. The ratio of transverse stretching is from about 1:8.0 to 1:12.0, preferably from about 1:8.5 to 1:10.5.
The biaxially stretched film is heat-set at a temperature ranging from about 150° to 180° C., preferably from about 155° to 165° C.
The film of the invention having a thickness in the range of from about 4 to 30 μm, preferably from about 8 to 20 μm, is particularly suited for employment in the construction of capacitors, and these capacitors can be impregnated considerably more rapidly and with better results than capacitors prepared from film according to the state of the art. Several hundreds of capacitors comprised of the inventive film did not show any failures due to short circuits or punctures.
In addition to its preferred use in the preparation of capacitors, the film of the invention may also be employed for the sheathing of cables, if the cables are impregnated. In the manufacture of the inventive film, it is an obvious prerequisite to use a raw material which is optimal for electrical applications, i.e., which has a very low residual ash content, does not contain any organic or inorganic lubricants and is free from ionogenic constituents.
In the drawings, FIG. 1 represents a typical roughness measurement made on the film of the invention. It clearly shows the contiguous zones of different degrees of roughness and also the fine channels extending between these zones.
FIG. 2 shows two films A according to the invention, which are metallized on one surface and used for the manufacture of the capacitor depicted in FIG. 3.
The capacitor represented in FIG. 5, on the other hand, is wound from alternating layers of the inventive film C and aluminum foil B which are shown in FIG. 4. | Disclosed is a film for use in the field of electrical insulation comprising a biaxially stretched rough polypropylene film comprising a plurality of first zones of high roughness, the first zones having a relatively high number of α-crystallites; and a plurality of second zones of substantially lesser roughness, the second zones having a substantially lesser number of α-crystallites than the first zones, the first zones being adjacent to the second zones and the adjacent first and second zones forming fine channels between each other. Also disclosed is a method for producing this film. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/789,064 filed Feb. 26, 2004, entitled Combination Weeding and Raking Tool.
FIELD OF THE INVENTION
[0002] This invention is directed toward a manually operable gardening or landscaping tool which can be used either as a weeder, as a rake or as a ground contouring tool. The person using the tool can use the same tool for each operation without having to switch tools. Thereby saving time and the added expense of additional tools.
BACKGROUND OF THE INVENTION
[0003] Methods and apparatus for expanding the usefulness of hand tools by affixing alternate types of tool heads to a single tool handle have been the subject of much inventive effort over the years. The basic approach of providing multipurpose tools flows naturally form the need to utilize a number of different hand tools serially in time to accomplish a gardening or landscaping task. In gardening or landscaping uses, a first tool type might be used to precondition the soil, and a second tool type might be needed to further prepare particular areas, or to complete processes which were missed on the initial pass. The use of a long-handled hoe followed by the use of a long-handled rake to collect the debris produced by the hoe and then an inverted long-handled rake to contour or groom the soil gives an example of where iterative uses of alternative tool types are commonly needed. Hence, multipurpose tools of wide varieties abound, as do devices where a number of different tool heads may be affixed to a single, specially adapted handle.
[0004] Common to hand operated gardening tools is the use of an elongated handle. Secured to one end of the handle is an implement for use in cultivating, weeding and/or grooming of the soil. The tools are typically arranged to complete a specific task and the tool is thereafter exchanged for the tool required to complete the next task. Attempts have been made to combine tools or to construct tools with interchangeable implements. However, such attempts typically employ the use of bayonet mounts or other clamping devices which do little to assist the interchange of tool heads on the handle.
DESCRIPTION OF THE PRIOR ART
[0005] U.S. Pat. Nos. 2,268,066 and 2,314,685 teach a rake attached to an elongated handle via a spring mechanism. The device further includes a weed cutter attached to the handle in a manner that allows the rake to be stood upright without assistance. The weed cutter is formed of metal having an elongated body which partly surrounds the handle to provide support and a “spoon” shaped and sharpened cutter end.
[0006] U.S. Pat. No. 3,987,609 teaches a manually operable garden tool which combines the functions of a rake and a weeder. The tool employs an elongated handle with a generally flat section coplanar with the handle. A plurality of spring tines essentially coplanar with the section are provided. Each tine is secured at one end to the curved periphery and extends outward at right angles whereby the handle, tines and section define a rake. An elongated weed blade extends in the same direction as the handle and is secured at one end of the handle. The other end of the blade lies in a plane parallel to the tines.
[0007] U.S. Pat. No. 3,921,725 teaches a combination hoe and fork device. The device includes a handle fixed to a blade by means of a tang. The tang curves upwardly from the blade and then generally at a right angle to the blade and is attached by a suitable socket in the usual manner. The fork is of standard construction having an outwardly extending stem which can be attached to the tang of the hoe with U-bolts or hose clamps.
[0008] U.S. Pat. No. 4,236,742 teaches a retractable rake for use as a courtesy rake by a golfer at a sand trap or for light raking chores in general. The rake has a plurality of projecting tines which diverge outwardly when they are in their extended position. When the rake is not in use, the tines are retractable into the shank of the rake so the rake is compact and may be stored and carried within a golf bag.
[0009] U.S. Pat. No. 4,843,667 teaches a combination broom, rake, and pruning knife for use as a household, yard, garden, or industrial tool. The combination tool includes an elongated handle. The handle has at one end a removable broom assembly that is held in place by a post, which fits in a socket, and a lock screw. A rake tine support chamber is mounted parallel to the broom support chamber. The rake tine support chamber provides mounting and support for a plurality of retractable rake tines, which may be provided with hooked ends. The retractable rake tines are arranged in two groups, one on each side of the centerline of the tool, each having a similar number of tines. Each group of rake tines is attached by a pivot pin to a sliding linkage. When the tines are extended, they are supported by the flared end of the rake tine support chamber and the broom head serves as a backing for the rake tines limiting their deflection. The rake tines may be retracted into the rake retraction chamber by pulling the sliding hand grip. The opposite end of the handle is provided with a removable knife which may be used by hand or attached the handle for pruning purposes.
[0010] U.S. Pat. No. 5,185,992 teaches a tool expanding assembly which provides the means for rapidly coupling any one of a number of different tool heads to a preexisting mother tool. The tool expanding assembly includes a pair of cylinder-like portions which are fabricated from metal and rigidly connected together. In use, one of the cylinder-like portions is fitted over the handle of the mother tool and fasteners are inserted to secure the assembly. The second cylinder-like portion is constructed to include a square J-shaped bayonet connector slot, which is adapted to receive corresponding male bayonet connector elements used to terminate the ends of various tool heads.
[0011] U.S. Pat. No. 5,411,101 teaches a combination cultivator and edging tool including a handle and a head attached to one end of the handle. The head includes a transverse support member and a row of long cultivator tines, each tapering from a point of connection to the support member toward a tip. The tines extend in a common plane of extension disposed generally perpendicular to the handle and the traverse support member. The head further includes a blade having a support edge and a sharpened edge opposite the support edge. The blade is disposed in the same plane as the handle and the traverse support member. In use, the handle is disposed at an angle to the ground for cultivating. The handle is alternatively disposed vertically with respect to the ground for edging.
[0012] U.S. Pat. No. 5,743,340 teaches a device for pulling weeds, plants, small trees and the like which includes an elongate handle portion terminating in a first end, with a leveraging head member attached to the first end. This leveraging member has a first side bearing a weed clamp having at least one pivoting jaw adapted to close proximate to a clamping surface and a second side opposite the first side bearing a lever arm for mechanical advantage.
[0013] Hand tools utilizing bayonet type mounts have the disadvantage of requiring the user to perform the desired task using two individual tools, wherein each of the tools has to be handled separately in order to do the job. Often changing tools with a bayonet mount takes longer than exchanging complete tools.
[0014] The prior art also fails to teach a combined tool that allows the operator to cultivate and change tools to groom without bending over to change tools. Standing upright lessens the strain on an individual's back and combining tools increases efficiency.
[0015] Thus, what is lacking in the art is a combination tool that includes a scuffle and rake for gardening and landscaping. The combination tool should include a loop type scuffle blade and a retractably mounted rake head. The loop shaped scuffle blade should allow weeding and cultivating operations to be performed while pushing or pulling on the elongated handle for increased efficiency. The combination tool should merely require the handle to be rotated to change tools, allowing cut vegetation to be raked or cultivated soil to be groomed without bending over to change tools. The rake head should be retractable and/or collapsible to facilitate weeding operations to be performed in tight areas.
SUMMARY OF THE INVENTION
[0016] This invention pertains to hand operated gardening and landscaping tools for use in cultivating soil and/or removing inferior or unwanted plants from a selected area. More particularly, the present invention relates to a combination scuffle and rake assembly. The combination tool allows an operator to cut unwanted weeds below the ground surface and thereafter groom the weeded area without having to use separate tools to complete the task.
[0017] The tool employs an elongated handle with a scuffle portion and rake portion attached at a distal end thereof. The scuffle portion comprises a generally elongated metal blade formed into a trapezoid shaped loop and sharpened on both edges. The metal blade is secured at the distal end of the handle at an obtuse angle with respect to the longitudinal centerline of the handle.
[0018] In one embodiment, the rake assembly is slidably mounted on the elongated handle and includes a locking means to secure the rake assembly in either a retracted or an extended position. The rake assembly includes a plurality of tines. Each tine is fixed in a diverging manner generally coplanar to the flat portion of the loop blade and includes a formed tip for drawing together leaves or cut grass as well as grooming loose soil. The center portion of each tine extends through a guide member secured to the distal end of the handle whereby moving the sliding member toward the distal end of the handle causes the tines to extend and diverge outwardly. The tines are positioned within the confines of the scuffle.
[0019] In an alternative embodiment, the assembly includes a guide member which is substantially longer than the guide member of the first embodiment. In this alternative embodiment the tines are secured to a sliding member at one end. The center portion of each tine extends through the guide member secured to the distal end of the handle whereby moving the sliding member toward the distal end of the handle causes the tines to extend and diverge outward. Since the length of the guide member is greater than the width of the scuffle the rake is able to cover an area of ground substantially larger than the area covered by the scuffle.
[0020] The construction of the device allows the rake to be locked into the retracted position while cultivating for easy access to confined areas. The rake assembly can then be extended so the tool can be used as a rake to gather cut weeds and/or groom the cultivated surface.
[0021] Accordingly, it is an objective of the instant invention to provide a novel combination tool that is versatile and efficient in use and lends itself to a variety of gardening and landscaping activities.
[0022] It is a further objective of the instant invention to provide a combination hand tool having a scuffle blade and a sliding retractable rake assembly.
[0023] It is yet another objective of the instant invention to provide a combination hand tool which provides a scuffle and a rake assembly having a set of folding and retracting tines.
[0024] It is a still further objective of the invention to provide a hand tool which can perform a plurality of tasks without using separate tools or changing the tool on the handle.
[0025] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1 is a front elevational view of the instant invention with the rake assembly in an extended position.
[0027] FIG. 2 is a rear elevational view of the instant invention with the rake assembly in an extended position.
[0028] FIG. 3 is a side perspective view of the instant invention with the rake assembly in an extended position.
[0029] FIG. 4 is a front perspective view of the instant invention illustrating the position of the rake tines inside the scuffle.
[0030] FIG. 5 is a side perspective view of the instant invention.
[0031] FIG. 6 is a bottom perspective view of the instant invention with the rake assembly in an extended position.
[0032] FIG. 7 is a side elevational view of the invention with the rake in the retracted position.
[0033] FIG. 8 is a front elevational of the instant invention with the rake in the retracted position.
[0034] FIG. 9 is a top view of the instant invention with the rake in the retracted position.
[0035] FIG. 10 is a bottom view of an alternative embodiment of the invention.
[0036] FIG. 11 is a side elevational view of an alternative embodiment of the instant invention.
[0037] FIG. 12 is a bottom view of another alternative embodiment of the instant invention with the rake in the retracted position.
[0038] FIG. 13 is a side view of another alternative embodiment of the invention with the rake in the retracted position.
[0039] FIG. 14 is a top view of another alternative embodiment of the instant invention with the rake in the retracted position.
[0040] FIG. 15 is a bottom view of another alternative embodiment of the instant invention with the rake in the extended position.
DETAILED DESCRIPTION OF THE INVENTION
[0041] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0042] Referring now to the figures, there is shown a combination weeding and raking devices embodying the principles of the present invention. The combination hand tools provide convenience and efficiency by employing a scuffle and a rake in a single assembly to minimize operator stooping and tool exchange when gardening or landscaping. The combination tool also provides for shipping and storing in a compact manner.
[0043] The combination weeding and raking devices 100 u include an elongated handle 10 of a type well known in the art, preferably constructed of wood, but alternatively may be constructed of fiberglass or metal or suitable combinations thereof. The elongated handle 10 has a proximal end 14 , a distal end 16 and a gripping surface 12 . The distal end 16 supports means to for cultivating a working surface illustrated herein as a scuffle assembly 20 and a means for grooming a working surface illustrated herein as an extended rake assembly 50 ( FIGS. 1-6 , 10 , 11 and 15 ) or folded rake assembly 80 ( FIGS. 7-9 and 12 - 14 ). The scuffle and the rake assembly are preferably positioned on the same side of axis A which extends through the longitudinal centerline of the elongated handle 10 ( FIGS. 5, 11 and 13 ). This construction allows the operator to rotate the handle about the first axis to selectively utilize the scuffle or the rake without the need to change tools.
[0044] Referring to FIG. 4 , in one embodiment the scuffle assembly includes a metal blade 22 formed generally into a trapezoid shape, including two upright portions 24 , a bottom portion 26 , and a top portion 28 . Two brackets 29 secure the hoe assembly to the handle 10 at the desired angle. The top portion 28 of the hoe assembly is attached to each bracket 29 by passing through a slot formed in an end portion of a bracket member. The top portion 28 is not rigidly held in the slots. A small amount of play exists between the top portion 28 and the slots of the brackets 29 . This play allows the scuffle to pivot back and forth slightly when it is cultivating a working surface. As shown in FIG. 3 the metal blade 22 includes a first cutting edge 30 and a second cutting edge 32 . The first cutting edge 30 is generally constructed and arranged to cultivate a working surface during a pushing motion of the weeding and raking tool and the second cutting edge 32 is constructed and arranged to cultivate a working surface during a pulling motion of the weeding and raking tool. The scuffle is positioned at an obtuse angle with respect to axis A of the handle.
[0045] Referring to FIGS. 3 and 4 , the rake assembly 50 includes a plurality of tines 52 arranged in an outwardly diverging array. The tines 52 have a base end 54 , a center portion 56 and a tip end 58 . The tip end includes a hook portion 60 for gathering cut vegetation and grooming the cultivated soil. The tip ends of the tines extend in an upward direction and the scuffle extends in a downward direction with respect to the axis A of the handle. The base ends of the tines are attached to a sliding member 82 . The rake assembly is slidably mounted along the first axis A and movable between an extended position and a retracted position. The rake 50 extends beyond the scuffle while the rake assembly is in its extended position and the scuffle extends beyond the rake while the rake assembly is in its retracted position, as shown in FIGS. 7-9 . The sliding member 82 also includes a means for locking the rake assembly in the extended or retracted position. The locking means is illustrated as a lever actuated clamp 62 , as shown in FIG. 3 . When the rake assembly is to be extended or retracted, the clamp 62 is first released by pivoting lever 64 down and away from handle 10 . The sliding member 82 can now be slid toward or away from the distal end of the handle and locked in its new position by pivoting the lever up towards the handle, thereby extending or retracting the rake assembly.
[0046] The rake assembly also includes a guide member 86 which is provided with apertures 84 through which the center portion 56 of the tines pass ( FIG. 3 ). The guide member is attached to two brackets 88 positioned on either side of the handle and on the outside of brackets 29 , as shown in FIGS. 4 and 5 . Alternatively, the brackets 88 could be positioned inside of the brackets 29 and adjacent the handle. Utilizing this construction, movement of the sliding member 82 toward the distal end of the handle from the proximal end will cause the tines 52 to extend and diverge outwardly. Moving the sliding member 82 toward the proximal end 14 of the elongated handle 10 will cause the tines to fold together and retreat behind the scuffle.
[0047] Locating the scuffle and rake assembly on the same side of axis A allows the rake tines 52 to be positioned within the confines of the scuffle when they are in their extended position. This construction provides greater lateral stability of the flexible tines by confining the tines between the upright supports 24 of the scuffle. These supports will prevent the tines from flexing outwardly laterally too far during use which may lead to the tines becoming bent. The blade portion 26 of the scuffle also provides support for the tines when they are deflected in the vertical direction as a result of the user placing too much pressure downwardly when using the rake. In addition, the overall height of the device is substantially reduced since there are no tools on one side of the axis A. This reduction in height enables the device to be used in confined areas such as under porches and other structures with very little ground clearance.
[0048] In an alternative embodiment illustrated in FIGS. 10 and 11 the tips of the tines of the rake and the scuffle extend in the same direction with respect to the axis A of the handle of the tool ( FIG. 11 ). This arrangement permits the user to alternatively use either the scuffle or the rake without turning the tool over.
[0049] A further alternative embodiment is illustrated in FIGS. 12-14 wherein the width of the rake is substantially greater than the width of the scuffle. This arrangement results in a rake with a larger number of tines and a substantially larger area of coverage. Since the number of tines exceeds the width of the scuffle, the guide 86 for the rake tines is positioned on the opposite side of axis A as the position of the scuffle ( FIG. 13 ). FIG. 15 illustrates the rake tines in their extended position in this embodiment.
[0050] In another embodiment the entire device would be substantially smaller, similar to a single handed shovel or rake. This would enable the user to use the device in flowerbeds or bonsai gardens.
[0051] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0052] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
[0053] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | The present invention relates to hand operated gardening and landscaping tools for use in cultivating soil and/or removing inferior or unwanted plants from a selected area. More particularly, the present invention relates to a combination scuffle and rake assembly. The combination tool allows an operator to cut unwanted weeds below the ground surface and thereafter groom the weeded area without having to use separate tools to complete the task. | 0 |
(REFER TO PREVIOUS PROVISIONAL) U.S. 60/832550
[0001] This is a utility patent application
CROSS REFERENCE TO SOME RELATED PATENT APPLICATIONS ARE
[0000]
U.S. patent numbers:
U.S. Pat. No. 4,319,454—Mar. 16, 1982 (Perhaps the nearest likeness)
U.S. Pat. No. 228,860—Oct. 14, 1980 & Jun. 8, 1979
U.S. Pat. No. 5,027,000—Sep. 7, 1989
U.S. Pat. No. 4,185,947—Dec. 28, 1977
U.S. Pat. No. 3,664,125—Mar. 30, 1970
U.S. Pat. No. 3,746,875—Aug. 4, 1972
U.S. Pat. No. 4,851,704—Oct. 17, 1988
U.S. Pat. No. 4,023,041—Mar. 1, 1976
U.S. Pat. No. 3,012,938—Jan. 25, 1974
U.S. Pat. No. 4,091,618—Jan. 14, 1976
U.S. Pat. No. 4,627,240—Feb. 27, 1981
U.S. Pat. No. 4,719,158—Mar. 27, 1987
U.S. Pat. No. 3,959,663—Oct. 19, 1974
U.S. Pat. No. 4,563,591—Jan. 7, 1986
U.S. Pat. No. 4,389,843—Jun. 28, 1983
BACKGROUND OF INVENTION
[0018] This final invention has come from ideas I originally conceived in the 1960's while boating in the Pacific Ocean off the coast of the states of Oregon and Washington, U.S.A. I then started to develop a way to capture some of the energy of water wave action to produce electricity. To show an earlier time of conception before today's date, I started certified mailings to myself beginning Feb. 19, 1999 that verifies work progress in the years of 1995 and 1996. I have several certified mailings to myself since to show my progress on this invention.
[0019] In earlier conceptions of this invention I was trying to carry this electric generating station only on a fixed support from the floor of the ocean or body of water, as well as trying to harvest tide and current action at the same time.
[0020] In 2002, I was using mechanical means with wire cables and rotating cylinder to transfer the energy to the generator, but now have the new idea of using only hydraulic energy to turn the generator within the body of a vessel.
[0021] My latest conception includes the new way to harvest water wave energy by using a specially constructed float, plus the use of a water reservoir and water pump within the vessel's hull to receive and transport energy to the generator located also in the hull for production of electricity. My invention submitted herewith requires a floating vessel to carry the electrical generating station.
BRIEF SUMMARY OF THE INVENTION
[0022] The object of this invention is to produce electricity from the ocean water or large body of water by harvesting some of the uplifting power or action of a water wave or swell. The actual weight of a float being pulled down by gravity on the wave will transfer its weight as the energy to the turbine to produce electricity. The float and float arm on the vessel will be using the simple lever system as a mechanical means to transfer this energy to the water pump. One end of the lever system extending inside the hull of the ship will pump and force fresh and recycled water into a large water reservoir under pressure for use by an electrical turbine on board the vessel . . . . This vessel will carry the total and complete electrical generating station. Severe storms or water action will not affect the delivery of uniform energy towards the generator. Each float is delivering secondary or indirect energy from the waves, not the direct force of a wave, because the float's actual weight from gravity will be the uniform energy necessary to pass on to the electrical station, but not the direct energy from a rising wave.
[0023] In actual use: The rising and falling floats located at one end of the lever with their fulcrums attached to the vessel's bow, will move up against gravity on the water wave to capture and store energy. The float's weight, on the down stroke, and sometimes out of and above the receding wave, will transfer this energy at the opposite end of the lever. This lever has an attached connecting rod extending down into the vessel that can either pull the attached piston directly up in a vertical direction to do work or change the stroke of the water piston to a “pushing action” of the water piston by employing a “cam and camshaft” between the water piston and the end of the float's arm. I will use the camshaft method in this invention. This change of direction will cause the water pump piston to be pushed down in the hull instead of being pulled up directly by the connecting rod. One side of the cam will be connected to a float arm with a metal rod. The other end of the cam will be connected to the water piston's shaft, which will then move in the opposite direction as it rotates on the camshaft itself. This camshaft will change the pulling direction to a pushing motion from the force of the connecting rod adhered to the float arm. This pushing action now will transfer the energy from the piston in the water pump to water that will go into a large pressurized holding tank. This water tank now under extreme pressure, will allow water to be forced into the water turbine to generate electricity. This electrical energy will carried to shore with a “submarine” or underwater cable.
[0024] Some unique features have been added since the original conception of this invention that I put on paper Apr. 1, 2002, plus simplification for efficient operation and less maintenance for lasting operation of this floating electrical station.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
[0025] Drawing # 1
[0026] General view of the entire floating electrical station with (6) floats
[0027] Drawing # 2
[0028] General view of a float arm using the vessel's side as a fulcrum with a float at one end and a cam rod connected to the opposite end and within the vessel's hull, to operate a water pump.
[0029] Drawing # 3
[0030] General view and location of two water pumps, water holding tank, turbine, and water lines within the vessel's hull.
DETAILED DESCRIPTION OF THE INVENTION
There will be (3) major parts for the invention
[0031] #1—Floating ship, hull, or vessel showing side floats
[0032] #2—Floats and its hardware
[0033] #3—Water piston area and water flow plan
[0034] #4—Generator or hydro turbine
[0035] A floating (ship or) vessel can be used to produce electricity anywhere in the world where there is some water wave action. The use would be of particular importance for isolated islands needing electricity, or communities on land near the ocean without adequate electricity. The best location for use should be where constant wave or swell action for long periods of time exists.
[0036] A variety of cargo vessels with different lengths, widths, and freeboard with open hulls can be used. A cargo ship approx. 300 feet long would be best to carry this electrical station. The open-type vessel with less than 40 feet freeboard is suggested. There is a surplus of vessels worldwide that could be adapted for this use.
[0037] The construction would allow for low maintenance, easily floated to a new location, and built of materials to withstand salt water and severe weather conditions. A small fossil fueled motor would perform necessary functions on board, such as raising anchors, maintaining drift, pumping water, emergency electricity, air pressure for raising the floats and maintaining an air supply in the pressurized water tank, etc. Some of the electricity generated by ocean waves might also be used for these tasks also. The floating vessel will be equipped with (6) floats, three on each side, that are moving up vertically from water or wave action. When gravity pulls these floats down, the opposite end of the float will rise up and do work within the vessel. The fulcrum of this lever action is secured on the vessels side, between both ends of the floats arms. A metal rod will tie the upper end of the float's arm to the cam below to change direction from a pulling action to a pushing downward direction. The pushing up action of the water piston will force water into a large pressure tank. The pulling motion of the water piston will pull water back into its chamber to be pushed out again. Water will then be forced by this piston into the large and pressurized water tank as energy. This water tank will force water through a turbine nearby to generate electricity. The electricity generated will then be transferred to shore. An underwater or “submarine” cable would be used, available worldwide.
[0038] The vessel should be moved in water by utilizing either towing or pushing boats, consequently the motors, fuel, and original hardware to operate or navigate the vessel could be removed. A vessel with a “no motor” feature, and “gutted out” can be purchased for less money, and would have more room for the new use as an electrical station.
[0039] Anchoring the vessel from the bow to the seafloor or lake bottom will help insure the hull of the vessel will “trail” back from the wave action direction to produce the best action for the floats. Extra anchors on this vessel should be required. The hull can also be anchored or fixed stationary to a coastal or lake outcropping, cliff, or other solid anchor point(s) on the shore, or, rising from the ocean or lake bottom. This vessel will be purchased, built, or remodeled to be very stable in the worst of weather, water or extreme storm actions. The ship's “Roll” and pitch action may help the float action. Stabilizing plates for the vessel located in the water could be used perhaps to get more float action from consistent swells or waves, if the vessel is rising excessively with the water waves. The float system will operate however with any wave action. The floats, their support arms, or beams, should be the only parts of this station exposed to the weather. All other mechanical hardware will be below the “deck” area or covered for protection from salt water or weather.
[0040] The floats can have a plurality of shapes and sizes, from long and cylindrical, round or rectangular, depending upon water or wave action. Cylindrical floats may be best for carrying a large amount of weight when the wave action is coming from one direction. The shape of the floats will be designed to insure the most lift from a swell or wave, also built to resist high winds or storms. Each float with its attached hardware (including the float arms extending within the vessel) will weigh many tons. An electrical or mechanical engineer, after knowledge of water waves in the area, may choose the floats size and weight to determine the maximum electrical output. The floats will be filled with water, but the water reservoir within the float will hold air to keep them floating, but just above its desire to sink below the surface, and mostly “buried” within the water wave. The water level within the float could be adjusted with a fixed air pipe or hose along the floats arm, so the vessel's auxiliary motor could change its weight for best working weight, or storms, travel, repair, out of service, etc. The floats can be raised mechanically to an “out of service” position anytime. The floats themselves could be made of tough plastic or metal and strapped or adhered securely, or made part of the float arm. Metal could add rigidity and weight. The float arm itself will be of metal, reinforced with cable for strength. The length of the float arm is about 80 feet, adjustable at the extreme, upper end, extendable to about 20 feet more than normal use within the confines of the vessel. In other words the float arm head can be adjusted at any length from 0 to 20 feet longer than its shortest length. This upper end of the float's arm will carry the fixed hardware to push and pull the water piston. The adjustable float arm's head and cable assembly will accomplish two things: #1, It will change the energy the water piston receives from the float's arm, depending upon its length or distance from its fulcrum or axle it pivots upon. It is ideal to have all float arm extensions to be located from the fulcrum evenly on all float arms to help receive and deliver the same energy. #2, the arms can be extended or adjusted to reach or better fit the different widths of different vessels as well as the ship's curved bow, where the float is pivoting and anchored at different locations. Any extra weight added to this upper end of the float arm should be added to the lower end of the float arm, or the float, to help enhance the weight of this lower arm so maximum energy can be passed to the primary cylinder.
[0041] The float's arm should be approx. 80 feet long, with its fulcrum or pivoting axle, approx. 53.3 feet from the extreme lower end of the float in the water to the side or bow of the ship. The final 26.7 feet will be extended inside the vessel from this pivot point, but note it has another approx. 20 feet, if needed, with its extension head. The float should have three support arms. The main and centrally located float arm will begin on the top and center of the float in the water, or at its farthest point from the vessel. The two separate supporting side arms for this float will also start (or end) on this topside of the float. From here, the side support arms will widen to a maximum width of approx. 40 feet away from where the center support arm is positioned on the ship's bow. This 80 foot float support with its three arms will all share the same fulcrum or axle that is mounted upon the vessel's bow. The 40 feet of width allows the three arms of the float to be anchored at three places on one main axle. The center arm will be the strongest, as it must carry the major weight of the float plus the arm's weight extending beyond the fulcrum to the center of the vessel. This center arm carries the heavy hardware to do the work. This float arm will support those two separate “side” arms of the float that will help prevent twisting, or other damage due to the violent wave action and will be secured or fixed or become permanently attached to each other as one unit, and will be adhered permanently to the fulcrum's axle. The cylindrical axle thus attached and holding up all three attached float arms, but at separate locations, will be the fulcrum for the float as it moves up and down. The fulcrum or axle holding the heavy float arms will be attached very strongly to the vessel to prevent damage in the extreme low and high positions as well as the vessels pitch and roll actions. Again, the two side arms of the float should be securely held to the main center arm of the float to help withstand the twisting or damaging effect of the water, weather, etc.
[0042] When the floats are in the lower than normal position, they may stop upon hitting the side of the hull on a large vessel. An additional padding material of softer very resilient material could be permanently placed on the float's underside making contact to the hull, or the out of service cable to raise the floats could be used as the stopping point if needed occasionally. On a small vessel, a cushion could be placed under the float arm to contact the hull of the vessel, if ever necessary, in a gentle manner. These cushions should have special shock absorbing qualities. The hull may have to be reinforced where it may contact the hull at this lowest float position if necessary.
[0043] Each float on the vessel should maintain the same weight for producing the same energy or power. When mounting the working floats from the bow to the stem of a vessel, different distances from the bow to the centerline of the vessel will occur. The floats fulcrum or pivoting axles may be moved to conform to the rounding hull, or have the extendable heads used which would change the distance to the center of the vessel, but, again, would not matter. It is necessary to have these axles holding the floats be parallel to each other, or on the same horizontal plane.
[0044] The following paragraphs describe the fulcrum or pivoting axle for the floats on a 300 foot or longer vessel.
[0045] The total length of the axles that are inside and not the “end” axles holding the floats in place should be 45 feet. The “end” axles can be 50 feet, but a minimum of 47.5 feet. There will be room for (3) floats on each side, rotating on an axle or fulcrum totaling 240 feet (each side), or 80 feet for each float. The diameter of the axle or fulcrum should hold the floats weight and hold the pitch and roll stress during extreme weather. There will be two bearings and bearing caps on the axle between the two outside arms of the float. Between each float's outside arm there will be another bearing and cap separating these two arms. The axles will be split here for separate rotation for each float assembly containing the three float arms of each float. The bearing and cap should have a stop groove so each axle won't move horizontally. All bearings should be alike, except the two end bearings, which will not have a split axle in them. The axle will be rigidly supported from the bottom and sides of the vessel to hold the extreme weight of the floats, the float's support arms, and hardware. There will be a framework of steel perhaps coming from the floor of the vessel, as the base, to hold the float arms and the rotating axles. These axles must be high enough for the float arms to clear the top of the hull when moving up and down. The framework to block up the float's arm on the bow can be of different height or thickness, but mounted primarily to support the float arms and secondly to clear the top of ship's hull when the floats are at their lowest and highest positions.
In the Vessel's Hull:
[0046] The connecting rod at the end of the float arm that is extended downward within the vessel's hull is working within a steel pipe or cylinder in the vertical up and down direction and its distance of travel is dictated by the height of the wave at the other end of this float arm. This action will pump water under pressure to a main line on this side of the vessel that all three float areas and water pumps are using together. This water line will go to the large, high pressure tank that will then keep supplying the turbine with high pressured water at an even rate. After the water has passed through the turbine, it will pool up in a small reservoir, then flow by gravity in one pipe that is shared by each side of three working water pump stations. This will help disallow air to entrain itself into the water. The pressurized water tank can be placed at any elevation that is close to the turbine, but the turbine must be placed above the recycled water supply and return water pipe to the water pumps for gravity to flow the water back to the water pumps. There can be several methods used to supply the water from the piston to the water tank receiving the water pressure. This invention will use the following water pipe and valve plan:
[0047] There will be only one collector pipe on each side of the vessel that will transfer the high pressure water from all three water pumps on their respective side to the water holding tank. This one pipe will collect all water pumped from one side of the vessel from the three water pumps and deliver it into the holding tank. There will be “check valves” installed close to the water pump and for extra safety, close to the holding tank also, so water pressure is not lost. Water used by turbine will be recycled and collected in a small lagoon, or open tank type structure. There will be only one recycled water pipe from the base of this water reservoir to supply all three water pistons on their respective sides. This water will be fed to the pumps from the force of gravity. There is the possibility that for reasons of placement, or location of the turbine, a closed pipe system using some of the water pressure from the water tank could be used to force the water to the pumps for its re-use.
Water Pumps:
[0048] There are pluralities of water pumps that can be used, however, I will use the following one in this invention. The water pump will consist of a water piston, a connecting rod from it to the camshaft's cam, and the pipe or metal cylinder it is fitted into. The water piston's cylinder is secured to the bottom of the vessel at the correct elevation for the water piston to operate in at a safe length so that the piston will not touch the chamber's extreme end. This cylinder or water pipe will extend upwards to the cam, but not to touch or contact it when the piston is at its extreme position due to high water wave action. Both the high pressure valves and water return check valves are located below the head of the piston. This will allow the top of the piston's cylinder to be open for the connecting rod from the float's arm to work and not touch the cylinder wall. It will also allow any excessive water forced around the piston rings from pushing water to be expelled for recycling. 12 or more inches of water should be sufficient above, or behind the piston to disallow any air to be sucked along the walls of the piston while it is sucking in water from the front of the head.
The Camshaft:
[0049] (To change direction of the energy from the float arms)
[0050] The camshaft tower should be welded to the bottom hull of the vessel and directly below the end of the upper float arm area. There will be extreme force on the cam-shaft to be lifted upwards due to the heavy weight of the float. The bottom half of the cam and the cam-shaft will be made strong with heavy metal to withstand this force. The top half of the covering on the cam-shaft need only to hold the camshaft together properly. | This is a unique way for an anchored vessel at sea near an isolated island or outpost to be able to generate electricity and transfer it from within its hull for use onshore with an electrical underwater cable for that community.
The floating vessel, or electrical station, is unique because it is anchored in water wave action and has a total of (six) side floats, moving up and down from water waves and these floats and float arms are used as simple lever machines rotating on the ship's bow to transfer this energy to fresh and recycled water inside the vessel by means of a water piston and water pipes into a pressurized water tank for turning a water turbine there, then recycling or pumping this water again, and again for generating electricity within the body of this floating vessel. | 5 |
DESCRIPTION
The invention relates to the tunnel sprayer for rows of plants described in European patent EP 1 449 433 B1 of the type comprising, on the uprights of a portal which is made to travel over the row, opposing vertical shields or screens which have the same height as the row to be treated and each of which is provided with at least one vertical spray bar which operates on the discharge outlet, also vertical, of a chamber which supplies a flow of pressurized air in parallel with the jets of treatment liquid supplied by the nozzles of the said bar, each shield also being provided, laterally and parallel to this chamber, with a vertical suction chamber having a large vertical mouth facing the row and communicating with the said delivery chamber via a plurality of axial fans, the two shields being located on the two sides of the row and being positioned with the said air flow delivery and intake mouths in opposing and inverted positions, so that the air and liquid delivery chamber of one shield is opposed to the intake chamber of the opposing shield, and vice versa. This opposing and staggered arrangement of the air flows improves the penetration of the treatment liquid into the depth of the row, provides uniform wetting of the plants in the row, and enables the treatment liquid mist to be recovered, so as to limit the dispersion of this liquid in the air and to the ground, with all the consequent advantages in economic and environmental terms. The invention relates to constructional and functional improvements to this type of machine, to enable it to achieve the desired results and to operate in a reliable way. The characteristics of these improvements are specified in the attached claims and will now be detailed in the following description which refers to the attached sheets of drawings, in which:
FIG. 1 is a schematic side elevation of the machine in the version towed by a tractor;
FIG. 2 shows the machine from the front, on one side, with a pair of shields open and with one of these in the air chamber maintenance condition;
FIG. 3 is a plan view from above, in partial section, of one of the machine shields which operate on opposite sides of the row;
FIG. 4 is a side elevation of one of the shields shown in FIG. 2 , viewed from the inner side which faces the row;
FIGS. 5 and 6 are perspective views from outside of the upper and lower ends of a shield respectively;
FIG. 7 is a perspective view of one of the telescopic arms which support a pair of shields of the machine;
FIG. 8 is a schematic elevation taken from the outer side which lies outside the shields shown in FIG. 7 ;
FIGS. 9 , 10 and 11 are perspective views, taken at different angles, of the front part of the machine, with the pump which supplies the treatment liquid to the plants, with the generator or generators and with the electrical accumulators which supply the power at least for the operation of the motors for the axial fans of the shields;
FIGS. 12 and 13 are perspective views of the upper and lower parts respectively of a single shield of the machine, viewed from the side which faces the row;
FIG. 14 shows the inside of the intake chamber of one shield, with the corresponding filter port in the open position;
FIG. 15 shows the profile of the bars which form the slatted buffer of the filter port located on the intake chamber mouth of each shield;
FIGS. 16 and 17 are enlarged views of further details of the components which operate in the intake chamber of each shield, particularly those of the fans and of the recovered liquid recycling pump.
In the prior art cited in the introduction to the present description, the portal structure with the opposing shields which are positioned and made to advance on opposite sides of the row was located in the rear part of a trailer towed by a tractor, which carried the treatment liquid reservoir and all necessary equipment for the operation of the machine, including the hydraulic power unit for actuating the corresponding hydraulic motors for rotating the axial fans which produce the delivery and intake air flows required for the operation of the machine. This solution with the shields located behind the wheels of the towed trailer caused major difficulties in the manoeuvring of the machine when moving into and out of the rows of plants. In the same prior art, the fans were driven by hydraulic motors which proved inadequate because they required the use of a high-power tractor for operating the machine's hydraulic power unit, and therefore, if the seals or the corresponding supply circuit ruptured, could cause leakage of oil which was carried by the pressurized air and dispersed on to the plants, damaging them irreparably. As shown in FIG. 1 and FIG. 2 , these initial drawbacks have been overcome by mounting the shields S in the front part, closest to the wheels R of one or more parallel axles of a trailer C provided at the front with a shaft T for fixing to the tow hook G of a tractor, this shaft having steering properties if necessary, so that the said wheels R are located immediately behind the said shields. This solution enables the machine to be maneuvered easily when it is brought into or out of the rows, and brings the shields S into a position nearer the tractor and therefore more visible to the driver. The reservoir Q of plant treatment liquid is mounted in the rear part of the trailer C. The letter M indicates a telescopic vertical elevator whose movable upper part can be raised and lowered by the appropriate actuator M 3 and extends towards the shields S to support transversely and in a projecting way the set B of telescopic arms with their actuating jacks (see below), which support the shields S, S′ as stated below, to position the latter correctly on the opposite sides of the row. The machine can be set up to operate on only one row at a time, with a single pair of shields S, S′ positioned so that they project from one side of the trailer C, or can advantageously be of the type shown in FIG. 2 , with two pairs of shields, one pair being positioned on each side of the trailer C, to operate simultaneously on two parallel and adjacent rows of plants. The small number of hydraulic cylinders of the aforesaid units B and M can be actuated by the power unit incorporated in the towing tractor of the machine, which in this case can be low-powered and therefore small, facilitating maneuvering at the ends of the rows, especially since the tractor does not have to operate an auxiliary hydraulic power unit. The axial fans located in the shields S (see below) are designed in this case for electrical operation, and the means described below with reference to FIG. 1 and FIGS. 9 to 11 are mounted on the trailer C for this purpose. The high-pressure hydraulic pump P, which draws the treatment liquid from the reservoir Q, supplies it at the correct pressure to the aforesaid spray bars, and is driven by a universal coupling shaft A rotated by the tractor power take-off, is mounted on the front part of the trailer C. A step-up gear V, which is fixed by brackets to the trailer C, and which, by means of another joint or a suitable transmission, drives one or more alternators D protected inside a suitable container Z fixed to the trailer and designed to contain additionally a sufficient number of electrical accumulators, is connected by a suitable joint to the other end of the shaft of the pump P. If desired, the hydraulic cylinders of the upper unit B for positioning the shields S and the actuator M 3 of FIG. 1 can be replaced by electrically operated linear actuators, so as to eliminate all hydraulic drive systems from the machine, with all the advantages, including environmental advantages, that are obtained thereby.
With reference to Figures and FIGS. 3 to 6 , it will be seen that the shields S, S′ are made with self-supporting characteristics and comprise corresponding lower and upper base frames 1 and 2 made from suitable tubular steel sections, having a shape in plan view substantially in the form of an elongate semi-circle, and fixed together by the ends of the straight sides by a pair of uprights 3 , also made from suitable tubular steel sections, with corner reinforcements 5 , and also fixed together by other parts described below. The U-shaped edges of shells 4 made from a suitable strong and lightweight plastics material, ABS for example, are fixed to the uprights 3 , and are also fixed to the straight sides and to suitable cross-pieces of the bases 1 and 2 , these shells being provided with suitable transverse reinforcing ribs both at the ends, as indicated by 104 and 204 in FIGS. 5 and 6 , and in the intermediate parts as indicated by 304 in FIG. 14 . FIGS. 5 and 6 show how the curved sides of the base frames 1 and 2 project slightly from the general boundary in plan view of the shields 4 , so as to act as bumpers.
FIG. 7 shows how the upper bases 1 of the self-supporting shields S, S′, made as described above, are provided with suitable reinforcing cross-pieces 101 which are fixed to the three-point securing brackets 6 , 6 ′ mounted on the ends of corresponding arms B 1 and B 2 which can slide telescopically into each other and into a fixed section of the arm B fixed to the elevator unit M shown in FIG. 1 . M 2 indicates the external jack which actuates the arm B 2 and M 1 indicates the internal jack which actuates the arm B 1 . On the outer end of the arm B 2 and on that of the fixed section B there are mounted sliding means 7 , 107 , which preferably also comprise idle rollers, including for example at least lower and lateral rollers, to facilitate the sliding of the movable arms B 1 , B 2 which with the passage of time tend to become soiled with the treatment material sprayed by the machine in question. The inner shield S which is more visible to the driver of the tractor and is therefore easier to position with respect to the row, has its bracket 6 fixed directly to the arm B 2 . The outer shield S′, as also shown in FIG. 8 , which is more likely to encounter obstacles in the row which are not immediately visible to the operator, has its upper bracket 6 ′ fixed to the support arm B 1 by means of a cylindrical hinge 8 , with an axis parallel to the longitudinal axis of the arm B 1 , and this shield is fixed to the support arm in such a way that its vertical median axis H is behind the said hinge 8 , in such a way that, owing to the greater weight applied to this hinge, the shield tends to swing in the direction of advance K of the machine, while this shield is held correctly in the vertical position by its upper base 1 which bears on a stop member 9 fixed to the arm B 1 . This interaction can be achieved by interposing a damper 10 which extends in a substantially unrestricted way if the shield S′ encounters an obstacle which makes it rotate in the anti-clockwise direction according to the view in FIG. 8 , but which can suitably retard the swing in the opposite, clockwise direction, by which the shield returns under the effect of gravity to the vertical position when it clears the obstacle.
To limit the rocking movements of the shields S, S′ when the machine is in transit with the shields lowered and retracted, the lower bases 2 of at least the shields S closer to the trailer C can be structurally connected to the trailer by at least one corresponding telescopic or pantograph connection, shown partially and indicated by 11 in FIG. 10 .
Purely by way of example and without restrictive intent, good results have been achieved in the treatment of rows of grapes or other plants of average height above the ground by using shields S, S′ with a length of approximately 1250 mm, a depth of approximately 450 mm in the intermediate area and a height of approximately 2150 mm.
FIGS. 3 and 4 and FIGS. 12 to 14 show how a wall 12 is fixed transversely and over the whole height in the intermediate part of each shell 4 , dividing the inner space of the shell into two adjacent chambers X and Y having different horizontal extensions or lengths, the chamber X having a length equal to or slightly less than about ⅓ of the total length of the shield and being used as the fluid delivery chamber, while the longer chamber Y is used as the intake chamber. On the said wall 12 there are formed, at equal distances from each other and from the lower and upper edges of each shell, three round apertures 13 with a diameter of about 400 mm, to the edge of each of which is fixed the stator ring of a corresponding electrically operated axial fan 14 , these fans being for example of the type used for cooling heat exchange radiators, whose electric motors are sealed and are preferably located in the delivery chamber X, so as to be protected behind the solid central part 214 of the corresponding impeller ( FIGS. 16 and 17 ). The motors of the fans 14 are supplied by the electrical circuit which comprises the alternator or alternators D and the accumulators E of FIG. 1 .
A small wall 15 , which extends over the whole height of the chamber X to close off part of the inner side of the chamber facing the row, and which has a horizontal extension or length of approximately 100 mm, is fixed to the straight sides of the bases 1 and 2 and to the adjacent vertical side of the dividing wall 12 . The other end of the said inner side of the chamber X is closed off over a horizontal extension of approximately 100 mm by the straight wall of a V-section 16 , fixed with this wall to the adjacent upright 3 and fixed by the end of its other curved wall to the inner wall of the shell 4 , as indicated by 17 . The opening of the inner side of the chamber X, lying between the section 16 and the wall 15 , is divided horizontally into two parts or mouths 18 and 19 by a further vertical section 20 , which also has a substantially V-shaped profile and has one straight wall coplanar with the wall 15 and fixed like the latter to the straight sides of the base frames 1 and 2 , and which has a curved wall positioned inside the chamber X in a position which substantially mirrors that of the curved wall of the section 16 , this wall being fixed, for example, to a rod 21 whose ends are fixed to the base frames 1 and 2 . The flow of pressurized air produced by the fans 14 which draw air from the chamber Y is divided into two parts in chamber X by the curved wall of the section 20 which enters the chamber X to a depth of approximately 160 mm for example, and is thus partially directed to the mouth 18 and partially to the mouth 19 . Because of the curvature of the inner wall of the shell 4 and the presence of the curved connecting wall of the section 16 on the final part of the inner wall, the air flow leaving the mouth 18 forms an angle with the inner side of the shell S which is presumably less than 90°, and is directed back towards the inside of the shield. Good results have been achieved by designing the mouths 18 and 19 with horizontal apertures of approximately 60 mm and approximately 100 mm respectively, so that the air emerges at higher pressure from the outer mouth 18 . The sum of the areas of the mouths 18 and 19 is less than the sum of the areas of the apertures 13 in which the fans 14 operate, and therefore the flow of air drawn in by these components is compressed in the delivery chamber X and leaves the mouths 18 and 19 with characteristics of pressure and flow rate which are substantially constant and are uniformly distributed over the whole height of these mouths.
At the side of the mouth 19 which is formed by the section 20 , there is a vertical bar 22 , which is connected to the pump P for delivering the plant treatment liquid, and which in the present example is provided with twelve nozzles 122 spaced at equal intervals and distributed vertically, which spray the liquid perpendicularly and uniformly over the whole height of the row. The pressurized flat air stream leaving the inner mouth 19 accompanies the jets of liquid supplied by the said nozzles 122 in a parallel way and contributes to the uniform and penetrating distribution of the liquid among the plants of the row. The pressurized flat air stream leaving the outer mouth 18 retains on the side of the shield the treatment flow leaving the inner mouth 19 , eliminates any drift phenomena caused by the wind, and because of its possible re-entrant inclination and its higher pressure, promotes the formation of a vortex which improves the quality of the wetting of the plants of the row by the nozzles 122 .
In order to create a uniform vertical distribution of the pressurized air flows produced by the fans 14 , and also to cancel out the rotary component imparted to these flows by the rotation of the blades of the fans, distribution and guide flaps 23 are located immediately downstream of these components in the delivery chamber X, these flaps being provided in the appropriate quantity and distributed over the height of this chamber. Each of these flaps 23 is fixed, for example, at one end to the shell 4 and at the other end to the wall 15 , and the flaps 23 extend into the mouth 19 and are, for example, positioned horizontally in the intermediate area of this mouth, while at the ends or at least at one end of this mouth 19 they are suitably inclined, with respect to the direction of rotation of the blades of the fans 14 , to prevent downward or upward leakage of the air and liquid flow leaving the said mouth 19 .
As shown in FIGS. 3 and 4 and in FIG. 13 , a small projecting horizontal wall 24 is fixed on edge, in a sealed way, on the lower side of the inner side of the intake chamber Y, from the vertical wall 15 to the opposing upright 3 of this chamber, and forms, in combination with the lower part of the shell 4 of the said chamber Y, a vessel for collecting the treatment liquid recovered from the shields by the suction of the electric fans 14 . A vertical rod 25 whose ends are fixed to the bases 1 and 2 of the shield is provided in the corner area between the vertical wall 12 and the said horizontal containing wall 24 , this rod being used as a fulcrum for the flaplike rotation of a hatch 26 which in the operating position is located with an appropriate inclination inside the intake chamber Y, as shown in FIGS. 3 and 4 and in FIGS. 8 , 12 and 13 , with its vertical side opposite the side engaged with the fulcrum 25 bearing on stops 27 and locked in this position by at least one intermediate catch 28 . The hatch 26 is positioned above the upper edge of the said lower containing plate 24 ( FIGS. 3 and 4 ) in such a way that, when the said catch 28 is released, the hatch can be rotated out of the chamber Y, as shown in FIGS. 14 and 16 , to enable an operator to access the chamber Y for any necessary inspection and/or maintenance operation. The hatch 26 is designed to form a filter with a sufficiently close mesh to prevent the entry of foreign bodies into the chamber Y and to drain off the liquid component of the sprays sucked in by this chamber and formed during the treatment of the rows with the shielded machine in question, these sprays originating to a very small extent from the nozzles of the bar 22 of the shield of which the hatch 26 forms part, and partly from the nozzles of the spray bar of the shield located on the opposite side of the row. The hatch 26 is closed by at least one slatted buffer formed by a plurality of vertical bars 126 of suitable plastics material, having for example the irregular sinuous profile shown in FIG. 15 , to capture and drain off the liquid portion of the sprays passing through them, these bars being positioned parallel to each other at equal intervals and with a suitable inclination with respect to the horizontal sides of the frame of the hatch 26 which have a grooved shape to house the ends of the bars in question. The ends 226 of the bars 126 are enlarged and fitted into complementary recesses of suitable supporting cross-pieces 326 of which, for example, two are provided with a symmetrical arrangement on the outer face of the hatch 26 (see FIGS. 12 and 13 ) and at least one is provided in the middle of the inner face of the hatch 26 (see FIGS. 14 and 16 ), and the ends of these cross-pieces are fixed to the uprights of the frame of the hatch 26 . The lower horizontal side of the frame of the hatch 26 is provided with suitable apertures (not shown) to discharge to the base of the chamber Y all the liquid drained off by the filter formed by the bars 126 . Clearly, as an alternative to the illustrated arrangement, the hatch 26 could be provided with a double buffer formed by two files of rods 126 suitably staggered with respect to each other and having, for example, opposing inclinations. In FIGS. 12 and 13 , the number 29 indicates a strip of rubber which is fixed to the plate 15 to form a link between this plate and the adjacent vertical side of the frame of the hatch 26 , to close the gap between the two parts, and has a lower end which drains into the base vessel of the intake chamber Y.
As an alternative to the arrangement shown in FIGS. 14 and 16 and in FIG. 3 , a latticed protector similar to the device 114 mounted on the delivery ends of the fans can be provided on the ends of the fans 14 facing the chamber Y. On the base of the chamber Y, the shell 4 is provided with a recess which forms a well 30 closed with a degree of play by a lid 130 which may be latticed and which holds within the well a first filter 31 ( FIG. 3 ) connected to the end of a pipe 32 which is connected through a secondary filter 33 to the intake aperture of an electric pump 34 which is fixed to the base of the chamber Y and is of the type used, for example, for safety in boats. The outlet of this pump is connected to the recycling pipe 35 which rises to the top of the shield S and which discharges the recovered liquid into the tanks Q of FIG. 1 through the bundle F ( FIG. 2 ) formed additionally by the supply tube to the bar 22 and the electrical power cable for the fans 14 . As an alternative to the illustrated arrangement, the inner lateral walls of the chamber Y can be roughened by a suitable painting treatment or by the application of suitable pads which may be removable, in order to increase the quantity of liquid recovered by filtration in the said intake chamber Y.
The electric pumps for recycling the liquid recovered from the bottom of the shields can be substituted by suction ducts connected to e membrane pump (not shown) analogous to the pump P which feeds the liquid to the spraying bars and arranged in line with said pump on the frame of the trailer C.
On one or both of the uprights 3 of each shield it is possible to mount hinged vertical flaps (not shown), pushed by springs against the row, which change their position by contact with parts of the row and which can provide all or some of the following functions: contributing to the formation of a more effective shield which retains the treatment fluid on the part of the row which is progressively treated by the machine; and forming, in combination with suitable proportional sensors, probes which enable the position of the shields S, S′ to be corrected automatically by the operation of the actuators M 1 , M 2 of the unit B shown in FIGS. 1 and 7 , using simple automatic control systems of the type already used in other agricultural machines, for example in sugar beet harvesting machines, for aligning the harvesting arm with the row of plants.
Clearly, the dimensions and materials specified in the present description are mentioned purely for guidance and can be modified to adapt the machine to various operating requirements. Clearly, the invention can be modified in any minor ways which provide equal utility and which use the same innovative concept, without departure from the limits of protection of the present industrial model as described above, as illustrated and as claimed below. In the claims, the references in brackets are provided purely for guidance and do not limit the scope of protection of the said claims. | Tunnel sprayer for rows of plants, is of the type having opposing shields (S, S′) which substantially cover the whole heights of the opposing sides of at least one row, and which comprise fans ( 14 ) to create a flow of air which in delivery travels parallel to the flow of treatment liquid sprayed on to each side of the row by at least one corresponding bar ( 22 ) with nozzles ( 122 ) and which in intake sucks in the air and treatment liquid delivered by the shield operating on the other side of the row, so as to avoid the dispersion due to wind drift and limit losses in the air and drips of excess liquid on to the ground. In each shield (S, S′) the area of the mouth or mouths ( 18, 19 ) for the delivery of the pressurized fluid is suitably smaller than the sum of the area of the apertures ( 13 ) occupied by the fans ( 14 ), in such a way that the said delivery mouth or mouths give out corresponding air flows whose flow rates and pressures are uniformly distributed and substantially constant over the whole height of this delivery mouth or these delivery mouths. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/865,864 filed Aug. 3, 2010, know U.S. Pat. No. 8,822,227), which is a national filing of international application serial no. PCT/IB2009/050396, filed Feb. 2, 2009, which claims the benefit of EP application serial no. 08101328.6 filed Feb. 6, 2008, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a biosensor device, such as a biosensor device using frustrated total internal reflection (FTIR).
BACKGROUND OF THE INVENTION
The demand for biosensors is increasingly growing these days. Usually, biosensors allow for the detection of a given specific molecule within an analyte, wherein the amount or concentration of said target molecule is typically small. For example, the amount of drugs or cardiac markers within saliva or blood may be measured. Drugs-of-abuse are generally small molecules that only possess one epitope and for this reason cannot be detected, e.g., by a sandwich assay. A competitive or inhibition assay is a preferred method to detect these molecules. A well-known competitive assay setup is to couple the target molecules of interest onto a surface, and link antibodies to a detection tag, that may be an enzyme, a fluorophore or magnetic beads. This system is used to perform a competitive assay between the target molecules from the sample and the target molecules on the surface, using the tagged antibodies. For road-side testing, the assay should be fast so that a test may be performed in about 1 min, and robust.
Generally, a biosensor device using frustrated total internal reflection (FTIR) comprises a sensor device in which a sensor cartridge is to be inserted. The sensor cartridge comprises a sensor chamber wherein at least a portion of a sensor surface or volume in said sensor chamber is prepared for the detection of the target molecules. Usually, the sensor surface includes various binding spots. The sensor cartridge may be a disposable polystyrene cartridge. Paramagnetic beads are arranged in the sensor chamber. To increase the reaction speed of target molecules in a liquid which is inserted into the sensor chamber, actuation means, such as actuation coils, are arranged below the cartridge to generate an actuation force to pull the beads towards the sensor surface. After a predetermined time, which should be sufficient for the beads to bond on the binding spots, the lower coil is switched off and thus the actuation force is removed. In order to pull the non-bonded beads away from the sensor surface, another magnetic field may be applied which is generated by another coil arranged above the cartridge. Subsequently, the presence of beads at the binding spots on the sensor surface may be detected. Usually, a predetermined coil current is applied to the coils in order to generate a predetermined magnetic field. The magnetic force applied by the coils may also be used to further manipulate the assay.
In a FTIR sensor device, a camera, preferably a CCD or a CMOS camera, may be used to image the light reflected from the sensor surface and to observe the binding on the binding spot on the sensor surface. A typical picture obtained with a FTIR biosensor device is shown in FIG. 1 . In FIG. 1 , the image of a sensor surface 11 is shown, the surface 11 comprising various binding spots A 1 , A 2 which are surrounded by a white area B 1 and B 2 . The pictures are obtained by substantially homogeneously illuminating the sensor surface 11 and projecting the reflected light via an optical system to the camera. The relative darkening of a binding spot, for example binding spot A 1 , compared to the surrounding white area B 1 is a measure for the number of bindings. In FIG. 1 , the situation is shown where the relative darkening of spot A 1 is greater than the relative darkening of spot A 2 . FIG. 1 further shows alignment marks 10 which define the positions of the binding spots.
Even thought the coil currents, and thus the generated magnetic field, may be controlled in a precise and reproducible way, the effect of the magnetic actuation applied on the magnetic beads depends on various parameters. For example, the assays may degrade over time which may change the composition of the matrix and the magnetic properties of the beads. The positioning of the cartridge in the reader and also the positioning of the actuation coils with respect to the cartridge and the binding spots may also change due to production tolerances when manufacturing the reader device and cartridge. The viscosity of the liquid applied to the sensor cartridge may vary since, e.g., different saliva samples which may be used, may have different viscosity. Moreover, the strength and quality of the chemical bindings may vary. For example, especially when measuring in blood, fragile bindings may occur, so that too low coil-currents will decrease the effect of the actuation, while too large currents may break the bindings or form clusters when non-bonded beads are to be pulled away from the sensor surface. The above-mentioned parameters may also vary depending on the temperature of the sensor device which may particularly change when the device is used for road-side testing. These parameters, which may strongly influence the magnetic actuation applied on the magnetic beads in the sensor cartridge, are difficult and expensive to control.
SUMMARY OF THE INVENTION
There is therefore a need to provide a method and a device for controlling and possibly optimizing the effect of actuation, in particular magnetic actuation, on label particles in a biosensor device. Specifically, the effect of parameters which influence the actuation, such as the parameters mentioned above, should be reduced or avoided.
According to the present invention, the force for actuating the label particles is controlled based on a determination of the effect of the applied actuation force in the binding volume or surface of a sensor cartridge of a biosensor device. Thus, a feedback control may be implemented. In case the binding volume or surface is analyzed optically, such as in a FTIR biosensor device, the feedback loop may comprise optical imaging and magnetic actuation. The magnetic actuation force may be controlled by controlling the coil currents or by controlling the positioning of the coil relative to the sensor cartridge. Furthermore, when a plurality of coils is used, also the geometric shape of the magnetic field may be controlled in order to influence the magnetic actuation and steer beads to a particular area of the sensor.
When the analysis of the binding volume or surface is done by observing the binding volume or surface with a camera, such as a CCD, the analyzing step may include real-time image processing to obtain enough control bandwidth and gain. Alternatively, determining the effect of the applied actuation force in the binding volume or surface may be performed by observing optical spots or using magnetic sensors, such as GMR or AMR, in order to obtain the parameters necessary to control the actuation force. The method may further be used in combination with any known detection method, such as magnetic or optical methods as mentioned above, in combination with any label particles or target molecules which may be actuated, for example in a magnetic or electrical way, using the Hall-effect, by flow or pressure or any other actuation means.
The invention further provides a device which is particularly adapted to perform the method according to the invention.
With the method and the device according to the invention, the influence of many assay parameters, which may otherwise hamper a correct measurement, may be reduced and the robustness of the biosensor may be enhanced significantly, especially when used under varying conditions like road-side drugs-of-abuse tests.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an image observed in a FTIR biosensor device;
FIG. 2 schematically shows a set-up for a FTIR biosensor device according to an embodiment of the present invention; and
FIG. 3 shows a diagram of a signal observed in a FTIR biosensor as a function of the magnetic actuation field.
DETAILED DESCRIPTION OF EMBODIMENTS
According to an embodiment of the present invention, a FTIR biosensor device as illustrated in FIG. 2 may be used. The device includes a sensor cartridge 1 which may be removable from the biosensor device. In the sensor cartridge, a sensor chamber including appropriately prepared magnetic beads is provided. The biosensor device further comprises a light source 4 , such as a laser diode or LED, for generating a light beam which illuminates a binding surface 11 of the biosensor cartridge under an angle which fulfills the requirements for total internal reflection. The light reflected from the sensor surface 11 is detected by a detection means 5 , such as a photo-diode or a camera, e.g. a CCD.
In order to increase the reaction speed of the magnetic beads, a magnetic actuation coil 3 is arranged below the cartridge 1 facing the sensor surface, to generate a magnetic field to pull the beads towards the sensor surface 11 . A further magnetic coil 2 may be arranged above the cartridge to pull the beads, which, after a predetermined time, do not establish a bonding with the binding areas on the sensor surface 11 , away from the sensor surface 11 . I.e., in this so-called washing step, un-specified and un-bonded beads may be removed from the sensor surface 11 , in order to avoid any perturbation of the measurement caused by beads which accidentally are arranged close to the sensor surface 11 .
The force required to pull the non-bonded beads away from the sensor surface in the washing step is very critical to tune. It is particularly difficult to find a balance between washing sufficient beads away from the sensor surface 11 while not breaking the fragile bindings between the sensor surface 11 and the bonded beads. The effect of a relatively small wash-current in a coil 2 may be observed and processed in real-time by analyzing the image observed by camera 5 . This may be done by connecting the output of the CCD camera 5 with a video interpreter 7 and controlling the actuation coils 2 , 3 using an actuation driver 6 in response to the output of video interpreter 7 . Video interpreter 7 and actuation driver 6 may be implemented by a computer.
When the current in coil 2 is increased, the washing of the beads, i.e., pulling the non-bonded beads away from the sensor surface 11 , gradually takes place, which again may be simultaneously observed in real-time. The effect of the applied current may be observed even more precisely by observing the effect in both, the binding-areas, i.e. the binding spots A 1 , A 2 , and non-binding areas, such as areas B 1 , B 2 as shown in FIG. 1 .
With this embodiment of the present invention, the actuation force needed to reliably remove only non-bonded beads from the sensor surface 11 may be performed by real-time observing the sensor surface 11 and, based on this observation, controlling the actuation force, i.e. the magnetic force applied by actuation coil 2 .
The above-described process to selectively control the actuation force acting on the beads in the sensor cartridge 1 may also be used to determine the quality of the chemical bindings of the beads on the binding spots on the sensor surface 11 . This may be done by increasing the wash-current in actuation coil 2 until also bonded beads disappear from the sensor surface 11 , thereby effectively breaking or stretching the bindings. The result of such a measurement may be used as a measure of the reliability of the assay.
FIG. 3 shows a schematic diagram of the magnetic field generated by actuation coil 2 as a function of the intensity observed in a FTIR biosensor device. At low magnetic fields, the intensity increases slowly with an increasing magnetic field. This reflects the removal of the non-bonded beads from the sensor surface 11 . From a certain threshold indicated with H thres , also bonded beads are pulled away from the sensor surface 11 . Accordingly, the reflected intensity observed in the FTIR biosensor device increases until substantially all beads are removed from the sensor surface 11 . Accordingly, from a certain magnetic field, the intensity remains substantially constant. Such a measurement may be used to determine the magnetic field required to remove substantially all non-bonded beads as fast as possible from the sensor surface. I.e., in order to reliably remove only non-bonded beads, the magnetic field of actuation coil 2 should be kept below H thres .
The principle of the above-described embodiment of the present invention may be extended to various applications. For example, attracting beads to the sensor surface 11 using actuation coil 3 in order to facilitate the binding of the beads to the binding spots on the sensor surface 11 may be optimized by observing the beads on the sensor surface 11 and controlling the actuation in such a way that unspecific bindings and clusters are avoided. Furthermore, by applying coil-currents alternately to both actuation coils 2 and 3 and, simultaneously, observing the position of the beads in the sensor chamber, the beads may be moved across the sensor chamber or sensor surface 11 in a predetermined way, in order to steer and mix a liquid in the sensor chamber.
With the device and method of the present invention, an increased assay robustness may be achieved by reducing the effect of various assay tolerances, which is especially important for road-side drug testing. Furthermore, the production tolerances when manufacturing biosensor devices and in particular sensor cartridges and thus the production price may be reduced. The present invention offers an optimal balance between hardware and software processing needed in a biosensor device, in particular a FTIR biosensor device.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and non-restrictive; the invention is thus not limited to the disclosed embodiments. Variations to the disclosed embodiments can be understood and effected by those skilled in the art and practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures can not be used to advantage. Any reference signs in the claims should not be considered as limiting the scope. | A biosensor device controls actuation of label particles e.g., using frustrated total internal reflection. By applying a predetermined actuation force on the label particles and determining the effect of the applied actuation force in a binding volume or surface of a sensor cartridge of the biosensor device, a feedback control of the actuation force is applied. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to gas burners, and, more particularly, to methods and apparatus for gas burner assemblies including inner and outer burners.
For gas burners that are used as surface heating units in cooking appliances such as ranges and cooktops, having a high turndown ratio, which is a ratio of maximum output to minimum output, is desirable. For a given burner, the maximum output typically signifies the “power” or “speed” of the burner and the minimum output is related to the simmer capability of a burner. The maximum output is limited by system gas flow handling capabilities and safety considerations. The minimum output is limited by the ability of the burner to maintain a stable flame under transient pressure fluctuation conditions caused, for example, by air currents in the room, or sudden opening or closing of nearby cabinet doors or the oven door.
A vast majority of gas burners used in cooking applications are partially pre-mixed burners using both primary-air and secondary-air. Based on whether the primary-air is drawn from above the cooktop or below the cooktop, these burners are termed either top-breathers or bottom-breathers respectively. In bottom-breather burners, also referred to as sealed burners, there are no gaps around the burner to allow spills or air to get inside the cooktop. However, the sealed burners are sensitive to pressure fluctuations under the cooktop.
At least some known gas burner assemblies include an inner gas burner and an outer gas burner for collectively producing a plurality of rings of flame to heat a utensil supported thereon. Such gas burners are generally secured on a cooktop surface by screws, and it is difficult to clean the cooktop surface around and between the burners. The inner burner is surrounded by the outer burner, and secondary-air cannot flow through the outer flame ring to enter the inner flame ring, such that the maximum energy output of the inner burner is undesirably limited unless a gap is provided either through or under the other burner. This further increases the difficulty of cleaning the cooktop.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, a gas burner assembly is provided for a cooking appliance that includes a cooktop surface. The gas burner assembly includes a first gas burner including a first burner body. The first burner configured to be mounted on, and contact, the cooktop surface, and provide a cooking flame. The gas burner assembly also includes a second gas burner including a second burner body. The second burner configured to be mounted on, and contact, the cooktop surface and to be concentric with the first burner and separated from the first burner by a distance at all points along the burners. The second burner body including at least one air passage defined therethrough that is configured to allow air to flow through the second burner and to the cooking flame.
In another aspect, a cooking appliance is provided that includes a cooking panel having a cooktop surface and at least one gas burner assembly mounted on the cooking panel. The gas burner assembly including a first gas burner mounted on the cooktop surface and including a first burner body. The first gas burner configured to provide a cooking flame. The gas burner assembly also includes a second gas burner contacting the cooktop surface and surrounding the first burner. The second burner including a second burner body having at least one passage defined therethrough. The passage configured to allow air to flow through the second burner and to the cooking flame. At least one of the first burner and the second burner configured to be removed from the cooktop without removal of the other of the first burner and the second burner.
In another aspect, a method is provided for assembling a cooking appliance. The method includes providing a cooking panel having a cooktop surface and mounting a first gas burner on, and in contact with, the cooktop surface. The first burner including a first burner body and configured to provide a cooking flame. The method further including mounting a second gas burner on, and in contact with, the cooktop surface such that the second gas burner surrounds the first burner and is separated from the first burner by a distance at all points along the burners. The second burner including a second burner body. The method further including defining at least one passage through the second burner body. The passage configured to allow air to flow through the second burner and to the cooking flame.
In another aspect, a cooking apparatus is provide that includes a cooktop surface and at least one gas burner assembly mounted on the cooktop surface. The gas burner assembly further including a gas simmer burner mounted on, and in contact with, the cooktop surface. The simmer burner includes a simmer burner body and it is configured to provide a cooking flame. The gas burner assembly further includes a second gas burner mounted on, and in contact with, the cooktop surface and concentric with the simmer burner. The second burner comprising a second burner body having at least one passage defined therethrough. The passage configured to allow air to flow through the second burner and to the cooking flame. Wherein the second burner configured to be removed from the cooktop surface without removal of the first burner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of an exemplary free-standing gas range;
FIG. 2 is an exemplary burner assembly applicable to the gas range shown in FIG. 1 ;
FIG. 3 is an exploded view of the burner assembly shown in FIG. 2 ; and
FIG. 4 is a cross sectional view of the burner assembly shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an exemplary free-standing gas range 10 in which the herein described apparatus and methods may be practiced. Range 10 includes an outer body or cabinet 12 that incorporates a generally rectangular cooktop 14 . An oven, not shown, is positioned below cooktop 14 and has a front-opening access door 16 . A range backsplash 18 extends upward from a rear edge 20 of cooktop 14 and contains various control selectors (not shown) for selecting operative features of heating elements for cooktop 14 and the oven.
Cooktop 14 includes four gas fueled burner assemblies 22 which are positioned in spaced apart pairs positioned adjacent each side of cooktop 14 . Each burner assembly 22 extends upward through an opening in cooktop 14 , and a grate 28 is positioned over each burner assembly 22 . Each grate 28 includes a horizontally extending support structure thereon for supporting cooking vessels.
Cooktop 14 also includes control devices, such as, knobs 32 , 34 , 36 , and 38 that are manipulated by a user to adjust the setting of a corresponding gas valve (not shown) to control the amount of heat output from the corresponding one of burner assemblies 22 . For example, rotating knob 32 in one direction switches the valve from off to the full on position. Continued rotation gradually moves the valve from the full open position to the minimum setting position. Accordingly, the user may adjust the heat output of the corresponding burner to the desired level.
It is contemplated that the herein described apparatus and methods are applicable, not only to cooktops which form the upper portion of a range, such as range 10 , but to other forms of cooktops as well, such as, but not limited to, cooktops that are mounted to a kitchen counter. Therefore, range 10 is provided by way of illustration rather than limitation, and accordingly there is no intention to limit application of the herein described apparatus and methods to any particular appliance or cooktop, such as range 10 or cooktop 14 . It is also to be understood that there can be any other number of burner assemblies or any combination of burner assemblies and other type of cooking surfaces, such as, grills and hot plates, included in cooktop 14 .
FIG. 2 is an exemplary burner assembly 50 applicable to gas range 10 shown in FIG. 1 , and FIG. 3 is an exploded view of burner assembly 50 shown in FIG. 2 . Burner assembly 50 is mounted on a cooktop surface 52 of a cooktop 54 , and includes a central simmer burner 60 , and an outer gas burner 62 concentric with simmer burner 60 . In the exemplary embodiment, cooktop 54 is fabricated from one of steel and glass, and cooktop surface 52 includes a first and a second mounting opening 64 , 66 for mounting simmer burner 60 and outer burner 62 thereon, respectively. Alternatively, cooktop 54 is made of other suitable materials.
Simmer burner 60 includes a simmer burner body 68 having a simmer burner chamber 70 defined therein, a central cap 72 for covering simmer burner body 68 , a plurality of ports 74 defined on an outer circumferential surface 76 of simmer burner body 68 , and a venturi 78 extending downward from simmer burner body 68 . Central cap 72 is substantially circular in shape, and is removably mounted on simmer burner body 68 for enclosing simmer burner chamber 70 therein. Removal of cap 72 also enables an operator to clean simmer burner chamber 70 . Ports 74 are in flow communication with simmer burner chamber 70 , and are shown in the form of slots in FIG. 3 . In alternative embodiments, ports 74 have shapes other than slots. Venturi 78 is in flow communication with simmer burner chamber 70 , and is inserted into mounting opening 64 . Venturi 78 includes a gas inlet 80 positioned beneath cooktop 54 for receiving gas from a gas supply (not shown) and channeling the gas into chamber 70 .
Outer gas burner 62 is separate from simmer burner 60 and surrounds simmer burner 60 therein. Outer burner 62 includes an outer burner body 82 having a ring-shaped outer burner chamber 84 defined therein, an outer cap 86 for covering outer burner body 82 , a first group of ports 88 and a second group of ports 90 defined thereon. A venturi 92 extends downward from outer burner body 82 . In alternative embodiments, at least one of burner bodies 82 , 84 have a shape other than ring-shaped.
Outer cap 86 is substantially ring-shaped, and is removably mounted on outer burner body 82 for enclosing outer burner chamber 84 therein. In alternative embodiments, outer cap 86 is other than ring shaped. First group of ports 88 are located on an inner circumferential surface 94 of outer burner body 82 , and second group of ports 90 are located on an outer circumferential surface 96 of outer burner body 82 . Both first group of ports 88 and second group of ports 90 are in flow communication with outer burner chamber 84 , and are illustrated as slots in FIG. 3 . However, in alternative embodiments, ports 88 , 90 have other shapes. Venturi 92 is also in flow communication with outer burner chamber 84 , and is inserted into mounting opening 66 . Venturi 92 includes a gas inlet 98 positioned beneath cooktop 54 for receiving the gas from the gas supply and channeling the gas into chamber 84 .
FIG. 4 is a cross sectional view of burner assembly 50 shown in FIG. 2 . In the exemplary embodiment, both simmer burner 60 and outer burner 62 are mounted on cooktop 54 without using screws. As such, simmer burner 60 and outer burner 62 are easily removed from cooktop by an operator's hands without using additional tools. This easy removal facilitates conveniently cleaning cooktop surface 52 beneath and around burners 60 , 62 . In a further exemplary embodiment, simmer burner 60 and outer burner 62 are not fastened onto cooktop 54 to facilitate even easier removal of burners 60 , 62 from cooktop 54 . In another embodiment, simmer burner 60 is fastened, or sealed, to cooktop 54 and outer burner 62 is not mounted to cooktop 54 with fasteners.
In the exemplary embodiment, simmer burner 60 is a sealed burner, and simmer burner body 68 includes a continuous and flat bottom surface 100 that contacts cooktop surface 52 . Surface 100 thus forms a substantially annulus seal surrounding mounting hole 64 . This seal restricts liquid and/or spillage collected on cooktop surface 52 from flowing therethrough and into an interior of cooktop 54 through mounting hole 64 . In alternative embodiments, simmer burner body 68 has other shapes and includes other structures known in the art to form a seal between the simmer burner 60 and cooktop surface 52 .
Outer burner 62 includes a bottom surface 102 and a plurality of passages 104 circumferentially defined on bottom surface 102 . Passages 104 are illustrated as slots in FIG. 4 , and are positioned above cooktop surface 52 . In alternative embodiments, the number of passages 104 is varied, and passage 104 has other shapes and is defined through outer burner body 82 at other positions for allowing air flow therethrough.
The gas supply (not shown) includes a plurality of gas conduits (not shown), a first orifice 106 and a second orifice 108 coupled in flow communication with the gas conduits and positioned beneath cooktop surface 52 . Orifices 106 , 108 face gas inlets 80 , 98 of venturis 78 , 92 and supply gas into burner chambers 70 , 84 , respectively. In alternative embodiments, gas is fed to each burner chamber 70 , 84 via multiple orifices.
In operation, simmer burner chamber 70 receives the primary-air from an underside of cooktop surface 52 . The primary-air beneath cooktop surface 52 mixes with the gas supplied via orifice 106 to form an air-gas mixture. The air-gas mixture flows through venturi 78 to simmer burner chamber 70 , and flows out from ports 74 defined on outer circumferential surface 76 of simmer burner body 68 . The air-gas mixture is ignited by an ignition source (not shown), such as a spark ignition electrode or a hot surface igniter, to generate an inner ring of flame 110 .
The primary-air beneath cooktop surface 52 also mixes with the gas supplied via orifice 106 to form an air-gas mixture. The air-gas mixture flows through venturi 92 to outer burner chamber 84 . The air-gas mixture also flows out from first and second group of ports 88 , 90 defined on inner and outer circumferential surfaces 94 , 96 of outer burner body 82 . The air-gas mixture exiting ports 88 is ignited to generate a middle ring of flame 112 , and the air-gas mixture exiting ports 90 is ignited to generate an outer ring of flame 114 .
Secondary-air above cooktop 54 flows towards outer flame ring 114 to complete combustion. The secondary-air above cooktop 54 also flows through passages 104 along direction A shown in FIG. 4 , and then to inner and middle flame rings 110 , 112 . The secondary-air flows below outer flame ring 114 , and into the interior of outer burner 62 to complete combustion of inner and middle flame rings 110 , 112 .
In the exemplary embodiment, outer burner 62 has a maximum energy output larger than a maximum energy output of simmer burner 60 . In addition, both simmer burner 60 and outer burner 62 are operable simultaneously when burner assembly 50 is operated at levels above a simmer range. Alternatively, only one of simmer burner 60 and outer burner 62 is operated during a particular cooking event such as, for example, when burner assembly 50 is operated within the simmer range. Specifically, when knob 32 (shown in FIG. 1 ) is moved to a position within the simmer range, outer burner 62 is de-energized, and simmer burner 60 is energized to a level indicated by a position of knob 32 . When knob 32 is turned from a low level to a high level, the energy output of simmer burner 60 increases to a higher rate, and outer burner 62 is ignited when knob 32 is turned to a level above the simmer range. When knob 32 is turned to an “off” position, both burners 60 , 62 are de-energized.
By allowing the secondary-air to flow through the underside of the outer burner and to the central burner, the central burner is able to reach a much higher energy output. In addition, the central and outer burners are removably mounted on the cooktop surface, which facilitates cleaning the cooktop surface beneath and around the burners.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A gas burner assembly for a cooking appliance that includes a cooktop surface includes a gas burner assembly having a first gas burner including a first burner body. The first burner configured to be mounted on, and contact, the cooktop surface, and provide a cooking flame. The gas burner assembly also includes a second gas burner including a second burner body. The second burner configured to be mounted on, and contact, the cooktop surface. The second burner also configured to be concentric with the first burner and separated from the first burner by a distance at all points along the burners. The second burner body including at least one air passage defined therethrough that is configured to allow air to flow through the second burner and to the cooking flame. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation, under 35 U.S.C. §120, of copending international application No. PCT/EP2014/065884, filed Jul. 24, 2014, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. 10 2013 012 489.1, filed Jul. 26, 2013; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a door handle system for a vehicle door, in particular for a vehicle door that can be moved automatically by way of a door adjusting motor.
[0004] In the case of modern (motor) vehicles, in particular passenger motor vehicles, the aim is usually to reduce the consumption of energy and in the case of internal combustion engines that are conventionally used to reduce the consumption of fuel. In addition to improving the drive technology itself (for example internal combustion engines and electric motors), it is frequently desired to decrease the air resistance of the vehicle. For this purpose, in part a vehicle outer surface that is closed as completely as possible and is virtually smooth is styled for the vehicle.
[0005] However, in the case of a large proportion of vehicles, in order to open the vehicle doors, door handles are used that are arranged in such a manner that they protrude in a handhold-like manner from the vehicle surface or are arranged above a grip recess that is formed in the vehicle surface. Door handles of this type disrupt both the vehicle surface as well as the aesthetic appearance of the vehicle and in addition offer an increased air resistance—in particular in the case of an additional grip recess being used.
[0006] U.S. Pat. No. 7,108,301 B2 and its counterpart European patent application EP 1 402 138 A1 describe covering the grip recess flush with the door handle by means of a flap so that the grip recess is advantageously hidden in an aerodynamic manner. This flap is provided with a sensor by means of which it is possible to detect in the immediate vicinity of the door handle the presence of the hand of the vehicle user who wants to operate the door handle. In the case that the hand is in the proximity of the door handle, the flap is automatically folded into the grip recess and the door handle is consequently revealed.
SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide a door handle which overcomes the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and which provides for an improved door handle system for a vehicle.
[0008] With the foregoing and other objects in view there is provided, in accordance with the invention, a door handle system for a vehicle door, the door handle system comprising:
[0009] a door handle having a rear side;
[0010] at least one flap for reversibly closing off a grip recess formed in the vehicle door and set back with respect to an outer surface of the vehicle door relative to the rear side of said door handle;
[0011] an adjusting device configured to pivot said at least one flap between a closed position that covers said grip recess and an opened position that reveals said grip recess;
[0012] a distance sensor at least in part disposed on said at least one flap or on one of a plurality of said flaps; and
[0013] a control and evaluating unit configured:
with reference to a first measuring signal output by said distance sensor in the closed position, to conclude that a vehicle user is approaching said at least one flap; to control said adjusting device so as to adjust said at least one flap into the opened position when detecting that the vehicle user is approaching said at least one flap; and to determine with reference to a second measuring signal output by said distance sensor in the opened position whether said door handle is being gripped by the vehicle user.
[0017] In other words, the door handle system in accordance with the invention comprises a door handle and at least one flap for reversibly closing off a grip recess that is set back with respect to the surface of the vehicle door in relation to the rear of the door handle. When the door handle is actuated in the appropriate manner, the hand of the vehicle user regularly grips in this grip recess. Furthermore, the door handle system comprises an adjusting device by means of which it is possible to pivot the one or each flap between a closed position that covers the grip recess and an opened position that reveals the grip recess. In addition, the door handle system comprises a distance sensor (also: proximity sensor) that is arranged at least in part on the flap or on at least one of the flaps. In other words—if the distance sensor comprises multiple parts—at least the part of the distance sensor that is sensitive to proximity is arranged on the flap. Furthermore, the door handle system comprises a control and evaluating unit that is configured so as to conclude with reference to a first measuring signal that is output by the distance sensor in the closed position that the vehicle user is approaching the one or each flap. In addition, the control and evaluating unit is configured so as to control the adjusting device for adjusting the one or each flap into the opened position when the approach is detected. In addition, in accordance with the invention, the control and evaluating unit is configured so as to determine with reference to a second measuring signal that is output in the opened position by the distance sensor whether the door handle has been gripped by the vehicle user, preferably by the hand of the vehicle user. In other words, the control and evaluating unit is configured in a first measuring mode in which the measuring region of the distance sensor, in other words the volume of space that is monitored by means of the distance sensor, is aligned towards the outer side of the vehicle, so as to monitor the surrounding area of the one or each flap for an approach by the vehicle user. In a second measuring mode, the measured region of the same distance sensor is aligned in an opposing direction into the grip recess in order to be able to detect whether the door handle is being gripped by the vehicle user.
[0018] This is in particular advantageous for the case that the vehicle door is a vehicle door that can be automatically adjusted by means of a door adjusting motor, said vehicle door preferably being used in conjunction with a so-called keyless entry function (keyless entry/keyless go function). In the case of this function, the vehicle lock that is allocated to the respective vehicle door is by way of example unlocked if the person that is approaching is carrying the (radio) key that is associated with the vehicle. The control and evaluating unit is in particular configured for the purpose of interpreting a gripping of the door handle as being the vehicle user's wish to open the door and consequently to output a door opening command to the door adjusting motor so as to adjust the vehicle door into its open position. As a consequence, it becomes easier to handle the vehicle door and consequently the operating comfort increases.
[0019] Advantageously, owing to the fact that the desire to open the door is identified automatically, the door handle can be embodied in such a manner that it does not move with respect to the vehicle door. A conventional unlocking mechanism that is coupled to the door handle for the vehicle door can consequently be omitted.
[0020] Moreover, by virtue of using the one or each flap for covering the grip recess, it is advantageously rendered possible to embody the vehicle surface as smooth, in particular from an aerodynamic point of view.
[0021] It is preferred that the control and evaluating unit is in addition configured so as in the opened position to detect that the door handle is no longer being gripped and furthermore to adjust the one or each flap back into its closed position. Optionally, the control and evaluating unit is furthermore expediently configured for the purpose of monitoring the grip recess merely for a predetermined time (by way of example 2 to 15 seconds) after opening the one or each flap in order to establish whether the door handle is being gripped. If it is detected in this period that the door handle is not being gripped, the control and evaluating unit is expediently configured so as to control the adjusting device so as to close the one or each flap. As a consequence, it is prevented in a simple manner that in the case of falsely detecting the approach (by way of example if the vehicle user passes the vehicle door in close proximity to the one or each flap) the one or each flap remains in its opened position until further notice.
[0022] In a preferred embodiment, the distance sensor is embodied as a capacitive distance sensor. In this case, the one or each flap supports in particular in each case a sensor electrode of the capacitive distance sensor. By way of example, the sensor electrode is integrated into the respective flap. In one embodiment that is expedient in terms of production technology, the flap is embodied for this purpose as a synthetic material injection molded part in which the sensor electrode is injection molded with synthetic material as an electrically conductive insert part.
[0023] In an alternative embodiment, the one or each flap itself forms in each case a sensor electrode of the capacitive distance sensor. This is in particular advantageous in the case in which the surface of the flap that is facing towards the outer side of the vehicle is embodied from an electrically conductive, in particular metal, basic material (by way of example sheet metal). This electrically conductive outer layer (in particular an electrically conductive paint layer) of the flap only needs in this case to make contact with the corresponding connection of the distance sensor. Alternatively, however, it is possible within the scope of the invention for the flap to be produced from a sufficiently electrically conductive synthetic material, by way of example injection molded. Embodying the flap as a sensor electrode offers the advantage that on the one hand the installation space that is taken up by the flap and the sensor electrode is particularly small and on the other hand, the entire (outer) surface of the flap can be used for sensing, whereby in turn the range of the distance sensor is increased.
[0024] In one embodiment, the one or each flap is pivoted in the opened position against the wall of the grip recess. The flap lies by way of example flush in the wall of the grip recess in or on said grip recess.
[0025] In an alternative embodiment, in the opened position the one or each flap is pivoted onto the rear side of the door handle. In this case, the hand of the vehicle user lies directly on the one or each flap when gripping the door handle so that the distance with respect to the sensitive part of the distance sensor, preferably in other words with respect to the capacitive sensor electrode, is minimal. In the case of the capacitive distance sensor, the sensor capacitance of the sensor electrode is preferably maximal so that it is possible in a simple manner to detect that the door handle is being gripped.
[0026] Within the scope of the invention, it is fundamentally possible that the door handle covers the grip recess in part in a strip-like manner from only one side, in particular from the upper side. In this case, it is only possible when actuated in the appropriate manner—when viewed in the vehicle vertical direction—to grip the door handle from one side (for example from below). In a preferred embodiment, the door handle is however embodied in such a manner that said door handle spans the grip recess in a bridge-like manner—preferably in the vehicle longitudinal direction. The door handle can be consequently gripped (in accordance with a type of handhold) from two sides. In the case of this embodiment of the door handle, the grip recess is closed in the closed position expediently on two sides (for example from above and below) in each case by a flap.
[0027] In an alternative embodiment of the invention, two flaps are arranged in each case on a side of the door handle and in the opened position one of said flaps is pivoted against the wall of the grip recess and the respective other flap is pivoted to the rear side of the door handle. The advantage of this embodiment is in particular that the flaps comprise a smaller flap surface (in comparison to a flap that covers the grip recess alone) and consequently it is possible in the opened position in a particularly simple manner to fit said flaps flush into the wall of the grip recess and into the rear side of the door handle. As a consequence, a virtually smooth and homogenous curve of the wall of the grip recess and in particular of the door handle is achieved in an advantageous manner. As a consequence, it is possible for the vehicle user when gripping the door handle to experience the door handle as virtually smooth, in other words without any protruding edges of the pivoted flap and as a consequence, said door handle can convey a significant operating feeling. In addition, for the case that each flap comprises a sensitive part of the distance sensor, preferably a capacitive sensor electrode, a particularly high level of adjustability of the measuring regions that are allocated in each case to the closed position and the opened position is achieved.
[0028] For the case that the door handle system comprises only one sensor electrode, the control and evaluating unit is expediently configured for the purpose of performing a measurement with the aid of this sensor electrode with respect to ground. In other words, the sensor capacitance of the capacitive distance sensor is determined between the sensor electrode and an object that is connected to ground and is arranged in the surrounding area of the sensor electrode. Within the scope of the invention, it is however also feasible that the control and evaluating unit in each case performs a measurement with respect to ground by means of multiple sensor electrodes.
[0029] For the case that the door handle system comprises multiple flaps and multiple sensor electrodes that are arranged on these flaps, these sensor electrodes are however interconnected in a preferred embodiment at least in the opened position in each case in pairs as a transmitting electrode and as a receiving electrode. It is possible in a particularly precise manner in comparison to a distance sensor that performs a measurement with respect to ground to set the measuring region of the distance sensor, said measuring region being covered by means of the measuring field between the transmitting- and receiving electrode. The “measuring field” is by way of example an alternating field that is generated by an electrical alternating voltage that is applied to the transmitting- and receiving electrode. The transmitting- and receiving electrode consequently form a sensor capacitor.
[0030] In a simple embodiment, the sensor electrodes are also controlled in pairs as sensor- and receiving electrodes in the folded out state, in other words when the flaps are in the closed position. Alternatively, the sensor electrodes are controlled in the closed position so as to perform a measurement with respect to ground.
[0031] In particular in the case that the grip recess is covered in the closed position on the two sides of the door handle in each case by means of the two flaps, the sensor electrodes are expediently controlled in the opened position in such a manner that the sensor electrodes that are arranged in each case on a side of the door handle in pairs are used as associated transmitting- and receiving electrodes. As a consequence, it can be precisely detected by means of the respective electrode pairs whether the door handle is being gripped on each side of the door handle in the grip recess. As a consequence, the reliability of detecting that the door handle is being gripped is increased. In particular, it can be detected in a particularly simple manner whether only one foreign body is protruding from only one side of the door handle into the grip recess or that the door handle is being gripped on both sides.
[0032] Within the scope of the invention, it is furthermore feasible that in addition to each sensor electrode that is arranged in or on each flap, a sensor electrode (“grip electrode”) is arranged in the door handle itself. This or each additional grip electrode cooperates in the opened position with in each case a sensor electrode that is arranged on the flaps in accordance with the transmitter-receiver principle.
[0033] In a further optional embodiment, the one or each sensor electrode is segmented in the vehicle longitudinal direction so that it is possible to determine by means of the control and evaluating unit a movement direction of the vehicle user or at least the hand of said vehicle user. In this case, the control and evaluating unit is preferably configured so as in addition to identifying that the vehicle user is approaching the door handle approximately from the front (in other words approximately in the normal direction to the outer side of the door) to also identify a stroke over the one or each flap in the vehicle longitudinal direction and evaluate this stroke as different to the frontal approach. By way of example, the measuring signals that are output by the segments of the sensor electrode are evaluated in dependence upon time. If the changes in the sensor capacitances that are measured by means of the respective segments comprise at least one predetermined temporal offset, the control and evaluating unit concludes that a stroke over the segments has occurred in the longitudinal direction. Otherwise, the control and evaluating unit concludes that a frontal approach has occurred.
[0034] In particular, it is provided that a stroke over the one or each flap is to be interpreted in dependence upon the direction as a locking or unlocking command for the vehicle door, in particular for the central locking of the vehicle. In other words, the one or each flap is pivoted into the opened position in the case of a frontal approach to the door handle while the vehicle door is locked if the vehicle user strokes the one or each flap by way of example in the direction of the door lock of the respective vehicle door.
[0035] In a further embodiment, the control and evaluating unit is configured for the purpose of activating an illuminating device of the vehicle when detecting that the vehicle user is approaching the one or each flap. An illuminating device of this type is in particular the headlight of the vehicle, in particular circumstances it is the “parking” light or the “low beam” light. Alternatively however, the illuminating device can also be a light source that is arranged on the vehicle door or on the door handle and that when activated illuminates the area of the vehicle door or the grip recess.
[0036] In a further embodiment, the control and evaluating unit is configured so as when detecting that the vehicle user is approaching the one or each flap to control a window regulator that is allocated to an adjustable window pane of the vehicle door. This is in particular advantageous in the case of using so-called frameless vehicle doors, by way of example in the case of convertibles or coupes. In this case, namely when opening the vehicle door, the window pane is opened along a small part of its adjustment path with respect to its closed position so that the window pane cannot clamp in its window pane seal that is arranged on the fixed vehicle frame. The control and evaluating unit is expediently configured for the purpose of lowering the window pane of the vehicle door by this predetermined part of the adjustment path in addition to opening the one or each flap. In particular, in the case of a wire-actuated window regulator it can be provided alternatively to control the window regulator merely so as to tension the wire without lowering the window pane.
[0037] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0038] Although the invention is illustrated and described herein as embodied in a door handle system for a vehicle door, 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.
[0039] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0040] FIG. 1 illustrates in a schematic side view a vehicle door having a door handle module;
[0041] FIG. 2 illustrates in a schematic sectional view the door handle system in a closed position, wherein the one grip recess that is arranged to the rear of the door handle is closed off by means of two flaps with respect to the vehicle outer side;
[0042] FIG. 3 illustrates in accordance with FIG. 2 the door handle system in an opened position, wherein the flaps are pivoted inwards so as to reveal the grip recess; and
[0043] FIGS. 4 to 10 illustrate in a view in accordance with FIG. 2 various exemplary embodiments of the door handle system in the closed position or in the opened position.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown an exemplary vehicle door 1 having a door handle system 2 that is arranged thereon. The vehicle door 1 is a frameless door that does not comprise a window frame that delimits the side window of the vehicle with respect to the upper side, the side window being arranged on the vehicle door 1 . A vehicle door 1 of this type is used by way of example in the case of convertibles or coupes. The door handle system 2 comprises a door handle 3 that is aligned in the vehicle longitudinal direction 4 and spans a grip recess 6 that is formed in the outer surface 5 of the vehicle door 1 .
[0045] In order on the one hand to embody the outer surface 5 of the vehicle door 1 as smooth and therefore to improve the aerodynamic characteristics of the vehicle, the grip recess 6 is closed off with respect to the outer side by means of two flaps 12 and 14 in a closed position 10 that is illustrated in FIG. 2 . The flap 12 is arranged above the door handle 3 in relation to the vehicle longitudinal direction 4 . The flap 14 is accordingly arranged below the door handle 3 . The door handle system 2 furthermore comprises an adjusting device by means of which the flaps 12 and 14 can be automatically adjusted between the closed position 10 that is illustrated in FIG. 2 and an opened position 16 that is illustrated in FIG. 3 . In each case, of the adjusting device, only the adjusting lever 18 that is allocated to the flap 12 or 14 is illustrated for purposes of clarity.
[0046] In an alternative embodiment, the door handle 3 and also the flaps 12 and 14 can also be arranged vertically on the vehicle door 1 . Such an arrangement of the door handle 3 (and the flaps 12 and 14 ) is in particular provided for the case that the vehicle door 1 is the tailgate of the vehicle.
[0047] In addition, the door handle system 2 comprises a capacitive distance sensor and also a control and evaluating unit that is not further illustrated. The control and evaluating unit is configured and provided for the purpose of detecting by means of the capacitive distance sensor the vehicle user approaching the door handle 3 and furthermore to control the adjusting device so as to adjust the flaps 12 and 14 from the closed position 10 into the opened position 16 . A capacitive sensor electrode 20 or 22 of the distance sensor is integrated in each case in each flap 12 or 14 . The sensor electrodes 20 and 22 cooperate together as a transmitting- and a receiving electrode so that in the closed position 10 , a roughly horseshoe-shaped measuring field 24 spreads out towards the outer side of the vehicle door 1 (cf. FIG. 2 ). The measuring region that is covered by the measuring field 24 is consequently in front of the door handle 3 . The measuring field 24 is generated as an electrical alternating field by means of applying an electrical alternating voltage to the sensor electrodes 20 and 22 . The sensor electrodes 20 and 22 consequently form a sensor capacitor whose sensor capacitance is detected by the control and evaluating unit.
[0048] FIG. 3 illustrates the arrangement of the flaps 12 and 14 in their opened position 16 . The flaps 12 and 14 are pivoted onto the inner side of the grip recess 6 , in other words against the wall 30 of the grip recess 6 . The alternating field (described as recess measuring field 31 ) that is generated in the opened position 16 between the electrodes 20 and 22 extends in the opened position 16 approximately in a linear manner between the electrodes 20 and 22 and consequently extends in a transverse manner over the interior space (of the grip recess 6 ) that is delimited by a wall 30 of the grip recess 6 . In the opened position 16 , in other words the measuring region that is covered by the recess measuring field 31 is located within the grip recess 6 and to the rear of the door handle 3 .
[0049] A guard electrode 32 is arranged in the door handle 3 , said guard electrode being connected to ground potential and configured and provided so as to shield the recess measuring field 31 in the opened position 16 with respect to influences from outside the grip recess 6 . The shielding electrode 32 also prevents the presence or a movement of the vehicle user being detected outside the grip recess 6 by the distance sensor (that comprises the sensor electrodes 20 and 22 ).
[0050] The control and evaluating unit of the door handle system 2 is configured so as within the scope of a door opening method when the vehicle door 1 is in the closed state to monitor the immediate surrounding area of the door handle 3 for an approaching person (in short, the vehicle user) by means of the sensor electrodes 20 and 22 arranged in the closed position 10 . If the vehicle user is located in the measuring field 24 , the sensor capacitance of the sensor electrodes 20 and 22 is altered. This change in the sensor capacitance is registered by means of the control and evaluating unit. In this case, the control and evaluating unit controls the adjusting device so as to open the flaps 12 and 14 into the opened position 16 so that the vehicle user can grip in the grip recess 6 and grip around the door handle 3 . In the opened position 16 of the flaps 12 and 14 , the control and evaluating unit monitors by means of the recess measuring field 31 whether the hand of the vehicle user is located in the grip recess 6 . A change in the sensor capacitance in the opened position 16 by a predetermined value is indicative of the door handle 3 being gripped by means of the hand of the vehicle user. The control and evaluating unit interprets such a change in the sensor capacitance as the vehicle user wishing to open the door and furthermore outputs a door opening signal to the door adjusting motor of the vehicle door 1 .
[0051] In order to prevent that the flaps 12 and 14 remain open in the case of the door handle 3 not being gripped for an undetermined period of time, the control and evaluating unit is configured so as to monitor the grip recess 6 after opening the flaps 12 and 14 only during a predetermined waiting time, by way of example during 10 seconds, for whether the door handle 3 has been gripped. If the waiting time expires without event, in other words without it being registered that the door handle 3 is being gripped, the control and evaluating unit controls the adjusting device so as to close the flaps 12 and 14 .
[0052] The case that the sensor capacitance (in the case of the flaps 12 and 14 being in the opened position 16 ) returns to its idle value (in the absence of the hand in the grip recess 6 ) is interpreted by the control and evaluating unit as an indication that the vehicle user has let go of the door handle 3 . In this case, the control and evaluating unit likewise controls the adjusting device so as to close the flaps 12 and 14 .
[0053] FIG. 4 and FIG. 5 illustrate an alternative exemplary embodiment of the door handle system 2 , wherein the sensor electrodes 20 and 22 are controlled in the closed position 10 in such a manner that a distance measurement can be performed with respect to ground by means of each sensor electrode 20 or 22 . This is indicated in FIG. 4 in an exemplary manner by means in each case of field lines 34 that extend from each sensor electrode 20 or 22 and are indicated by way of example in a linear manner. In this measuring mode, each sensor electrode 20 or 22 consequently forms a sensor capacitor with the nearest grounded object that is arranged in the surrounding area of the vehicle. In the opened position 16 , the sensor electrodes 20 and 22 are in turn controlled as transmitting- and receiving electrodes so that the distance sensor can be used according to the exemplary embodiment in accordance with FIGS. 2 and 3 (cf FIG. 5 ).
[0054] In accordance with a further alternative exemplary embodiment that is illustrated in FIG. 6 , in addition two further sensor electrodes (described as “grip electrodes 40 and 42 ”) are arranged in the door handle 3 . The distance sensor in this exemplary embodiment is configured so as in the opened position 16 to control the sensor electrode 20 and the grip electrode 40 and also the sensor electrode 22 and the grip electrode 42 in each case in pairs as transmitting- and receiving electrodes. As a consequence, in the opened position 16 , the sensor electrode 20 and the grip electrode 40 and also the sensor electrode 22 and the grip electrode 42 form in each case a sensor capacitor having a respective allocated recess measuring field 44 or 46 . It is possible by means of controlling the sensor electrodes 20 and 40 or 22 and 42 to separately detect that the grip recess 6 is being gripped on each side of the door handle 3 by means of the respective allocated electrode pair.
[0055] In a further exemplary embodiment in accordance with FIGS. 7 and 8 , the flaps 12 and 14 are hinged on the door handle 3 in such a manner that they can pivot so that the flaps 12 and 14 are folded in the opened position 16 onto the rear side of the door handle 3 . The flaps 12 and 14 form a part of the surface of the door handle 3 , said part of the surface of the door handle facing the grip recess 6 . The recess measuring field 31 of the sensor electrodes 20 and 22 extends in the illustrated exemplary embodiment in the opened position 16 approximately in a U-shape and thereby approximately parallel to the wall 30 of the grip recess 6 .
[0056] In a further alternative exemplary embodiment in accordance with FIGS. 9 and 10 , the grip recess 6 is closed in the closed position 10 on the two sides of the door handle 3 by means of in each case two flaps. In each case, one of the flaps (hereinunder described as the upper recess flap 50 and the lower recess flap 52 ) can be pivoted onto the grip recess 6 so that the upper and the lower recess flap 50 or 52 in the opened position 16 lie against the wall 30 of the grip recess 6 . The two other flaps are described hereinunder as the upper grip flap 54 and lower grip flap 56 and are pivoted in the opened position 16 onto the rear side of the door handle 3 (cf. FIG. 10 ). A sensor electrode of the distance sensor is arranged in each case on the recess flaps 50 and 52 and the grip flaps 54 and 56 .
[0057] As is illustrated in FIG. 9 , the sensor electrodes are controlled in the closed position 10 in such a manner that the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 form a common upper electrode. The sensor electrodes of the lower recess flap 52 and the lower grip flap 56 are controlled in a similar manner and consequently form a common lower electrode. The upper electrode and the lower electrode are controlled in a manner that can be compared to the exemplary embodiment in accordance with FIG. 2 as a transmitting- and receiving electrode and form the horseshoe-shaped measuring field 24 with respect to the outer side of the door handle 3 .
[0058] In the opened position 16 (cf. FIG. 10 ), the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 and also the sensor electrodes of the lower recess flap 52 and the lower grip flap 56 in contrast are controlled in pairs as transmitting- and receiving electrodes. Consequently, a measuring field 60 is formed between the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 and a measuring field 62 is formed between the sensor electrodes of the lower recess flap 52 and the lower grip flap 56 . The control and evaluating unit can be configured in a manner comparable to the exemplary embodiment in accordance with FIG. 6 so as to detect that the door handle 3 is being gripped.
[0059] In an alternative (not further illustrated) exemplary embodiment, the control and evaluating unit is configured so as in the opened position 16 to control the sensor electrodes of the recess- and grip flaps 50 to 56 in an alternating manner. In a first step, the sensor electrodes are controlled in accordance with the exemplary embodiment in accordance with FIG. 10 . In a second step, in contrast the sensor electrodes of the recess flaps 50 and 52 are switched off. The sensor electrodes of the grip flaps 54 and 56 are then controlled as transmitting- and receiving electrodes. This second control corresponds essentially to the exemplary embodiment in accordance with FIG. 8 . It is possible by means of controlling the sensor electrodes in an alternating manner to detect in a particularly precise manner that the door handle 3 is being gripped on all sides and the reliability of the door handle system 1 is thereby increased.
[0060] The subject matter of the invention is not limited to the above-described exemplary embodiments. On the contrary, further exemplary embodiments of the invention can be derived by the person skilled in the art from the above description. In particular, the individual features of the invention that are described with reference to the various exemplary embodiments and their embodiment variants can also be combined with one another in other ways.
[0061] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
1 Vehicle door 2 Door handle system 3 Door handle 4 Vehicle longitudinal direction 5 Outer surface 6 Grip recess 10 Closed position 12 Flap 14 Flap 16 Opened position 18 Adjusting lever 20 Sensor electrode 22 Sensor electrode 24 Measuring field 30 Wall 31 Recess measuring field 32 Guard electrode 34 Field line 40 Grip electrode 42 Grip electrode 44 Recess measuring field 46 Recess measuring field 50 Upper recess flap 52 Lower recess flap 54 Upper grip flap 56 Lower grip flap 60 Measuring field 62 Measuring field | A door handle system for a vehicle door has a door handle and at least one flap for reversibly closing a grip recess set back to the rear of the door handle. An actuating device pivots the one or more flaps between a closed position that covers the handle recess and an open position that exposes the handle recess. A distance sensor is disposed on the flap. A control and evaluation unit uses a first measurement signal that is output by the distance sensor in the closed position, to deduce that a vehicle user is approaching so as to activate the actuation device to move the one or each flap into the open position. A second measurement signal that is output by the distance sensor in the open position indicates that the door handle is grasped by the vehicle user. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Phase Application under 35 U.S.C. 371 of International Application No. PCT/JP2014/076495, filed on Oct. 3, 2014 and published in Japanese as WO 2015/053170 A1 on Apr. 16, 2015. This application claims priority to Japanese Patent Application No. 2013-212658, filed on Oct. 10, 2013. The entire disclosures of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a sealing device, and more particularly relates to a sealing device in which a screw achieving a fluid pumping action is provided in a sliding portion of a seal lip. The sealing device according to the present invention is used, for example, in an automobile-related field, or used in a field of a general purpose machine.
[0004] 2. Description of the Conventional Art
[0005] There has been conventionally known a sealing device in which a screw achieving a pumping action applied to a sealed fluid is provided in an atmosphere side lateral face of a seal lip sliding portion for improving a sealing performance in relation to the sealed fluid such as an oil. In the case that the other sliding member (hereinafter, refer simply to a shaft) such as a rotary shaft rotates in both forward and reverse directions, a bidirectional screw 53 is provided in an atmosphere side lateral face 52 of a sliding portion of a seal lip 51 , as shown in FIG. 5 .
[0006] The bidirectional screw 53 is structured by circumferentially and alternately lining up and arranging forward direction screws 54 which achieve a sealing function based on a pumping action when the shaft rotates in a forward direction (an arrow C), and reverse direction screws 55 which achieve the sealing function based on the pumping action when the shaft rotates in a reverse direction, one by one, or several by several, or several tens by several tens. Each of the screws 54 and 55 is formed into a so-called parallel screw in which its longitudinally perpendicular cross sectional shape (including a screw height and a screw width) is formed uniformly over a whole length of the screw.
[0007] The prior art described above can achieve an excellent sealing performance on the basis of the pumping action of each of the screws 54 and 55 , however, since each of the screws 54 and 55 is formed as the parallel screw as mentioned above, there is a problem that the pumping action is lowered in the case that wear caused by the sliding motion makes progress.
[0008] In order to countermeasure the problem mentioned above, it can be thought that each of the forward direction screw 54 and the reverse direction screw 55 is formed into a ship bottom-like screw in place of the parallel screw, as shown in FIG. 6 which shows a comparative example with the present invention. Since the ship bottom-like screw is provide with a shape that a screw height is enlarged little by little from a lip leading end 56 toward an atmosphere side B, the screw height thereof is hard to be lowered even if the wear makes progress. Accordingly, the pumping action is hard to be lowered.
[0009] However, even in the case that each of the forward direction screw 54 and the reverse direction screw 55 is formed into the ship bottom-like screw as mentioned above, sealed fluid may leak by spray from the screws 54 and 55 . In order to suppress the leak by spray from the screws 54 and 55 , an additional countermeasure is necessary.
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
[0010] The present invention is made by taking the above points into consideration, and an object of the present invention is to provide a sealing device having forward direction screws and reverse direction screws achieving a fluid pumping action provided in a sliding portion of a seal lip, wherein the pumping action is hard to be lowered even if wear of the screws makes progress, and leak by spray from the screws can be suppressed.
Means for Solving the Problem
[0011] In order to achieve the object mentioned above, in a sealing device according to claim 1 of the present invention, forward direction screws and reverse direction screws achieving a pumping action in relation to a sealed fluid are circumferentially provided in line in an atmosphere side lateral face of a seal lip sliding portion, each of the forward direction screws and the reverse direction screws has such a shape that a screw height is enlarged little by little from a lip leading end toward an atmosphere side, and a seal projection for preventing leak by spray is provided in any one or both of the forward direction screws and the reverse direction screws.
[0012] Further, a sealing device according to claim 2 of the present invention is the sealing device described in claim 1 mentioned above, wherein the seal projection is provided associated with the reverse direction screw, and is extended from the reverse direction screw toward an opposite side to a forward rotating direction of the shaft.
[0013] In the sealing device according to the present invention having the structure mentioned above, each of the forward direction screws and the reverse direction screws has such a shape that the screw height is enlarged little by little from the lip leading end toward the atmosphere side, that is, a corresponding to the ship bottom-like screw can be obtained. Accordingly, the screw height is hard to be lowered even if the wear makes progress. As a result, the pumping action is hard to be lowered. Further, the seal projection for preventing the leak by spray is provided in any one or both of the forward direction screws and the reverse direction screws. Therefore, the seal projection acts as a dam against the leak by spray of the seal fluid. As a result, it is possible to reduce an amount of the leak by spray.
[0014] The seal projection for preventing the leak by spray is provided in any one or both of the forward direction screw and the reverse direction screw as mentioned above. However, in the case that the shaft normally rotates forward, the seal projection for preventing the leak by spray is preferably provided associated with the reverse direction screw. In this case, the seal projection is extended from the reverse direction screw toward an opposite side to the forward rotating direction of the shaft.
Effect of the Invention
[0015] The present invention achieves the following effects.
[0016] More specifically, in the present invention, each of the forward direction screws and the reverse direction screws has such a shape that the screw height is enlarged little by little from the lip leading end toward the atmosphere side, as mentioned above. Accordingly, the screw height is hard to be lowered even if the wear makes progress, and the pumping action is hard to be lowered. Further, the seal projection for preventing the leak by spray is provided in any one or both of the forward direction screws and the reverse direction screws. Therefore, the seal projection acts as a dam against the leak by spray of the seal fluid. As a result, it is possible to reduce an amount of the leak by spray. Therefore, it is possible to provide the sealing device in which the pumping action is hard to be lowered even if the wear of the screw makes progress, and the leak by spray from the screw can be suppressed.
BRIEF EXPLANATION OF THE DRAWINGS
[0017] FIG. 1 is a half cut cross sectional view of a sealing device according to a first embodiment of the present invention;
[0018] FIG. 2 is an enlarged view of a substantial part in FIG. 1 ;
[0019] FIG. 3 is a front elevational view of a substantial part of a sealing device according to a second embodiment of the present invention
[0020] FIG. 4 is a cross sectional view of a substantial part of a sealing device according to a third embodiment of the present invention
[0021] FIG. 5 is a half cut cross sectional view of a sealing device according to the prior art; and
[0022] FIG. 6 is a half cut cross sectional view of a sealing device according to a comparative example.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] The case that the forward direction screws and the reverse direction screws are circumferentially and alternately provided is included in “forward direction screws and reverse direction screws are circumferentially provided in line” described in claim 1 mentioned above in the present invention. Further, the case that forward direction screws and the reverse direction screws are circumferentially provided half circumference by half circumference (the forward direction screws are circumferentially provided over one half circumference and the reverse direction screws are circumferentially provided over the other half circumference is also included in “forward direction screws and reverse direction screws are circumferentially provided in line” described in claim 1 mentioned above in the present invention.
Embodiments
[0024] Next, a description will be given of embodiments according to the present invention with reference to the accompanying drawings.
First Embodiment
[0025] FIG. 1 shows a half cut cross section of a sealing device (an oil seal) 1 according to a first embodiment of the present invention. FIG. 2 shows a substantial part in FIG. 1 in an enlarged manner. The sealing device 1 according to the embodiment is a bidirectional rotation seal corresponding to rotation in both forward and reverse directions of a shaft (the other member which is not shown), and is structured as follows.
[0026] More specifically, as shown in FIG. 1 , there is provided a seal lip (a main lip) 7 which slidably comes into close contact with a peripheral surface of the shaft together with an outer peripheral seal portion 4 , an end face cover portion 5 and a dust lip (a sub lip) 6 by a rubber-like elastic body 3 attached (vulcanization bonded) to a metal ring 2 , and a leading end sliding portion of the seal lip 7 is provided with a sealed fluid side lateral face (an inclined surface) 8 and an atmosphere side lateral face (an inclined surface) 9 . Reference numeral 10 denotes a lip leading end where both the lateral faces 8 and 9 intersect, and is formed as a pointed end.
[0027] The atmosphere side lateral face 9 in both the lateral faces 8 and 9 of the seal lip 7 is provided with a forward direction screw (a forward screw portion) 11 which achieves a sealing function by pushing back sealed fluid to a sealed fluid side A on the basis of a pumping action when the shaft rotates in a forward direction (rotates forward as shown by an arrow C), and is provided with a reverse direction screw (a reverse screw portion) 21 which achieves the sealing function by pushing back the sealed fluid to the sealed fluid side A on the basis of the pumping action when the shaft rotates in a reverse direction (rotates reverse). The forward direction screws 11 and the reverse direction screws 21 are circumferentially provided half circumference by half circumference, and a changing portion between the forward direction screws 11 and the reverse direction screws 21 is shown in the drawing.
[0028] As shown in FIG. 2 in an enlarged manner, the forward direction screw 11 is constructed by a spiral projection. A direction of the spiral is set to a direction which is inclined forward in a forward rotating direction C of the shaft from its atmosphere side end portion 11 a toward a sealed fluid side end portion 11 b. Further, the forward direction screw 11 is structured such that a parallel screw 12 starting from the lip leading end 10 and a ship bottom-like screw 13 connecting thereto are integrally provided.
[0029] The parallel screw 12 is formed so that a longitudinally perpendicular cross sectional shape thereof (including a screw height and a screw width) is uniform over a whole length of the screw, and the ship bottom-like screw 13 is provided with such a shape that a longitudinally perpendicular cross section thereof (including a screw height and a screw width) is enlarged little by little from the lip leading end 10 side (the sealed fluid side A) toward the atmosphere side B. Since the minimum height of the ship bottom-like screw 13 is set to be identical to the height of the parallel screw 12 , the maximum height of the ship bottom-like screw 13 is set to be larger than the height of the parallel screw 12 . Each of the longitudinally perpendicular cross sections of the parallel screw 12 and the ship bottom-like screw 13 is formed into a triangular shape or an approximately triangular shape.
[0030] On the other hand, the reverse direction screw 21 is also constructed by a spiral projection. A direction of the spiral is set to a direction which is inclined rearward in the forward rotating direction C of the shaft from its atmosphere side end portion 21 a toward a sealed fluid side end portion 21 b . Further, the reverse direction screw 21 is structured such that a parallel screw 22 starting from the lip leading end 10 and a ship bottom-like screw 23 connecting thereto are integrally provided.
[0031] The parallel screw 22 is formed so that a longitudinally perpendicular cross sectional shape thereof (including a screw height and a screw width) is uniform over a whole length of the screw, and the ship bottom-like screw 23 is provided with such a shape that a longitudinally perpendicular cross section thereof (including a screw height and a screw width) is enlarged little by little from the lip leading end 10 side (the sealed fluid side A) toward the atmosphere side B. Since the minimum height of the ship bottom-like screw 23 is set to be identical to the height of the parallel screw 22 , the maximum height of the ship bottom-like screw 23 is set to be larger than the height of the parallel screw 22 . Each of the longitudinally perpendicular cross sections of the parallel screw 22 and the ship bottom-like screw 23 is formed into a triangular shape or an approximately triangular shape.
[0032] Further, a seal projection 31 for preventing leak by spray is provided as a particularly characteristic structure of the present invention, and the seal projection 31 is provided associated with the reverse direction screw 21 in the embodiment, and is extended toward an opposite side to the forward rotating direction C of the shaft from the reverse direction screw 21 .
[0033] The seal projection 31 is structured as follows.
[0034] In the seal projection 31 , a base end portion 31 a thereof is connected to the ship bottom-like screw 23 of the reverse direction screw 21 , that is, is connected to a halfway position in a longitudinal direction of the ship bottom-like screw 23 .
[0035] The seal projection 31 is constructed by a spiral projection, and a direction of the spiral is set to a direction which is inclined rearward in the forward rotating direction C of the shaft from its base end portion 31 a toward a leading end portion 31 b. Therefore, the seal projection 31 is inclined in the same direction as the ship bottom-like screw 23 or the reverse direction screw 21 to which the seal projection 31 is connected, however, an angle of incline in relation to the lip leading end 10 is set to be smaller than the ship bottom-like screw 23 or the reverse direction screw 21 . The seal projection 31 may be extended in a circumferential direction of the sealing device 1 , and the direction of the spiral may be a direction which is inclined forward in the forward rotating direction C of the shaft from the leading end portion 31 b toward the base end portion 31 a a little.
[0036] The seal projection 31 is formed so that a longitudinally perpendicular cross sectional shape (including a projection height and a projection width) thereof is uniform over a whole length of the projection, in the same manner as the parallel screw 22 . Further, a height thereof is formed to be smaller than the height (the maximum height) of the ship bottom-like screw 23 , and is set to be identical or approximately identical to the height of the parallel screw 22 and the minimum height of the ship bottom-like screw 23 . Further, the longitudinally perpendicular cross sectional shape is formed into a triangular shape or an approximately triangular shape.
[0037] The height of the seal projection 31 is formed to be smaller than the height (the maximum height) of the ship bottom-like screw 23 because the ship bottom-like screw 23 does not come into contact with the surface of the shaft if the height of the seal projection 31 is made larger than the ship bottom-like screw 23 , whereby the pumping function can not be achieved. Thus, the ship bottom-like screw 23 can be brought into contact with the shaft surface by forming the height of the seal projection 31 smaller than the height (the maximum height) of the ship bottom-like screw 23 . As a result, it is possible to make the ship bottom-like screw 23 achieve the pumping function.
[0038] Further, the height of the seal projection 31 is set to be identical or approximately identical to the height of the parallel screw 22 because the parallel screw 22 does not come into contact with the shaft surface if the height of the seal projection 31 is made larger than the parallel screw 22 , whereby the pumping function can not be achieved. On the contrary, in the case that the height is made smaller than the parallel screw 22 , the pumping function of the parallel screw 22 is not obstructed, however, the effect of suppressing the leak by spray by the seal projection 31 becomes small. Thus, the parallel screw 22 can be brought into contact with the shaft surface by setting the height of the seal projection 31 to be identical or approximately identical to the height of the parallel screw 22 . As a result, it is possible to make the parallel screw 22 achieve the pumping function, and it is possible to achieve the effect of suppressing the leak by spray by the seal projection 31 .
[0039] Two seal projections 31 are provided in parallel each other to every one reverse direction screw 21 . However, the number of the seal projection 31 may be one or plural number equal to or more than three.
[0040] The sealing device 1 having the structure mentioned above is installed, for example, to an inner periphery of a shaft hole of a housing, and is structured such as to seal the sealed fluid within the machine so as to prevent the sealed fluid from leaking out to an outside of the machine by the seal lip 7 slidably coming into close contact with the peripheral surface of the shaft inserting into the shaft hole. The sealing device is structured as both rotation seal in correspondence to the rotation of the shaft in both the forward and reverse directions as mentioned above, and is characterized by a point that the following operations and effects can be achieved by the structure mentioned above.
[0041] More specifically, in the sealing device 1 having the structure mentioned above, since the forward direction screw 11 and the reverse direction screw 21 are respectively provided with the ship bottom-like screws 13 and 23 which are formed into the shapes that the screw heights are enlarged little by little from the lip leading end 10 toward the atmosphere side B, the screw height is hard to be lowered even if the wear makes progress together with the sliding motion with the shaft. Accordingly, the pumping action is hard to be lowered.
[0042] Further, since the seal projection 31 is extended from the reverse direction screw 21 toward the opposite side to the forward rotating direction C of the shaft associated with the reverse direction screw 21 , the seal projection 31 acts as a damp against the leak by spray of the sealed fluid. As a result, it is possible to reduce an amount of the leak by spray. The spray of the sealed fluid is created, for example, by a part of the fluid which is pushed back to the lip leading end 10 by the forward direction screw 11 achieving the pumping action, the part of the fluid flying in all directions to the atmosphere side B due to a centrifugal force when the shaft forward rotates (an arrow D). Since the seal projection 31 is provided at a position receiving the spray, it is possible to effectively suppress generation of the leak by spray. Further, since the seal projection 31 acts as the dam, an effect of inhibiting the dusts from entering from the atmosphere side B can be expected.
[0043] In the embodiment mentioned above, the seal projection 31 is extended from the reverse direction screw 21 toward the opposite side to the forward rotating direction C of the shaft associated with the reverse direction screw 21 so that the seal projection 31 acts as the damp when the shaft forward rotates. However, in the case of making the seal projection 31 act as the dam when the shaft reverse rotates, the seal projection 31 may be provided so as to extend from the forward direction screw 11 toward the forward rotating direction C associated with the forward direction screw. Further, the structure may be made such as to be provided with both the seal projection 31 which is extended from the reverse direction screw 21 toward the opposite side to the forward rotating direction C associated with the reverse direction screw 21 , and the seal projection 31 which is extended from the forward direction screw 11 toward the forward rotating direction C of the shaft associated with the forward direction screw 11 , so as to respectively correspond to the bidirectional rotation of the shaft.
[0044] Further, in the embodiment mentioned above, the seal projection 31 is provided to be branched from the reverse direction screw 21 or the forward direction screw 11 , however, it can be thought that the seal projection 31 is provided so as to be embedded at a halfway position in the longitudinal direction of the reverse direction screw 21 or the forward direction screw 11 .
Second Embodiment
[0045] FIG. 3 shows an example in which the seal projection 31 is provided so as to be embedded at the halfway position in the longitudinal direction of the reverse direction screw 21 , that is, the seal projection 31 is provided between the parallel screw 22 and the ship bottom-like screw 23 in the reverse direction screw 21 .
Third Embodiment
[0046] Further, FIG. 4 shows an example in which the seal projection 31 is provided so as to be embedded at the halfway position in the longitudinal direction of the reverse direction screw 21 , that is, the seal projection 31 is provided between the parallel screw 22 and the ship bottom-like screw 23 in the reverse direction screw 21 . Further, at the same time, the seal projection 31 is provided so as to be embedded at the halfway position in the longitudinal direction of the forward direction screw 11 , that is, the seal projection 31 is provided between the parallel screw 12 and the ship bottom-like screw 13 in the forward direction screw 11 .
[0047] According to the second and third embodiments mentioned above, each of the screws 11 and 21 is formed into a crank-like bent shape as well as the same operations and effects as those of the first embodiment can be achieved. Therefore, a circumferential space per one screw can be made smaller. As a result, more number of screws can be lined up circumferentially at this degree, and it is possible to enhance the pumping action and the sealing function achieved by the screws. Further, since the seal projection 31 acts as the dam as mentioned above, the dam can inhibit the dusts from entering from the atmosphere side B. | The purpose of the present invention is to provide a sealing device which has forward and reverse screw threads exhibiting a fluid-pumping action provided on a sliding portion of a seal lip, such that the pumping action is less susceptible to deterioration even with increasing wear on the screw threads and such that leakage of droplets from the screw threads is minimized. To achieve this, the forward and reverse screw threads which exhibit a pumping action on sealing fluid are arranged in a circle on the air-side lateral surface of the sliding portion of the seal lip. The forward and reverse screw threads each have a shape gradually increasing in thread height from the leading end of the lip to the air side. The forward screw threads and/or reverse screw threads are provided with seal protrusions for preventing leakage of droplets. | 5 |
The present application constitutes a continuation-in-part of the pending application Ser. No. 06/516,142 filed July 21, 1983 by Stephen R. Heneker and Leslie Todd Reeve, Deceased: by Jean M. Reeve, Executrix, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to valve assemblies and to domestic faucets for example.
2. Description of the Prior Art
U.S. Pat. No. 595,061 to Gulland relates to water valves.
Gulland discloses a faucet in which a ball resting on a valve seat is controlled by a flexible diaphragm. The diaphragm in turn is controlled by the pressure in a chamber. The chamber has upstream and downstream control valves which are rigidly coupled together for simultaneous operation.
When the faucet is shut off the upstream control valve is open and the downstream control valve is closed. When the faucet is fully open the upstream control valve is closed and the downstream control valve is open.
When the faucet is partially open both upstream and downstream valves are partially open allowing a continuous through flow of water, even under steady state flow conditions from the faucet.
The present invention is distinguished over the cited art in that both control valves are independently operable so that under steady state conditions for any degree of flow from the faucet both control valves are always closed.
With this arrangement for any flow rate setting of the faucet the control chamber is sealed and so has a fixed invariable volume. In this way the position of the diaphragm remains the same, irrespective of any fluctuation in the pressure of the water mains.
U.S. Pat. No. 2,222,141 to Denison discloses a gas valve.
Denison relates to a three-way pilot gas valve in which two control valves are coupled together for simultaneous operation. Neither control valve can move independently of the other.
It is an object of the invention to provide an improved valve assembly. In particular it is an object of the invention to provide a faucet in which the inlet and outlet control valves are independently operable so that the setting of the faucet can be adjusted to achieve any selected constant flow rate from the faucet.
SUMMARY OF THE INVENTION
According to the invention, there is provided a valve assembly comprising a chamber, a diaphragm dividing the chamber into first and second, separate sections, a main inlet and a main outlet, both communicating with the first section, a valve member carried by the diaphragm, movable by the diaphragm, to open and close communication between the main inlet and outlet, the arrangement being such that when fluid pressure in both sections is the same and the valve member is in a closed state, there will be a net force on the diaphragm holding the valve member in its closed state, a control passage communicating with the main inlet and extending to a discharge port, inlet and outlet valves located in the control passage, means providing communication between the second section of the chamber and the section of the control passage located between the two valves, and control means for controlling the two valves in such a manner that to open the flow path between the main inlet and main outlet, the inlet valve is closed and the outlet valve is opened, thereby to reduce pressure in the second section and so allow the diaphragm to move the valve member into an open state, and to close the flow path between the main inlet and main outlet, the inlet valve is opened and the outlet valve is closed.
According to the invention, there is also provided a valve assembly comprising a housing defining a chamber, a diaphragm located in the chamber to divide the chamber into two separate sections, a main flow path connected to one section and a control flow path connected to the other section, both the main and control flow paths being arranged to be connected to a common source of fluid, a valve member supported by the diaphragm and movable in response to relative changes in pressure between the two sections to open and close the main flow path, an inlet and an outlet control valve located in the control flow path respectively upstream and downstream of the connection of the flow control path to the said other section, the two control valves enabling the pressure in said other section to be changed and thereby controlling the opening and closing of the main flow path by said valve member.
BRIEF DESCRIPTION OF THE DRAWING
A domestic water pillar faucet or tap embodying the invention will now be described by way of example, with reference to the accompanying diagrammatic drawings, in which:
FIG. 1 is a section through the faucet;
FIG. 2 is a scrap view to an enlarged scale of the inlet control valve of the faucet of FIG. 1; and
FIG. 3 is a scrap view to an enlarged scale of the outlet control valve of the faucet of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The faucet shown in FIG. 1 includes an inlet 1 which, in use, is arranged to be coupled to the domestic water supply system. The body of the faucet defines a generally cylindrical chamber 16 which communicates both with the inlet 1 and a spout 20 which defines an outlet duct. The spout 20 has an upstream portion defining an annular valve seat extending into the lower end of the chamber 16 and a downstream portion terminating in a discharge port 2.
A diaphragm 15 located in the chamber separates the chamber in a liquid-tight manner into upper and lower sections. The diaphragm 15 supports a valve 14 in the form of a plug and constrains it for movement within the chamber towards and away from the valve seat. The under side of the plug carries a projecting guide 14a which is arranged to engage the inner wall of the valve seat so as to guide the plug on to the valve seat. The guide 14a has a stepped or fluted profile so that as the valve is progressively opened, the flow rate through the valve will increase in a non-linear manner; very slowly at first and then progressively faster.
An upper chamber 4 located above the generally cylindrical chamber 16 is in communication with the inlet 1 via a channel 3. A valve member 8 in the channel 3 controls the flow of water through the channel 3. The upper chamber 4 is in communication with the cylindrical chamber 16 through openings in the roof of the chamber 16. Another channel 5 provides communication between the upper chamber 4 and the downstream portion of the spout 2. A valve member 9, located in the channel 5, opens and closes the flow to the channel. An adjustable restrictor assembly 6 in the channel 5 controls the rate of flow of liquid through the channel 5.
A lever 7 supported by a shaft is housed in the upper chamber 4. The shaft 17 projects through an opening in the roof of the upper chamber 4. An O-ring seal 11 between the shaft 17 and the roof not only provides a liquid-tight seal between the wall and the shaft 17, but also pivotally supports the shaft on the roof.
The two valve members 8 and 9 are each provided with a respective control rod 30,32. Each control rod 30,32 has a central portion of reduced cross-section. The ends of opposite arms of the control lever 7 are bifurcated and slidably engage the reduced cross-section portions of respective ones of the control rods. In this way there is a degree of lost motion in the coupling between the lever and the control rods of the two valve members.
The valve member 8 is shown in more detail in FIG. 2. As shown the control rod 30 is slidably housed in a bore 34 which traverses the upper chamber 4. The control rod 30 has a diameter just less than that of the bore 34 to allow the rod to slide easily along the bore 34 and also to provide a gap for the passage of water between the rod 30 and the inner wall of the bore 34.
The rod 30 is preferably provided with axially extending grooves 36 in its outer circumferential surface to permit a greater flow of water between the rod 30 and the bore 34.
The rod 30 at its lower end carries a frusto conical valve member 40 which is arranged to engage a frusto conical valve seat 42, when the rod is urged into the raised position by the arm 7 pivoting in a clockwise sense to engage the axial end face of the upper step in the control rod 30.
When the arm 7 is pivoted in an anti-clockwise sense (with the valve 40 closed) it will engage the axial end face of the lower step in the rod 30 and displace the rod 30 downwardly to open the valve 40.
The valve member 9 is shown in more detail in FIG. 3. The control rod 32 is housed in a bore 50 which also traverses the upper chamber 4. The rod 32 has an intermediate portion 32A of reduced cross-section and an end portion 32B of enlarged cross-section which enlarged end portion is housed in an enlarged part of the bore 50.
The diameter of the rod 32 where it lies within the bore is slightly smaller than bore 50 so as to allow the rod 32 to slide easily along the bore and to allow water to flow between the bore and the rod 32. Preferably the rod 32 is provided with grooves or slots to increase the rate of flow of water through the bore 50. The upper axial end of the rod 52 carries a rubber washer 9a of considerably lesser diameter than the bore but which can engage an annular valve seat 56 at the upper end of the bore to close off the flow of water through the bore 50. The arm of the lever 7 is arranged to control the upward and downward movement of the rod by engaging the axial and face of the upper and lower steps in the rod 32. Pivotal movement of the lever 7 in an anti-clockwise sense moves the rod 32 upwards to cause the washer 9a to engage the annular seat and so close the valve 9. Pivotal movement of the lever 7 in a clockwise sense moves the rod 32 downwards to open the valve 9.
The shaft 17 carries a lever 10 at its upper end. A pair of "ON" "OFF" push buttons 12 and 13 are located above the lever 10, one adjacent each of the two arms of the lever 10.
Each push button 12 and 13 is spring-loaded away from the lever 10 but has a respective actuating pin extending towards the lever, to engage and tilt the lever 10 upon depression of the corresponding button.
The restrictor assembly 6 is in the form of a flexible flap 26 urged by a grub screw 28 into the channel 5 to form a constriction. Adjustment of the grub screw 28 will increase or decrease the size of the constriction and so effect the flow through the channel 5 accordingly.
In operation with the faucet in the OFF condition, depression of the ON button will cause the water flow to increase progressively. Release of the ON button will prevent further increase in the water flow rate, and the water flow through the faucet will continue at a constant rate. Depression of the OFF button turns the faucet OFF, preventing water flow through the faucet. If the ON button is only partially depressed, a small flow is established which will automatically be shut off as soon as the ON button is released. When a flow through the faucet has been established and it is required to reduce this flow without turning the faucet OFF, a partial depression of the OFF button will achieve this. When the flow rate from the faucet has been reduced to the desired rate, releasing the OFF button will cause the flow to remain constant again.
In FIG. 1 the faucet is shown in the OFF condition. In this state the valve 8 is maintained open by the force of gravity. Instead the valve is biased into its open state by other means. A detent mechanism (not shown) is provided to hold the valve in its open state until forcibly returned to its closed state. Water pressure from the faucet inlet 1 communicates with the upper portion of the chamber 16 through the upper chamber 4, the channel 3 and the inlet valve 8. The outlet valve 9 in the passage 5 leading from the upper chamber 4 is maintained closed by the pressure of water in the upper chamber 4. Instead of or in addition to the water pressure the valve 9 is held closed by a spring (not shown) or by its buoyancy.
In this condition, both sides of the diaphragm 15 are subjected to the same pressure from the supply. However, as there is a greater surface area under pressure above the diaphragm than below it, there will be a greater force acting on the upper surface of the diaphragm and so the diaphragm will urge the plug 14 against its valve seat to block any flow of water from the lower section of the chamber 16 to the spout 2.
Depression of the ON button tilts the lever 7 and therefore the shaft 17 about its O-ring seal 11. This in turn displaces the lever 7 to open the valve 9 and to close the valve 8. The valve 8 is then maintained against its valve seat by water pressure from the inlet 1. A small volume of water now flows from the outlet valve 9, past the restrictor 6 into the faucet outlet 2 via channel 5. This reduces the pressure in the upper part of the chamber 16 and so the diaphragm 15 will slowly rise by an amount corresponding to the volume of water lost through outlet valve 9. The plug 14 is lifted by the water pressure and flow of water from inlet 1 via the lower section of the chamber 16 to outlet 2 can now take place. The longer that the ON button 13 is held depressed the greater will be the amount of water discharged through the valve and consequently the greater the flow through the faucet. The increase in flow rate through the faucet may be arrested at any point during the opening cycle by releasing the ON button. With the ON button released, water will flow through the faucet at the required constant rate until altered by depression of either the ON or OFF buttons.
With the faucet running at a constant rate, but not at maximum flow, an increase in the flow rate through the faucet is achieved by further depressing the ON button until the flow has increased to the desired rate. Once the desired rate has been achieved, the ON button is released and once more, water will flow through the faucet at a constant but now increased rate.
To reduce the rate of water flow without turning the faucet off altogether, the mechanism operates in the following manner: It should first be noted that the OFF button has two operating pressures. The first pressure is when the button is partially depressed and the second pressure is when the button is fully depressed. To reduce the faucet water flow without turning the faucet OFF, the OFF button is partially depressed to its first operating pressure. This opens the inlet valve 8 partially, while leaving the outlet valve 9 closed. In this condition, water flows into the chamber 16 above the diaphragm effecting a downward displacement of the plug 14. The water flow through the faucet is therefore reduced. As valve 8 is only partially opened, hydraulic pressure in the passage 3 will cause inlet valve 8 to be lifted against its seat as soon as the OFF button is released, thereby preventing any further closing of the faucet. The flow of water from the faucet will then remain constant until altered by a subsequent depression of either the ON or OFF button.
To stop all flow from the outlet 2, with the faucet running at a steady rate, the OFF button is depressed to its second pressure position. This tilts the lever 7 to open the inlet valve 8. The lost motion built into the outlet valve 9 between its operating shoulders allows the lever 7 to rise without displacing the outlet valve 9 and so the outlet valve 9 remains closed. With inlet valve 8 fully open, the chamber 4 and the upper section of chamber 16 will fill rapidly causing the faucet to close rapidly. The inlet valve is so profiled that the flow of water past it tends to hold it open. When the faucet is closed and no further flow passes the inlet valve, it will open under gravitational force. However, when the faucet is open and there is no flow past the inlet valve, the valve will close as will be explained hereinafter.
With the faucet closed, a very small flow may be established by partially depressing the ON button. This has the effect of opening the outlet valve 9 but the inlet valve 8 will remain fully open. With the inlet valve still open, the diaphragm holds the plug in its closed state, but with the outlet valve 9 open, a small flow is created through the restrictor 6 and the outlet channel 5 to the main faucet outlet 2. This gives a drip control facility to the faucet for the dispensing of small volumes of water. Releasing the ON button automatically closes the faucet in this instance, without the need for depressing the OFF button, because the inlet valve will return to its fully open position, while the outlet valve will close again.
The rate at which the faucet opens is governed by the rate at which water from the upper chamber flows through the restrictor 6. This is affected by the water supply pressure. To compensate for supply pressure variations, the flow through the restrictor 6 may be adjusted which, in turn, alters the rate at which the faucet opens.
An air pocket chamber (not shown) holding air is coupled to the passage 3. This damps any fluctuations in pressure in the inlet due to water hammer when the faucet closes rapidly.
With the faucet running at a steady rate, there will be a small drop in pressure across the valve seat tending to cause the diaphragm to descend. This produces a slight pressure drop in the upper section of the chamber 16, which in turn causes the inlet valve 8 to be held against its seat under the pressure from channel 3. In this way the diaphragm can hold the plug in its open position and so maintain a steady flow condition. However, as soon as the inlet valve 8 is opened, the diaphragm moves to urge the plug on to its seat.
The O-ring which provides the only seal between the ON OFF buttons and the lever 7 is not subjected to any frictional forces by turning or sliding but is distorted by the rocking action of the valve lever shaft 17. This feature allows for the use of a tight fitting O-ring, while still permitting the light operation of the push buttons.
In a modification, the two push buttons are replaced by a single rocker coupled to or replacing the lever 10.
While the faucet described is a purpose-made unit, it will be appreciated that it can be arranged as a sub-assembly without a main inlet, a main outlet and valve seat to be fitted in place of the upper part of a conventional faucet of the type which can be unscrewed from the lower part, which lower part consists of an inlet, outlet and valve seat.
It will be appreciated that the described faucet operates in a "fail-safe" manner. A leakage of water past the outlet valve 9 will be compensated for by water flowing through the open inlet valve 8, thus maintaining the pressure above the diaphragm to keep the faucet closed. Even a rupture of the diaphragm will not cause the faucet to open but would tend to keep it in the closed condition until the ruptured diaphragm is replaced.
The described mechanism of the faucet can be incorporated in fluidic circuits for controlling motors and in jacks in hydraulic circuits.
While the controlling mechanism for the faucet is described as being located in the faucet body, it can instead be situated remote from the faucet, to be housed in a separate control panel built into a sink unit, a bath or even into a wall to control a shower head, for example. | A domestic pillar faucet has a main flow path and a control flow path, both connected to the same inlet. A diaphragm supports a valve member for displacement between a position in which the valve member is held open and a position in which the valve member closes the main flow path. Displacement of the diaphragm is controlled by fluid from the control flow path. The control flow path includes an inlet valve and an outlet valve and the section of the control flow path between the valves communicates with the diaphragm. By opening the outlet valve, the force on the diaphragm is reduced and the valve member will open. By closing the outlet valve and opening the inlet valve, the force on the diaphragm is increased and the valve member will close. The valves are operated by a lever through push buttons. The faucet is thus operated in a power assisted manner, not needing the dexterity required when opening or closing conventional faucets. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates generally to vehicle braking devices and more particularly to a warning mechanism for detecting wear in the brake shoe of a vehicle wheel braking assembly. The invention relates to a type of warning mechanism wherein a defaceable electrical circuit element such as a conductor wire is arranged to trigger a warning signal when depletion of the frictional brake shoe material has progressed beyond a predetermined limit.
In certain brake shoe wear warning devices of the type to which the present invention relates, a detection element for detecting the condition of wear of the brake frictional material in a brake assembly is provided behind the frictional material so that when wear of the friction material advances beyond a predetermined working limit, the warning device is electrically triggered to generate a signal notifying the occurrence of such excess wear. As a result, notification of the need to replace the brake friction material is acquired thereby preventing further deterioration of the brake performance, generation of undesirable braking noises and abnormal frictional heat.
In accordance with such known devices, however, the detection element is integrally incorporated in the brake friction material and cannot be readily separated therefrom. Accordingly, when trouble arises in the detection element, as for example would occur when the detection element malfunctions and produces a signal prematurely without the required amount of wear having occurred, it becomes necessary to replace extensive portions of the assembly including the frictional material and the detection element. Similarly, if problems should arise with regard to the brake friction material such as noise generation or improper braking effects, it again becomes necessary to replace both the brake friction material and the detection element even though only one of them may require replacement.
Moreover, when the wiring which is connected to the detection element becomes damaged, the brake friction material which is working normally must also be replaced together with the detection element. It will be apparent that the foregoing factors create disadvantages involving uneconomical utilization of braking elements.
The present invention is intended to overcome these problems by providing a warning mechanism having a detection element which is effective to indicate excessive brake shoe wear and which may be detachably mounted upon the brake shoe in cooperative engagement with the brake shoe friction material.
SUMMARY OF THE INVENTION
Briefly, the present invention may be described as a warning mechanism for detecting brake shoe wear in a wheel braking assembly including a brake shoe having a first side and a second side, a rotatable disc fixed to said wheel and positioned to be frictionally engaged by the first side of said brake shoe, and piston means disposed to contact the second side of the brake shoe to apply a braking force thereto. The warning mechanism of the invention comprises means defining a recess in the second side of the brake shoe at a part thereof which would be normally contacted by the piston means. The recess extends from the second side partially through the brake shoe into the friction material of the shoe and terminates a distance from the first side of the shoe which contacts the rotatable disc. A defaceable detection element is removably fitted in the recess and is adapted to be held in place by operation of the piston means against the second side of the brake shoe. A warning signal generating device is connected with the detection element and is adapted to produce a warning signal indicating brake shoe wear when frictional material on the first side of the brake shoe has been worn down by an amount exceeding workable limits. When this occurs, the detection element will be caused to contact the rotatable disc thereby triggering the warning device.
The key features of the invention reside in the fact that the defaceable detection element may be removably fitted within the recess in the brake shoe so that either the brake shoe or the detection element may be separately replaced without requiring replacement of both. Furthermore, the warning mechanism is so arranged that the operation of the piston means applying the braking force may be also utilized to maintain the detection element in place.
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 use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view of a disc brake assembly incorporating a brake shoe wear warning device in accordance with the present invention;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1;
FIG. 3 is a sectional view taken along the line III--III of FIG. 2;
FIGS. 4a and 4b are a front view and a plan view, respectively, of a detection element according to the present invention; and
FIG. 5 is a circuit diagram of the electrical warning signal generating device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIGS. 1-3 thereof, there is shown a disc brake assembly including an inner caliper 3 and an outer caliper 4 joined together by bolts 2 and mounted over a part of a disc 1 which is fixed to rotate with a wheel (not shown) to be braked by the assembly. Provided in the inner and outer calipers 3 and 4 are cylinders 5 and 6 arranged to operate in opposed directions. A pair of sealed pistons 7 and 8 are inserted, respectively, into the cylinders 5 and 6 and are mounted to be movable toward the disc 1 under the force of applied brake oil pressure. Above the calipers 3 and 4 there is provided a square opening 9 accommodating removal and replacement of portions of the brake assembly.
The assembly includes a pair of brake shoes including, respectively, back metal pads 14 and 15 each provided with shims 10, 11 and frictional material brake pads 12 and 13. The brake shoes are inserted through the opening 9 so that they may be positioned between opposite sides of the disc 1 and the pistons 7 and 8, respectively. The shims 10, 11 and the back metal pads 14, 15 are movably secured to the respective calipers 3, 4 by means of pins 18, 19 fixed in position by clips 16, 17 respectively. Between the pads 12, 13 and the back metal pads 14, 15 and one of the pins 19 there is provided an M-spring 20 adapted to retain the brake shoes in position.
Accordingly, when brake oil is applied to the cylinders 5, 6 the pistons 7, 8 are forced to move by the developed oil pressure to press the pads 12, 13 against the disc 1 so as to develop a braking force by frictional contact between the disc 1 and the pads 12, 13 thereby to brake the disc 1 and the wheel to which it is affixed.
In accordance with the device of the present invention, a brake shoe recess is formed on the rear side of the brake shoe with said recess being defined by a through-hole 21 extending through the back metal pad 15 and by a brake pad recess 22 extending partially through the frictional material of the brake pad 13. The recess is located in the central underside part of the back metal pad 15 at a location which is normally in contact with the piston 8 of the disc brake assembly. The brake pad recess formed in the pad 13 is located at a position in alignment with the hole 21 and the recess 22 is formed with a depth sufficient to allow insertion therein of a detection element 23. It will be noted that the recess 22 terminates at a distance spaced from the side of the brake pad 13 which engages the disc 1.
As shown in FIGS. 4a and 4b, the detection element 23 comprises a body portion 24 which is made of a defaceable resinous insulating material such as epoxy resin with the body 24 being formed in a bent or generally L-shaped at one end thereof. Embedded within the body 24 is a defaceable wire conductor element 25 which is formed with a loop having a part thereof projected at right angles along the bent end portion of the body 24 so that the body 24 may be broken or cut away at this portion.
When setting the detection element 23 in position within the disc brake assembly, the body 24 is removably fitted within the hole 21 in the back metal pad 15 and in the recess 22 in the pad 13 in contact with the shim 11 and it is secured in position in such a manner that it will not be dislocated by the pressing force of the piston 8, as shown in FIG. 2.
It is to be noted that if the projecting portion of the wire element is so positioned that the part to be broken away is directed in the direction of rotation of the disc 1, the wire element may slip aside making it unable to effect positive cutting at the correct said position thereby causing a delay in the issuance of a warning signal, so that even when fitting the detection element 23 in the tangential direction, let alone in its radial direction, the portion of the bare wire element to be cut must be disposed transversely to the direction of rotation of the disc 1.
The wire element 25 of the detection element 23 is grounded at one end and is connected at its other end to a battery 27 through a resistance 26 with a connection also being made to the base of a transistor 29 for switching through a diode 28. A warning lamp 30 is connected between the battery 27 and the collector of the transistor 29, as shown in FIG. 5.
As a result of repeated braking action, the pads 12, 13 will gradually wear down due to their frictional engagement with the disc 1, and when the degree of such wear becomes excessive and exceeds a working limit, a part of the body portion 24 of the detection element 23 will be severed by contact with the disc 1 thereby causing breakage of the wire element 25. Thereupon, the circuit portion defined by the element 25 will be broken and current flow therethrough will be terminated. As a result, the connection of the base of the transistor 29 to ground will be broken and the battery 27 will cause a signal to be applied to the base of the transistor 29 causing current flow between the base and the emitter thereof thereby rendering the transistor 29 conductive. As a result, current will also flow between the collector and the emitter of the transistor 29 and through the warning lamp 30 to cause the lamp to generate a blinking signal.
When it is desired to replace the detection element 23 along with the pads 12, 13 which have been worn down beyond their working limit, the clips 16 and 17 are first removed to enable removal of the pins 18, 19 with the spring 20 being subsequently removed. Thus, the back metal pads 14, 15 having the brake pads 12, 13 secured thereto as well as the shims 10, 11 may be removed through the opening 9 followed by removal of the detection element 23 between the back metal pad 15 and the pad 13. After thus removing the pads 12, 13 and the detection element 23, new pads and a new detection element are fitted into position by a procedure which is the reverse of the above-described removal procedure, thereby completing the desired replacement of the elements to restore the assembly to normal condition. An identical procedure is repeated when it is required to replace the newly fitted pads 12, 13 and the detection element 23.
Thus, according to the present invention, the pads 13 and the detection element 23 are assembled such that they are separable from each other, so that when it is necessary to replace one of them due to some malfunction, it is possible to remove both the pad 13 and the detection element 23 and to replace only the one that is defective. This results in a highly economical assembly since there is no need to replace both the pad 13 and the detection element 23 when only one becomes defective or inoperative. Also, since the detection element 23 is removed together with the pad 13, replacement of the detection element 23, when so desired, can be accomplished as easily as replacing the pad 13. Furthermore, should the detection element 23 come into contact directly with the disc 1 due to excess wear of the pad 13, there is no possibility that the detection element 23 will slip off and be dragged between the disc 1 and other parts of the assembly. Moreover, since the detection element 23 is fixed in a recess formed on the rear side of the brake shoe comprising the pad 13 on a side opposite from its friction surface, there does not occur any reduction in the area of frictional braking engagement of the pad 13 which would otherwise lessen the braking performance of the disc 1.
It is to be understood that although the present invention has been described as adapted within a disc brake assembly, it may, of course, be utilized as effectively by application to a drum brake assembly. Additionally, the detection element 23 may just as easily be assembled in combination with the opposite brake shoe comprising the pad 12.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the invention principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A warning mechanism for detecting brake shoe wear is adapted to be fitted into a recess formed on the rear face of a brake shoe such that when the front face of the shoe, which undergoes frictional engagement during braking, is worn to a sufficient extent, a defaceable detection wire in the warning mechanism will be ruptured to provide an indication of depletion of the braking material of the shoe. The detector element is removably secured within the recess of the brake shoe and is located such that it will not be dislodged by a braking force applied to the brake shoe by a piston of the brake assembly but will, instead, be held in position thereby. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority from Provisional Patent Application No. 61/228,553 filed on Jul. 25, 2009, which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The display magnetic hanger system relates to a set of devices and a method where a magnet location marker device is repeatedly attached at desired locations on a structures vertical or near-vertical surface, then using a remote installation tool hanger supports are installed which then can be used to support display items which have a connected wire. The term wire is used in this application to mean a wire, cord, or other similar material used to connect devices. The wire is supported on the hanger support to provide for display of the item. The set of devices can include multiple magnetic location markers, multiple hanger supports with a ferro-magnetic material insert, and the remote installation tool. The desired locations may be out of reach of the user desiring to display an item, but once the location markers are installed, the hanger supports are easily installed or removed using the remote installation tool.
2. Description of Related Art
Hanger supports using magnetic force for supporting display items are described in U.S. Patent D346,950, U.S. Pat. No. 3,275,818 (Campbell), U.S. Pat. No. 5,873,651 (Hofer et al.), U.S. Pat. No. 6,520,661 (Hill), and U.S. Pat. No. 6,855,890 (Vasichek). A tool for use in hanging a string of Christmas tree lights is shown in U.S. Patent D453,097 (Goodwin).
SUMMARY OF THE INVENTION
The display magnetic hanger system is a set of devices including a magnet location marker, a hanger support with a ferro-magnetic material insert, and a remote installation tool for supporting and displaying one or more items with a connected wire. One or more magnet location markers have a front side, a rear side substantially parallel to the front side, an installation opening between the front and rear sides, and a peripheral surface of a desired size and shape that is parallel to the installation opening. The magnet location marker is installed with the installation-opening axis normal to the structure surface at the location(s) on a structure desired to display items.
The hanger support assemblies have a hanger portion with a top end with a magnet location marker support arranged to engage the upper edge of the peripheral surface of a magnet location marker, and a ferro-magnetic material insert support with a recessed surface surrounded by a second surface substantially normal to the recessed surface and arranged in a desired shape to fit a ferro-magnetic material insert within the recess which magnetically engages with the magnetic location marker to retain the position of the hanger support; and a bottom end with an item support hook adjacent to an installation tool mating configuration of the bottom end. The hook extends from the bottom end toward the top end and has a top end approximately at the midpoint between the hanger support top and bottom ends, which is below the insert support. The configuration of the hook provides a constricted passageway for installation of the wire until the wire is in the item support opening.
The ferro-magnetic material insert has a front side and a rear side substantially parallel to the front side and a periphery surface arranged in a desired shape normal to the front and rear sides, the periphery surface is further arranged to fit in and be attached to the hanger portion insert support such that the installed ferro-magnetic material insert is engaged with the hanger portion insert support.
The hanger support ferro-magnetic material insert magnetically engages a magnet location marker, and the magnet location marker support is arranged to support the hanger support on the magnet location marker peripheral surface, such that the magnet location marker support provides support of the hanger support assembly in the plane of the structure surface and the magnetic location marker support is substantially normal to the ferro-magnetic material insert rear side with the ferro-magnetic material insert installed in the hanger support assembly ferro-magnetic material insert support so the magnet and ferro-magnetic material insert surfaces are substantially parallel and magnetically retain the hanger support on the magnet location marker.
The installation tool mating configuration of the hanger support lower end is a left mating surface located between the front and rear sides and a right mating surface located between the front and rear sides and substantially normal to the sides. These left and right mating surfaces have a front mating surface and a rear mating surface.
The installation tool has a shaft with a hanger support assembly installation end and a display item installation end. The hanger support assembly installation end is arranged with a front side with a cutout extending from the display item installation end to a cutout end located a predetermined distance from the hanger support assembly installation end, a rear side, and left and right sides and a substantially rectangular shaped opening at the end extending beyond the cutout end. The cutout and opening are further arranged such that a hanger support assembly is removably insertable in the opening with the item support hook located in the cutout. The display item installation end has a first manipulating finger extending beyond the shaft installation end and a second manipulating finger extending beyond the shaft installation end, each finger arranged at an opposing angle from the other finger. The angle of each finger is less than 45 degrees from the shaft axis.
OBJECTS AND ADVANTAGES
One advantage of the present invention is to provide one or more display hangers that may be removably installed in the same location(s) on a structures vertical or near-vertical surface.
A second advantage of the present invention is to provide a display hanger that may be installed and removed remote from the installation location.
A third advantage of the present invention is to provide a display hanger system that includes a dual-purpose tool for hanger installation and removal and display installation and removal.
A fourth advantage of the present invention is to provide a display hanger system that may be hidden from normal view when not in use and minimally in view when in use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A more complete understanding of the present invention can be obtained by considering the detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a front view of a magnet location marker.
FIG. 2 is a left side view of a magnet location marker.
FIG. 3 is a top view of a magnet location marker.
FIG. 4 is a front view of a hanger support with a ferro-magnetic material insert.
FIG. 5 is a rear view of a hanger support.
FIG. 6 is a left side view of a hanger support.
FIG. 7 is a right side view of a hanger support.
FIG. 8 is a bottom view of a hanger support.
FIG. 9 is a top view of a hanger support.
FIG. 10 is a front view of a remote installation tool. The shaft of the tool is cut-away to enable fitting the drawing on the sheet.
FIG. 11 is a left side view of a remote installation tool. The shaft of the tool is cut-away to enable fitting the drawing on the sheet.
FIG. 12 is a display item installation end view of a remote installation tool.
FIG. 13 is a hanger support assembly installation end view of a remote installation tool.
FIG. 14 is a perspective view of a remote installation tool with the hanger support assembly installation end engaged with a hanger support.
FIG. 15 is a perspective view of a remote installation tool with the display item installation end engaged with a display item that is in process of installation on multiple hanger support assemblies installed on the back side of a structure member.
FIG. 16 is an exploded view of a hanger support and magnetic location marker showing the parts and assembly to install a hanger support on a magnetic location marker on the back side of a structure. The structure is shown in broken lines to show the parts behind the structure.
REFERENCE NUMERALS IN DRAWINGS
These reference numbers are used in the drawings to refer to areas or features of the invention.
102 magnet location marker 114 hanger support 116 ferro-magnetic material insert 118 hook 120 insert support 122 location marker support 124 item installation gap 126 item support opening 128 removal tab 130 installation mating end 140 remote installation tool 142 installation tool hanger support assembly installation end 144 installation end mating support 146 installation end hook support 148 installation tool display item installation end 150 installation end finger 152 installation tool shaft 160 structure 170 fastener 180 display item
DETAILED DESCRIPTION OF THE INVENTION
The display magnetic hanger system set of devices to support items for display includes a magnet location marker ( 102 ), shown in FIGS. 1 through 3 and 16 , a hanger support ( 114 ) with a ferro-magnetic material insert ( 116 ), shown in FIGS. 4 , through 9 and 16 , and a remote installation tool ( 140 ) shown in FIGS. 10 through 15 .
The magnet location marker ( 102 ) is a substantially round magnet with a front and back surface with an opening that provides the means for attachment to a structure vertical or near-vertical surface between the surfaces as illustrated in FIG. 1 . Side and top views of the marker are in FIGS. 2 and 3 and show a substantially flat peripheral surface, although this contour may be convex. FIG. 16 shows the installation of a magnet location marker ( 102 ) on a structure ( 160 ) vertical or near-vertical surface, using a fastener ( 150 ). The magnet location marker ( 102 ) fastened to the structure is a locater that provides the means for positioning and supporting the hanger support.
The hanger support ( 114 ) is a molded device with the location marker support ( 122 ) molded on the front side top end and with an insert support ( 120 ) also molded on the front side top end as shown in FIG. 4 . The location marker support ( 122 ) is contoured to mate with the shape and size of the magnet location marker peripheral surface and assists in support of the hanger support ( 114 ) on a magnet location marker ( 102 ) by supporting its weight on the peripheral surface of the magnet location marker ( 102 ), which is shown in FIGS. 1 through 3 . Near the bottom, that is the installation mating end ( 130 ) of the hanger support ( 114 ) back side, is a hook ( 118 ) curving from the back side surface adjacent to the installation mating end ( 130 ) towards the top end. The display items ( 180 ) in FIG. 15 are mounted on a wire such that supporting the wire at one or more locations by hanger supports ( 114 ) will support the display item ( 180 ). A removal tab ( 128 ) may be provided near the hanger support ( 114 ) top end to provide a surface for moving the hanger support ( 114 ) away from an attached magnet location marker ( 102 ) for removal. The insert support ( 120 ) is a raised surface on the hanger support front side surface arranged to form an opening for placement of a ferro-magnetic material insert ( 116 ) into the opening formed by the insert support ( 120 ), as shown in FIG. 5 . The insert ( 116 ) may be attached either by an interference fit with the insert support, or by attachment with an adhesive, The ferro-magnetic material insert ( 116 ) is attracted by the magnetic force of the magnet location marker ( 102 ) which supports the hanger support ( 114 ). The magnetic coupling is between the two substantially flat surfaces of the insert ( 116 ) and the marker ( 102 ) as illustrated in FIG. 16 .
The hook ( 118 ) of the hanger support ( 114 ) is arranged with its base joined to the installation mating end ( 130 ) of the hanger support ( 114 ) and extending to substantially the mid-point of the hanger support between the top and bottom ends, as shown in FIGS. 4 through 7 . The hook is located below the insert support to allow access to the hook when the hanger support is installed. The hook ( 118 ) is configured to form an item installation gap ( 124 ) with an upper and lower end, the upper end with a chamfered entry between the inner surface of the hook and the back side surface of the hanger support ( 114 ). Near or at the base of this installation gap ( 124 ), as shown in FIGS. 6 and 7 , is an item support opening ( 126 ). This gap provides a retention location for the display item wire. The retention gap provides a restricted passage for installation of the item wire. Once the wire has traversed the installation gap ( 124 ), it will rest in the item support opening ( 126 ). Removal of the wire then requires application of force to move the wire into and up the installation gap ( 124 ). The hanger support ( 114 ) is the means for supporting and retaining the display items.
The remote installation tool ( 140 ) has a long shaft ( 152 ) with a hanger support assembly installation end ( 142 ) and a display item installation end ( 148 ). The shaft ( 152 ) is shown cutaway in FIGS. 10 and 11 . FIGS. 12 and 13 show end views of the hanger support assembly installation end ( 142 ) and the display item installation end ( 148 ) respectively.
The installation tool hanger support assembly installation end ( 142 ) is arranged with an installation end mating support ( 144 ) and a installation end hook support ( 146 ) that are configured to engage and support the hanger support ( 114 ) installation mating end ( 130 ) as shown in FIGS. 10 , 11 , 13 , and 14 . Using this end with a hanger support ( 114 ) engaged, the hanger support may be lifted to a desired location on a structure ( 140 ) within the range of the installation tool shaft ( 152 ) and attached to an existing magnet location marker ( 102 ) on the structure.
The installation tool display item installation end ( 148 ) is configured with end fingers ( 130 ) arranged at an angle to each other to form a V-shaped working area between the end fingers as shown in FIGS. 10 , 11 , and 15 . This configuration allows the tool to support the display item wire and allow lifting it to a hanger support ( 114 ) installed on a magnet location marker ( 102 ) on the structure for installation on the hanger support. FIG. 15 shows two hanger supports ( 114 ) with the display items ( 180 ) wire installed. The installation tool is the means for locating the hanger support and the means for locating the display items on the hanger support.
OPERATION
The use of the display magnetic hanger system set of devices to support display items on a wire uses the following method of installation. This method describes use for multiple display items connected by wires. The method is similar for a single display item with a wire used to hang the item. In this latter case one or two magnetic hanger system sets suffice to support the display item. First, one or more magnetic location markers ( 102 ) are first installed in desired locations on the surface of a structure member near the bottom of the member using common fasteners, as indicated by FIG. 16 . The opening in the magnetic location markers ( 102 ) provide the means for attachment to a structure. The use of a surface on the back side of the structural member is preferred as this places the magnet location markers ( 102 ) out of sight and faces the hook towards the front of the structure. They are placed near the bottom so in the preferred arrangement the hook portion of the hanger supports ( 114 ) is accessible by location below the structural member, and is the only portion visible when hung on the location marker. The hanger supports ( 114 ) may then be engaged with the installation tool hanger support assembly installation end ( 142 ) and magnetically attached to the magnetic location markers ( 102 ), where they are supported by the magnetic attraction between the magnet location marker ( 102 ) and the hanger support ( 114 ) insert ( 116 ), and mechanically supported by the location marker support ( 122 ) portion of the hanger support ( 114 ) as illustrated by FIG. 15 . This is repeated until all the desired locations have a hanger support ( 114 ) installed. Then the display item may be installed in a linear sequence using the installation tool display item installation end ( 148 ) to lift the display item by its attached wire and place the wire at the first hanger support ( 114 ) hanger support hook ( 118 ) item installation gap ( 124 ). The side of a display item installation end ( 148 ) finger ( 150 ) is then used to move the display item wire down the item installation gap ( 124 ) until the wire is resting in the item support opening ( 126 ), thus engaging the hanger support. This is repeated for each of the hanger supports ( 114 ) until all are engaged with the display item wire.
Removal of the display item is the reverse of this method. First the display item ( 180 ) wire is lifted into and along the first hanger support hanger support hook item installation gap ( 124 ) until the wire is disengaged from the hanger support. This is repeated for each of the hanger supports ( 114 ) in sequence until the entire display item has been disengaged. If another display item is to be installed, it may be done using the process already given. If there are no further display items to hang, the hanger supports ( 114 ) may be removed for storage by engaging them, one at a time, with the installation tool hanger support assembly installation end ( 142 ), lifting them slightly and moving them to an angle with the ferro-magnetic material location marker ( 102 ) to free them from the marker. | A display magnetic hanger system provides a hanger support that may be repeatedly attached and removed at desired locations on a structure using a remote installation tool to install the hanger support and to install items for display on the hanger support. The installation of the hanger support is to a pre-installed magnet location marker at the desired location(s) on a structure. The desired location may be out of reach of the user desiring to display an item but the system and display item is easily installed using the long-handled remote installation tool. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to fuel injection systems of internal combustion engines; more particularly to fuel rail assemblies for supplying pressurized fuel to fuel injectors for direct injection into engine cylinders; and most particularly, to an apparatus and method for coupling a fuel injector to a fuel rail for direct injection.
BACKGROUND OF THE INVENTION
[0002] Fuel rail assemblies for supplying fuel to fuel injectors of internal combustion engines are well known. A fuel rail assembly, also referred to herein simply as a fuel rail, is essentially an elongated tubular fuel manifold connected at an inlet end to a fuel supply system and having a plurality of ports for mating in any of various arrangements with a plurality of fuel injectors to be supplied. Typically, a fuel rail assembly includes a plurality of fuel injector sockets in communication with a manifold supply tube, the injectors being inserted into the sockets.
[0003] Fuel injectors may be divided generally into multi-port fuel injectors (MPFI), wherein fuel is injected into a runner of an air intake manifold ahead of a cylinder intake valve, and direct injectors (DI), wherein fuel is injected directly into the combustion chamber of an engine cylinder, typically near the end of the compression stroke of the piston. Since a direct injector is exposed to the pressures within a cylinder, a DI fuel rail assembly must handle significantly higher fuel pressures than a MPFI fuel rail assembly in order to provide precisely metered fuel into a cylinder's combustion chamber.
[0004] Because of the higher operating pressures, typically, DI fuel systems employ fuel injectors that are rigidly supported on the engine's cylinder head. The rigid connection between the cylinder head and injector provides enough structural support to withstand the higher operational pressures. However, such a rigid connection has a drawback in that the metal-to-metal contact of the rigid connection provides a direct path for transmitting injector noise. Current MPFI technology includes a hanging injector system that avoids the rigid connection between the cylinder head and the injector by suspending the injectors from the fuel rail via a mechanical coupling. However, while such a coupling solves the noise transmission problem of a rigid connection, the hanging injector connection employed by MPFIs cannot withstand the operating pressures of a DI system.
[0005] What is needed in the art is a fuel injector to fuel rail connection that is able to mechanically support loads originating from relatively high fuel pressures and from combustion pressure of direct injection fuel injection systems.
[0006] It is a principal object of the present invention to provide a high-pressure fuel injector coupling that easily connects a DI fuel injector to a fuel rail and that is able to manage relatively high separating loads between the fuel rail and the fuel injector due to relatively high DI fuel pressure levels.
SUMMARY OF THE INVENTION
[0007] Briefly described, a fuel injector coupling in accordance with the invention includes a retainer clip and a collar, which, when paired together, enable a simple, secure, and keyed fuel injector-to-fuel rail connection that is able to withstand separating loads originating from the relatively high fuel pressure of a direct injection fuel system. Moreover, the coupling provides for a centralized load path along the longitudinal axis of the fuel injector and fuel rail socket.
[0008] In one aspect of the invention, the retainer clip is U-shaped to capture an end face of the fuel rail socket and includes diametrically opposed windows for receiving features in a fuel injector collar to positively secure the injector in the socket via the clip and collar. Mating features between the clip and injector collar and between the retaining clip and fuel rail socket rotationally locate the injector to the cup to facilitate correct alignment of the injector relative to its associated combustion chamber in the cylinder head. The retainer clip is shaped to provide ease of assembly and disassembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0010] FIG. 1 a shows a fuel injector/fuel rail system, in accordance with the invention, with one of the injectors and sockets removed;
[0011] FIG. 1 b is an isometric exploded view of a section of the fuel injector/fuel rail system shown in FIG. 1 a;
[0012] FIG. 2 a is an isometric exploded view of one injector coupling, in accordance with the invention;
[0013] FIG. 2 b is an isometric view of an assembled coupling, in accordance with the invention;
[0014] FIGS. 3 a and 3 b are views of the retaining clip, in accordance with the invention; and
[0015] FIG. 4 is a sectioned view of the collar and injector, in accordance with the invention, the sectioned view taken at the top surface of the collar looking down toward the discharge end of the injector.
[0016] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring to FIGS. 1 a, 1 b, 2 a and 2 b, an injector fuel system 100 , in accordance with the invention, includes a fuel rail assembly 110 , at least one fuel injector 130 and, for each fuel injector, a coupling 150 . Fuel rail assembly 110 includes a fuel distribution conduit 112 that may be, for example, an elongated tube as shown in FIG. 1 or may be a non-round conduit. At least one injector socket 120 is assembled to conduit 112 to be in fluid communication with the interior of conduit 112 via an opening 114 , shown in a right-most position on the fuel rail in FIG. 1 before socket 120 is attached to conduit 112 . Fuel rail assembly 110 is connected to a typical fuel supply system (not shown). Fuel rail assembly 110 is secured to cylinder head 116 by, for example, bolts 118 such that, through coupling 150 , each fuel injector 130 is precisely aligned with its associated cylinder/combustion chamber (not shown).
[0018] Injector socket 120 may include a cylindrical body 121 that is closed at one end 122 and that is open at an opposite end 123 for receiving fuel injector 130 . Accordingly, injector socket 120 may have, but is not limited to, the shape of a cup as shown in FIG. 1 . Injector socket 120 may be straight sided as shown, or may include a flange (not shown) proximate to open end 123 . In one aspect of the invention, socket 120 includes a mating feature 126 , such as for example, opposing flatted sections 127 , disposed substantially 180° from one another, for rotationally positioning the injector relative to the cylinder head, which will be later described.
[0019] Fuel injector 130 includes a fuel inlet end 132 , a fuel discharge end 134 , and an overmold 136 surrounding a fuel tube 138 . Fuel tube 138 communicates fuel through the injector from fuel inlet end 132 to discharge end 134 . Overmold 136 is positioned such that fuel inlet end 132 of fuel tube 138 extends beyond an upper end 140 of overmold 136 for assembly into injector socket 120 . Fuel tube 138 includes a circumferential groove 141 , having a width 142 , that is positioned adjacent the upper end 140 of overmold 136 . In one aspect of the invention, overmold 136 includes anti-rotation feature 144 extending from proximate circumferential groove 141 to beyond an outer surface 139 of overmold 136 . The width 145 of anti-rotation feature 144 is approximately equal to twice the radius 146 of the root surface 143 of circumferential groove 142 . During manufacture of the injector, anti-rotation feature 144 is indexed to features of the injector, for precisely orienting the injector, rotationally, to the cylinder head. While fuel injector 130 is illustrated as a fuel injector for gasoline direct injection, it may be any other type fuel injector.
[0020] Coupling 150 includes a retainer clip 152 and a collar 172 . Retainer clip 152 paired with collar 172 enables a positive mechanical retention of fuel injector 130 to socket 120 even under relatively high separating loads. Accordingly, fuel injector 130 is suspended from fuel rail assembly 110 via mechanical coupling 150 such that no hard, metal-to metal contact is necessary between fuel injector 130 and the cylinder head itself to secure the injector to the cylinder head.
[0021] Retainer clip 152 may take a shape generally of a boxed-U having leg portions 154 , substantially parallel to each other, and bridge portion 156 joining the leg portions 154 to form the boxed-U shape. Referring to FIGS. 3 a and 3 b, leg portions 154 include lower sections 158 and upper sections 160 intermediate the lower sections and bridge portion 156 .
[0022] In one aspect of the invention, lower sections 158 of retainer clip 152 each include a window 160 sized and positioned for close-fittingly receiving locating features in collar 172 to be described below. Lower edge 168 of each window may include a slight curvature ( FIG. 3 b ) for making point contact with the locating features. Lower sections 158 are flat on their inside surfaces to snuggly engage mating features 126 of socket 120 , such as flats 127 , while, at the same time, bridge portion 156 engages closed end 122 of socket 120 , when the clip is assembled to collar 172 and socket 120 . Upper sections 160 may depart from the planar surfaces of lower sections 158 , on an angle α as shown in FIG. 3 a, in order to provide clearances 161 ( FIG. 1 a ) between the section of socket 120 shown as 125 and clip 152 to assure that the clip is firmly in contact with the socket at flats 127 and closed end 122 . Lower sections 158 may include chamfered or outwardly flanged ends (not shown) to facilitate assembly of the clip onto the socket and collar 172 . Retainer clip 152 may be formed from sheet spring steel, such as by stamping. In its free state before assembly, width 162 across the lower sections 158 of retainer clip 152 may be slightly less than width 128 across socket flats 127 ( FIG. 1 b ). In one aspect of the invention, bridge portion 156 may be slightly concaved (not shown), in the retainer clip's free state.
[0023] Referring to FIG. 4 , collar 172 is generally circular in shape on its periphery 174 . Slot 176 of collar 172 defines central opening 178 having parallel edges 180 and radial inner end 182 for being received in circumferential groove 141 of fuel injector 130 . Radius 184 of inner end 182 is equal to or slightly larger than radius 146 of the groove's root surface 143 . Width 186 of slot 176 is equal to or slightly larger than width 145 of anti-rotation feature 144 . Thickness 188 of collar 172 is slightly less than width 142 of circumferential groove 141 . As such, referring to FIG. 2 a, collar 172 fits snuggly into circumferential groove 141 of the fuel injector. When assembled into the groove, parallel edges 180 abut anti-rotation feature 144 of the injector thereby preventing the collar from rotating about the longitudinal axis 148 of the injector. In one aspect of the invention, one or more collar locating features such as tabs 190 project from periphery 174 and are indexed relative to slot 176 for precisely positioning fuel injector 130 axially and rotationally about its longitudinal axis 148 relative to its associated combustion chamber. In the embodiment shown, tabs 190 are located approximately 90° clockwise and counterclockwise (as shown in FIG. 4 ) relative to the center of slot 176 . Collar 172 may be formed from a non-resilient cold-formable material, such as by stamping, and may be plated for corrosion protection.
[0024] Next, a sequence for assembling coupling 150 will be described.
[0025] First, collar 172 is inserted into circumferential groove 141 of fuel injector 130 so that parallel edges 180 of slot 176 abut anti-rotation feature 144 and radial inner end 182 of slot 176 fits snuggly against root surface 143 of the circumferential groove. Next, with tabs 190 aligned generally with socket flats 127 , the inlet end 132 of injector 130 is inserted into open end 123 of socket 120 until collar 172 abuts the open end 123 of the socket. Finally, retainer clip 152 is slipped over the closed end 122 of socket 120 so that bridge portion 156 of the retainer clip contacts closed end 122 of the socket, lower sections 158 of the retainer clip firmly engage flats 127 of socket 120 and tabs 190 of collar 172 snap into windows 160 of the retainer clip. In one aspect of the invention, before retainer clip 152 is slipped over closed end 122 , the distance 164 between point 166 of bridge portion 156 of the retainer clip and edges 168 of windows 160 is slightly less than the dimension measured between the closed end 122 of socket 120 and a lower surface 192 of tabs 190 when collar 172 is abutted against the open end 123 of the socket. As such, when tabs 190 of collar 172 snap into windows 160 of the retainer clip after the retainer clip is in place, injector 130 is held firmly in place in its associated socket to withstand the separating loads originating from the relatively high fuel pressures of a direct injection fuel system. The coupling also provides for a load path centralized by bridge portion 156 and windows 160 of the retainer clip along the longitudinal axis 148 of the fuel injector and fuel rail socket. Moreover, since the injector is precisely positioned axially and rotationally relative to its associated socket via anti-rotation feature 144 , tabs 190 , windows 160 and flats 127 , correct alignment of the injector relative to its associated combustion chamber in the cylinder head is readily maintained.
[0026] As shown in FIG. 4 , complementary mating features 194 may be incorporated in the collar and in the anti-rotation feature so that the collar may be installed to the injector and held in place by the mating features during injector shipment and prior to assembly of the injector to the fuel rail/engine.
[0027] As can be seen in FIG. 1 a, one coupling 150 is needed per fuel injector 130 . Accordingly, coupling 150 may be utilized in an internal combustion engine employing two, four, six, eight, or any other number of cylinders.
[0028] While coupling 150 may be especially useful for applications in fuel injection systems for direct injection, applications in fuel injection systems for port injection may be possible.
[0029] While the locating feature in the collar and retention clip are shown as tabs and windows, respectively, it is understood that the mating features, in accordance with the invention, are not limited as such.
[0030] While the mating feature on the socket is shown as a pair of flats located 180° from each other, it is understood that the mating features can be other types of indexing features and need not be 180° apart and, moreover, can be more or less than two.
[0031] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims. | A coupling for suspending a fuel injector from a fuel rail assembly of an internal combustion engine includes a collar that mates with the fuel injector and a retainer clip that engages with the collar thereby mechanically connecting the fuel injector to the fuel rail assembly. The retainer clip includes windows to enable even load distribution upon the socket flange when assembled. Features are integrated in the collar to facilitate correct alignment of the injector relative to the fuel rail. Paired together, the retainer clip and the collar enable a secure, and a keyed fuel injector-to-fuel rail connection that is able to withstand high pressure separating loads. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Korean Application No. 10-2007-0089904, filed on Sep. 5, 2007, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a pelvis assembly for a dummy used to evaluate the comfort of a vehicle seat.
[0004] 2. Description of the Background Art
[0005] A dummy used to evaluate the comfort of a vehicle scat prototype should be able to accurately mimic various positions of human occupants. The angle of a human occupant's pelvis, for example, depends on the positioning of his/her thighs.
SUMMARY OF THE INVENTION
[0006] A pelvis assembly for a dummy includes a pelvic plate attached to a lumbar region of the dummy, and one of more pelvic units, attached to the pelvic plate to transmit motion from a femur bar of the dummy to the plate. Each pelvic unit includes a hip joint attached to the femur bar; a rotary axle, a first end of which is attached to the hip joint and which is disposed laterally, to rotate together with the hip joint when the femur bar pivots vertically; and one or more pelvic angle adjusters, installed near a second end of the rotary axle, to transmit rotation of the rotary axle to the pelvic plate, thereby changing a vertical angle of the pelvic plate.
[0007] The pelvic angle adjusters may include a seesaw lever, a core part of which is coupled near the second end of the rotary axle, and having front and rear lever parts that undergo a seesaw motion when the rotary axle rotates; and two spring members, a lower end of one being attached to the front lever part, a lower end of the other being attached to the rear lever part, and an upper end of each of which is attached to the pelvic plate.
[0008] A pair of adjuster bolts may be installed on the pelvic plate so as to be able to adjust an amount of compression of the spring members.
[0009] An angle sensor, which detects a rotational angle of the rotary axle, may be provided at the second end of the rotary axle.
[0010] The hip joint may include a body, to which the first end of the rotary axle is fixed; and a vertical rotary spindle, which is rotatably installed on the body and attached to the femur bar.
[0011] Two pelvic units may be provided at left and right sides of the pelvic plate. The vertical angle of the pelvic plate can be individually changed on a basis of movement of one of the femur bars.
BRIEF DESCRIPTION OF THE DIM WINGS
[0012] The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration, and thus are not limitative of the present invention, and wherein:
[0013] FIGS. 1 and 2 are views illustrating the relationship between the position of a femur and the positions of the pelvis and the vertebral column in a human;
[0014] FIG. 3 is a perspective view of a dummy according to an embodiment of the present invention;
[0015] FIG. 4 is a perspective view illustrating the pelvis assembly indicated by part A of FIG. 3 ; and
[0016] FIG. 5 is an exploded perspective view of the pelvis assembly of FIG. 4 .
[0017] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0018] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Reference will now be made in detail to a preferred embodiment of the present invention, an example of which is illustrated in the accompanying drawings and described below. While the invention will be described in conjunction with an exemplary embodiment, it should be understood that the description is not intended to limit the invention to the exemplary embodiment. On the contrary, the invention is intended to cover not only the exemplary embodiment, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0020] As mentioned above, a dummy used to evaluate the comfort of a vehicle seat prototype should be able to accurately mimic various positions of human occupants. In particular, the skeletal or articular structure of a human being needs to be mimicked in the dummy. In this respect, it is necessary to pay attention to the fact that the position of the vertebral column is influenced by the angle of the pelvis, and furthermore, that the angle of the pelvis is influenced by the position of the thighs.
[0021] FIGS. 1 and 2 show the position of the vertebral column of a seated human being. As shown in FIG. 1 , when each femur 1 is angled below a horizontal plane extending outwards from the hip joint, the pelvis 2 is rotated forward. Thus, a vertebral column, particularly the lumbar 3 , is bent forward towards the stomach. In contrast as shown in FIG. 2 , when the femur 1 is tilted above the horizontal plane, the pelvis 2 is rotated backward. Thus, the lumbar 3 is bent backward. In addition, the angular change of the femur 1 causes the shape of the thorax 4 to change slightly. The position of the vertebral column also has an influence on the position of the cervical vertebrae 5 .
[0022] The angle of the seat exerts a direct influence on the angle of the femur. For this reason, a dummy used to evaluate the comfort of a vehicle seat prototype should have a pelvis assembly that mimics changes in the position of the vertebral column depending on the change in the angle of the femur.
[0023] Referring to FIG. 3 , a dummy is generally humanoid in shape, include limbs, a vertebral column 31 , a neck/head 32 , and a pelvis assembly A, corresponding to a human pelvic region.
[0024] A posture restrictive rod 33 is connected between a shoulder girdle and a pelvic plate 20 of the dummy for restricting the change in the position of the dummy, particularly, the vertebral column 31 , within a predetermined range. When the angle of the pelvic plate 20 changes, the angle of the vertebral column 31 , particularly the lumbar region 30 , changes within a predetermined range. The angular change of the pelvic plate 20 is associated with the change in the angle of each femur bar 10 .
[0025] As illustrated in FIG. 4 , the lower end of the rod 33 is connected to the pelvic plate 20 . Although not illustrated in FIG. 4 , the lower aid of the lumbar region 30 is also connected to the pelvic plate 20 .
[0026] Referring to FIGS. 4 and 5 , the pelvis assembly A generally comprises the pelvic plate 20 and members for transmitting changes in the position of each femur bar 10 to the pelvic plate 20 .
[0027] The pelvic plate 20 is a flat, horizontal plate, and serves as a medium by which the position of the lumbar region 30 is changed depending on the movement of the femur bar 10 .
[0028] The members for transmitting the positional change of each femur bar 10 to the pelvic plate 20 , for example a hip joint 40 , a rotary axle 60 and pelvic angle adjusters 70 , 100 and 200 , are installed under the pelvic plate 20 . In some embodiments, two sets of the members are installed symmetrically on the left and right sides of the pelvic plate 20 . For simplicity, only one of the sets of members will be described below.
[0029] The hip joint 40 makes it possible to move the femur bar 10 in vertical and horizontal directions. To this end, the upper end of the femur bar 10 is coupled to the hip joint 40 , and the rotary axle 60 ( FIG. 5 ) is coupled to the hip joint 40 perpendicular to the femur bar 10 . More specifically, one end of the rotary axle 60 is fixed to the body 41 of the hip joint 40 . Thus, when the femur bar 10 is pivoted in a vertical direction, the hip joint 40 rotates together with the rotary axle 60 . Further, one end of the femur bar 10 is fixed to a vertical rotary spindle 43 , which is rotatably installed on the body 41 of the hip joint 40 via a support plate 42 . Thus, the femur bar 10 can be pivoted horizontally side to side.
[0030] A joint housing 50 , through which the rotary axle 60 passes, is disposed inside the hip joint 40 . A bearing 51 is interposed between the rotary axle 60 and the joint housing 50 , such that the joint housing 50 does not move, in spite of the rotation of the rotary axle 60 . This joint housing 50 functions to support the rotary axle 60 , which rotates together with the hip joint 40 .
[0031] The rotary axle 60 is installed horizontally side to side, one end thereof is coupled to the hip joint 40 , and the other end thereof is coupled to a seesaw lever 70 . When the hip joint 40 rotates, the rotary axle 60 rotates therewith. This rotation of the rotary axle 60 is transmitted to the pelvic angle adjusters 70 , 100 and 200 , including the seesaw lever 70 .
[0032] The pelvic angle adjusters 70 , 100 and 200 function to adjust the angle of the pelvic plate 20 on the basis of the rotation of the rotary axle 60 , and include the seesaw lever 70 and two spring members 100 and 200 .
[0033] The seesaw lever 70 includes a core part 70 a , a front lever part 71 , which is disposed in front of the rotary axle 60 , and a rear lever part 72 , which is disposed behind the rotary axle 60 . The rotary axle 60 is fixed through the core part 70 a . When the rotary axle 60 rotates, the seesaw lever 70 undergoes a seesaw motion, which is transmitted to the spring members 100 and 200 .
[0034] The spring members 100 and 200 are vertically installed on the front and rear lever parts 71 and 72 via lower end couplers 110 and 210 , respectively. The spring members 100 and 200 include housings 101 and 201 , in which springs (not shown) are installed. At upper ends of the housings 101 , 102 are upper end couplers 120 and 220 . When the upper end couplers 120 and 220 are pressed, the springs are compressed in the housings 101 and 201 . When the upper end couplers 120 and 220 are released, the springs can be restored to original positions.
[0035] Meanwhile, the upper ends of the spring members 100 and 200 , particularly the housing 101 and 201 , are fixed to the pelvic plate 20 . The pelvic plate 20 is provided with adjuster bolls 130 and 230 thereon such that the upper end couplers 120 and 220 can be compressed or released. Since one seesaw lever 70 is provided to each of the left and right femur bars 10 , a total of four adjuster bolts 130 and 230 are installed on the pelvic plate 20 , as shown in FIG. 4 .
[0036] The rotary axle 60 is exposed at the left side in FIG. 5 of the seesaw lever 70 . The exposed rotation axle 60 is coupled with an angle sensor 90 , which is supported by a sensor holder 80 , in an axial direction. The leading end of the angle sensor 90 is coupled to the rotary axle 60 , so that the angle sensor 90 can detect the amount of rotation when the rotary axle 60 rotates. A bearing 81 is interposed between the sensor holder 80 and the rotary axle 60 .
[0037] Although an exemplary embodiment of the present invention has been described for illustrative purposes, those skilled in the art wilt appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as defined in the accompanying claims. | A pelvis assembly for a dummy includes a pelvic plate attached to a lumbar region of the dummy, and one of more pelvic units, attached to the pelvic plate to transmit motion from a femur bar of the dummy to the plate. Each pelvic unit includes a hip joint, attached to the femur bar; a rotary axle, a first end of which is attached to the hip joint, and which is disposed laterally, to rotate together with the hip joint when the femur bar pivots vertically; and one or more pelvic angle adjusters, installed near a second end of the rotary axle, to transmit rotation of the rotary axle to the pelvic plate, thereby changing a vertical angle of the pelvic plate. | 6 |
BACKGROUND OF THE INVENTION
Peptide derivatives of phosphonic and phosphinic acids containing all amino acids other than glycine in the L-configuration are disclosed in U.S. Pat. No. 4,016,148 issued Apr. 5, 1977. These compounds are disclosed to be useful as potentiators of antibiotics including D-cycloserine.
British Pat. No. 1,356,723 describes an antibiotic SF-1293 which is a peptide phosphinic acid. However, this substance is distinguishable from the present compounds in that the phosphinic acid moiety is at the amino terminus in the prior art structure while it is at the carboxy terminus in the instant compounds. Additionally, while no indication is given in this patent as to the configuration of the amino acids, since the substance is produced by fermentation it is no doubt comprised exclusively of the natural or L-amino acids. Finally, the prior art compound is indicated to be an antibiotic primarily an anti-fungal agent with no indication of any potentiating effectiveness for other antibiotics.
A paper by Haricharan et al., J. Org. Chem. 40, 470 (1975) discloses the synthesis of dipeptides of aminophosphonic acids. The amino terminal amino acid in each instance is glycine which are compounds specifically excluded from the scope of the present invention due to the fact that R 3 in the instant compounds is other than hydrogen (R 3 =hydrogen would provide glycine) and further by the requirement that the amino terminal amino acid have the D configuration.
The presence of 2-aminoethylphosphonic acid from hydrolyzates of fractions derived from marine invertebrates was reported by Quin, Biochemistry 4 (2), 324 (1965). It was indicated that this compound was present in protein materials but the amino group apparently was blocked and the structure of the peptide was indeterminate.
Phosphonopeptides have also been disclosed in prior copending applications as follows: Ser. No. 707,158, filed July 21, 1976; Ser. No. 793,326, filed May 3, 1977 and Ser. No. 793,327, filed May 3, 1977.
DESCRIPTION OF THE INVENTION
The peptide derivatives provided by the present invention are compounds of the general formula ##STR1## wherein R 1 , R 2 and R 3 each represent the characterising group of an α-amino acid of the type normally found in proteins or a group of the formula --CH 2 X in which X represents a halogen atom with the proviso that at least one of R 1 , R 2 and R 3 represents a group of the formula --CH 2 X; R 4 represents a hydroxy or methyl group; n stands for zero, 1, 2 or 3; the configuration at the carbon atom designated as (a) is L or D,L (when R 3 ≠ H); the configuration at the carbon atom designated as (b) is L or D,L (when R 2 ≠ H); and the configuration at the carbon atom designated as (c) is (R) (when R 1 ≠ H),
and pharmaceutically acceptable salts thereof.
As used in this specification the term "the characterising group of an α-amino acid of the type normally found in proteins" means the residue R in a natural α-amino acid of the general formula ##STR2## which is of the type normally occurring in proteins. Thus, for example, if the amino acid is glycine then the residue R represents a hydrogen atom and if the amino-acid is alanine then the residue R represents the methyl group. In leucine the residue R represents the isobutyl group, in phenylalanine the residue R represents the benzyl group and in glutamic acid the residue R represents the 2-carboxyethyl group. R can also represent a residue which is linked with the amino nitrogen (with the loss of one of the hydrogen atoms attached thereto), thus forming a nitrogen-containing ring such as in proline. The term "halogen" means fluorine, chlorine, bromine or iodine.
It will be appreciated that when n in formula I stands for 2 or 3, the value of R 2 can be the same or different.
When R 1 in formula I represents other than a hydrogen atom the configuration at the carbon atom designated as (c) is (R); that is to say, the configuration which would be obtained by replacing the carboxyl group of a naturally occurring L α-amino acid by a phosphorus moiety.
Preferred compounds of formula I hereinbefore are those in which R 4 represents a hydroxy group. Also preferred are compounds of formula I in which at least one of R 1 , R 2 and R 3 represents a fluoromethyl [--CH 2 F] or chloromethyl [--CH 2 Cl] group. Yet again, compounds of formula I in which n stands for zero or 1 are preferred.
Examples of compounds of formula I are:
(D,L-3-fluoroalanylamino)-methylphosphonic acid, and
(1R)-1-(L-3-fluoroalanylamino)-ethylphosphonic acid.
According to the process provided by the present invention, the peptide derivatives aforesaid (i.e. the compounds of formula I and their pharmaceutically acceptable salts) are manufactured by
(a) cleaving off by methods known per se the protecting group(s) present in a compound of the general formula ##STR3## wherein R 10 , R 20 and R 30 have any of the values accorded to R 1 , R 2 and R 3 hereinbefore respectively except that any amino group (s) present may be in protected form and any other functional group which may be present in is protected form where required; R 40 represents a methyl group or R 41 ; R 41 represents a hydroxy group or lower alkoxy protecting group; R 5 represents a hydrogen atom or a protecting group; and n as well as the configurations at the carbon atoms designated as (a), (b) and (c) are as defined above,
or
(b) separating an (R,S)-diastereomeric compound corresponding to formula I into its diastereomers and isolating the (R)-diastereomer,
and, if desired, converting a compound of formula I obtained into a pharmaceutically acceptable salt.
The amino group or amino groups which may be present in R 10 , R 20 or R 30 in formula II can be protected with any amino-protecting group which is well-known in peptide chemistry. Especially suitable amino-protecting groups for the purpose of the present invention are aralkoxycarbonyl groups, particularly the benzyloxycarbonyl group, and the tert.-butoxycarbonyl group. The amino-protecting group may also be a formyl, trityl or trifluoroacetyl group. Any carboxy or hydroxy group which may be present in R 10 , R 20 or R 30 in formula II can be protected by a conventional carboxy-protecting or hydroxy-protecting group respectively. For example, a carboxy group may be protected by conversion into an alkyl ester (e.g. a tertbutyl ester) or an aralkyl ester (e.g. a benzyl ester). Again, for example, a hydroxy group may be protected, for example, by means of an aralkoxycarbonyl group (e.g. benzyloxycarbonyl), an alkanoyl group (e.g. acetyl, propionyl etc.), an aroyl group e.g. benzoyl), an alkyl group (e.g. tert.-butyl) or an aralkyl group (e.g. benzyl). The protection of other functional groups present in R 10 , R 20 or R 30 may be carried out in a known manner. The protecting group denoted by R 5 in formula II can be any of the amino-protecting groups mentioned earlier in connection with R 10 , R 20 and R 30 .
The cleavage of the protecting group or protecting groups present in a compound of formula II is carried out in accordance with methods known per se; that is to say, methods in actual use for or described in the literature on the cleavage of protecting groups. Thus, for example, an aralkoxycarbonyl group (e.g. benzyloxycarbonyl) or a tert.-butoxycarbonyl group may be cleaved off by hydrolysis (e.g. treatment with a mixture of hydrogen bromide and glacial acetic acid). An aralkoxycarbonyl group (e.g. benzyloxycarbonyl) can also be cleaved off by hydrogenolysis (e.g. in the presence of palladium-on-charcoal or platinum oxide). The tert.-butoxycarbonyl group may also be cleaved off by means of hydrogen chloride in dioxan. A lower alkoxy group denoted by R 40 and/or R 41 can be a straight-chain or branched-chain alkoxy group which preferably contains from 1 to 6 carbon atoms and may be converted into a hydroxy group by treatment with a mixture of hydrogen bromide in glacial acetic acid or by means of trimethylchorosilane followed by aqueous hydrolysis. It will be appreciated that the cleavage of the protecting groups can be carried out in a single step or in more than one step depending on the nature of the protecting groups present.
The separation of an (R,S) diastereomeric compound corresponding to formula I into its diastereomers and isolation of the (R)-diastereomer can be carried out according to known methods; for example, by fractional crystallisation or by high pressure liquid chromatography.
Compounds of formula I are amphoteric in nature and form pharmaceutically acceptable salts with strong acids (e.g. methanesulphonic acid, p-toluenesulphonic acid, hydrochloric acid, hydrobromic acid, sulphuric acid etc.) and with bases (e.g. sodium hydroxide etc.).
The starting materials of formula II hereinbefore may be prepared, for example, by condensing a compound of the general formula ##STR4## with a compound of the general formula ##STR5## or with a reactive derivative thereof, in which formulae l and m each stand for zero, 1, 2 or 3 with the proviso that the sum of l and m is zero, 1, 2 or 3; R 5 , R 10 , R 20 , R 30 , R 40 and R 41 have the significance given earlier; and the configuration at the carbon atoms designated as (a), (b) and (c) is as defined earlier.
Thus, when a compound of formula III in which l stands for zero is used, such a compound can be condensed with an appropriate compound of formula IV in which m stands for zero or a reactive derivative thereof to give a compound of formula II in which n stands for zero, or with an appropriate compound of formula IV in which m stands for 1 or a reactive derivative thereof to give a compound of formula II in which n stands for 1, or with an appropriate compound of formula IV in which m stands for 2 or a reactive derivative thereof to give a compound of formula II in which n stands for 2 or with an appropriate compound of formula IV in which m stands for 3 or a reactive derivative thereof to give a compound of formula II in which n stands for 3.
Again, a compound of formula III in which l stands for 1 can be condensed with an appropriate compound of formula IV in which m stands for zero or a reactive derivative thereof to give a compound of formula II in which n stands for 1, or with an appropriate compound of formula IV in which m stands for 1 or a reactive derivative thereof to give a compound of formula II in which n stands for 2 or with an appropriate compound of formula IV in which m stands for 2 or a reactive derivative thereof to give a compound of formula II in which n stands for 3.
Yet again, a compound of formula III in which l stands for 2 can be condensed with an appropriate compound of formula IV in which m stands for zero or a reactive derivative thereof to give a compound of formula II in which n stands for 2 or with an appropriate compound of formula IV in which m stands for 1 or a reactive derivative thereof to give a compound of formula II in which n stands for 3.
Finally, a compound of formula III in which l stands for 3 can be condensed with an appropriate compound of formula IV in which m stands for zero or a reactive derivative thereof to give a compound of formula II in which n stands for 3.
Alternatively, the compounds of formula II can be prepared by carrying out the foregoing condensation using an (R,S) compound corresponding to formula III and separating the (R) compound from the resulting (R,S) product in a manner known per se; for example, by crystallisation, chromatography or fractional crystallisation using a suitable base such as benzylamine.
The aforementioned condensation can be carried out in accordance with methods which are known per se in peptide chemistry; for example, by the mixed anhydride, azide, activated ester or acid chloride method.
In one method, an appropriate compound of formula III can be condensed with an appropriate compound of formula IV in which the terminal carboxy function is a mixed anhydride residue formed with an organic or inorganic acid. Suitably, a compound of formula IV carrying a free carboxy function is treated with a tertiary base such as a tri-(lower alkyl)-amine (e.g. triethylamine) or N-ethylmorpholine in an inert organic solvent (e.g. tetrahydrofuran, 1,2-dimethoxyethane, dichloromethane, toluene, petroleum ether or mixtures thereof) and the resulting salt is reacted with a chloroformic acid ester (e.g. the ethyl or isobutyl ester) at a low temperature. The mixed anhydride obtained is then suitably condensed in situ with the compound of formula III.
In another method, an appropriate compound of formula III can be condensed with an appropriate compound of formula IV in which the terminal carboxy group is in the form of an acid azide. This condensation is preferably carried out in an inert organic solvent such as dimethylformamide or ethyl acetate at a low temperature.
In yet another method, an appropriate compound of formula III can be condensed with an appropriate compound of formula IV in which the terminal carboxy function is in the form of an active ester group (e.g. the p-nitrophenyl, 2,4,5-trichlorophenyl or succinimido ester group). This condensation is suitably carried out in an inert solvent such as dimethylformamide aqueous dimethylformamide or an aqueous alkanol (e.g. aqueous ethanol).
In a further method, an appropriate compound of formula III can be condensed with an appropriate compound of formula IV in which the terminal carboxy function is in the form of an acid chloride. This condensation is preferably carried out in the presence of a base and at a low temperature.
The peptide derivatives provided by the present invention possess an antibacterial activity against gram-positive and gram-negative organisms such as, for example Escherichia coli, Staphylococcus aureus, Serratia marcescens, Klebsiella aerogenes, Enterobacter sp., Streptococcus faecalis, Haemophilus influenzae and Salmonella typhimurium. The following Table illustrates the minimum inhibitory concentration (M.I.C.) in μg/ml of a representative peptide derivative provided by this invention, namely (1R)-1-(L-3-fluoroalanylamino)-ethylphosphonic acid, in an in vitro test against various organisms.
Table______________________________________Organism M.I.C. (μg/ml)______________________________________Escherichia coli NCTC 10418 P.S. 0.25Escherichia coli NCIB 8879 P.S. 0.5Klebsiella aerogenes Type 33 Ba 1.0Klebsiella aerogenes O-G KAl 4.0Escherichia coli C.1.5 P.R. 4.0Haemophilus influenzae NCTC 4560 8.0______________________________________
The peptide derivatives provided by this invention also potentiate the activity of antibiotics, including penicillin and cephalosporin antibiotics and D-cycloserine. Among the antibiotics which are potentiated by the present peptide derivatives there may be mentioned amoxycillin, cephradine, cephalothin, cephalexin, carbenicillin, ampicillin, penicillin G, sulbenicillin, cephazolin, cefoxitin, rifampicin, [(R)-1-(2-furoyloxy)-3-methylbutyl]-penicillin, (6R)-6-[[(hexahydro-1H-azepin-1-yl)-methylene]-amino]-pinicillanic acid, (pivaloyloxy) methyl (6R)-6-[[(hexahydro-1H-azepin-1-yl)-methylene]-amino]-penicillanate, cephamandole, cephaloridin, cephaloglycin, phenethicillin, methicillin, propicillin, ticarcillin, amoxycillan arginine salt, phosphonomycin, vancomycin and kanamycin.
The present invention thus also provides a pharmaceutical preparation containing a peptide derivative aforesaid, and, if desired, an antibiotic, in association with a compatible pharmaceutical carrier material.
The carrier material present in the pharmaceutical preparations provided by this invention can be any solid or liquid carrier material which is compatible with the peptide derivatives aforesaid, and with the antibiotics when such are present, and which is suitable for therapeutic administration. The carrier material can be an organic or inorganic carrier material which is suitable for enteral (e.g. oral) or parenteral administration. Examples of such carrier materials are water, gelatin, lactose, starches, magnesium stearate, talc, vegetable oils, gum arabic, polyalkyleneglycols, petroleum jelly etc. The pharmaceutical preparations can be made up in a solid form (e.g. as tablets, dragees, suppositories, or capsules) or in a liquid form (e.g. as solutions, suspensions or emulsions). The pharmaceutical preparations which can be prepared according to methods known in the art, may be subjected to conventional pharmaceutical operations such as sterilisation and may contain adjuvants such as preserving agents, stabilising agents, wetting agents, emulsifying agents, salts for varying the osmotic pressure or buffers. When a buffer is used, the pH of the pharmaceutical preparation will, of course, vary within a range which is well-known in pharmaceutical practice.
When the present pharmaceutical preparations contain a peptide derivative and an antibiotic, the weight ratio of peptide derivative to antibiotic can vary within wide limits. In general, the pharmaceutical preparations can contain the peptide derivative and antibiotic in a weight ratio of from 1:100 to 100:1, preferably in a weight ratio of from 1:64 to 64:1 and especially in a weight ratio of from 1:16 to 16:1.
The daily dosage of peptide derivative administered alone or in combination with an antibiotic will vary within wide limits depending on factors such as the particular peptide derivative chosen, the particular antibiotic chosen, the route of administration and the infection to be treated. For example, when a peptide derivative is administered alone, a daily dosage for oral administration may amount to about 2000 mg to 4000 mg and a daily dosage for parenteral administration may amount to about 800 mg to 2000 mg. When a peptide derivative is administered in combination with an antibiotic, a daily dosage for oral administration may amount to about 750 mg to 1500 mg of a combination of the peptide derivative and antibiotic and a daily dosage for parenteral administration may amount to about 200 mg to 2000 mg of a combination of peptide derivative and antibiotic. It will be appreciated that daily dosages can be administered in a single dosage or in divided dosages and that the dosages mentioned earlier may be varied upwards or downwards according to individual requirements and fitted to the exigencies of a particular situation as determined by the prescribing physician.
The following Examples illustrate the process provided by the present invention:
EXAMPLE 1
Ca.40 mg of the monobenzylamine salt of (N-benzyloxycarbonyl-D,L-3-fluoroalanylamino)-methylphosphonic acid were dissolved in a minimum volume of 2 N ammonium hydroxide solution and passed down a column of 5 g of a sulfonated polystyrene cation exchange resin (Zerolit 225; freshly regenerated in the acid cycle). Elution was carried out using water. To the acid eluate (ca. 50 ml) were added 0.1 g of 5% palladium-on-charcoal catalyst, ca.50 ml of methanol and one drop of glacial acetic acid. The mixture was hydrogenated overnight at room temperature and atmospheric pressure. After completion of the hydrogenation, the catalyst was filtered off and the filtrate evaporated to give a gum. This gum was dried over phosphorus pentoxide at 60° C. for 2 hours and was then triturated to give (D,L-3-fluoroalanylamino)-methylphosphonic acid as an off-white solid of melting point ca. 150° C. (decomposition). The structure of this product was confirmed by nuclear magnetic resonance spectroscopy.
The starting material was prepared as follows.
(i) A solution of 0.535 g (5 mmol) of D,L-3-fluoroalanine in 1.25 ml (5 mmol) of 4 N sodium hydroxide was stirred at 5° C. while 0.935 g (5.5 mmol) of benzyl chloroformate and 1.5 ml (6 mmol) of 4 N sodium hydroxide were added alternately in five portions of each and while maintaining the temperature at below 10° C. and the pH at greater than 11. The mixture was stirred for a further 1 hour at 0° C. as the temperature was allowed to rise to room temperature. The mixture was stirred overnight at room temperature. 2 ml of ether were then added and the resulting mixture was stirred vigorously at room temperature for 1 hour. The organic and aqueous layers were separated and the aqueous layer was extracted with 5 ml of ether. The aqueous layer was cooled to 10° C. and treated dropwise with 1.2 ml of 5 N hydrochloric acid until the mixture became acid to Congo Red. The mixture was then stirred for a further 2 hours at 10° C. when a solid crystallised from the solution. This solid was filtered off and washed with a minimum volume of ice-cold water. The solid was dissolved in 10 ml of ether and the solution washed with two 10 ml portions of cold (0° C.) water. The ether solution was dried over sodium sulphate and evaporated to yield a solid which was triturated with petroleum ether. The solid was filtered off and dried to give 0.6 g of product of melting point 108°-110° C. (decomposition). Recrystallisation of 0.1 g of this product from a mixture of 0.5 ml of ether and 0.5 ml of petroleum ether gave ca.60 mg of N-benzyloxycarbonyl-D,L-3-fluoroalanine of melting point 112°-114° C. (decomposition).
(ii) 0.58 g (2.4 mmol) of N-benzyloxycarbonyl-D,L-3-fluoroalanine was stirred at 0° C. in 10 ml of dimethoxyethane while 0.276 g (2.4 mmol) of N-hydroxysuccinimide followed by 0.49 g (2.4 mmol) of dicyclohexylcarbodiimide were added. A precipitate was observed after stirring for a further 5 minutes. The mixture was stirred for a further 24 hours at 0° C. and then left to stand at 0° C. for 16 hours. The precipitate was filtered off and washed with dimethoxyethane. The combined filtrate and washing were evaporated and then re-evaporated with ether. Trituration with ether afforded 0.62 g of a solid of melting point 116°-120° C. (decomposition) which was recrystallised from 10 ml of isopropanol to yield 0.51 g of the succinimido ester of N-benzyloxycarbonyl-D,L-3-fluoroalanine of melting point 119°-120° C. (decomposition).
(iii) Ca.0.5 g (1.5 mmol) of the succinimido ester of N-benzyloxycarbonyl-D,L-3-fluoroalanine was dissolved in 10 ml of warm ethanol and the solution was added at 5° C. to a stirred mixture, also at 5° C., of 0.67 g (6 mmol) of aminomethylphosphonic acid in a mixture of 12 ml of water and 6 ml of ethanol to which 1.12 g (13.5 mmol) of sodium bicarbonate had been added.
The mixture was stirred for 1 hour and the temperature was allowed to rise to room temperature. The mixture was subsequently stirred for ca.60 hours at room temperature. The mixture was not homogeneous, and was therefore stirred at room temperature for a further 24 hours. The still heterogeneous mixture was evaporated, the residue dissolved in 50 ml of water and the solution extracted with 50 ml of chloroform and then twice with 25 ml of chloroform each time. The aqueous phase was separated, acidified to pH 2 with 2 N hydrochloric acid and then extracted with one 50 ml portion and subsequently with two 25 ml portions of ether, followed by one 50 ml portion and subsequently two 25 ml portions of chloroform. The aqueous layer was then evaporated, the residue taken up in a minimum volume of water and passed down a column of 50 g of a sulfonated polystyrene cation exchange resin (Zerolit 225; freshly regenerated in the acid cycle). Elution with three 50 ml portions of water afforded three acidic fractions, only the first of which contained the desired product. This fraction was evaporated and re-evaporated to remove hydrogen chloride. The residual gum was dissolved in water and titrated with 1 M aqueous benzylamine solution to pH 4.5. The solution was evaporated to give a solid which was recrystallised from 3 ml of water. The product was filtered off, washed with water until the filtrate was free from chloride ion, then washed with ethanol and subsequently with ether to give 0.030 g of the monobenzylamine salt of (N-benzyloxycarbonyl-D,L-3-fluoroalanylamino)-methylphosphonic acid. Evaporation of the mother liquors and washes and crystallisation of the residue from a mixture of 2 ml of water and 4 ml of ethanol removed 40 mg of aminomethylphosphonic acid. Evaporation of the filtrate and crystallisation of the residue from water afforded a further 10 mg of the desired monobenzylamine salt.
EXAMPLE 2
Ca. 0.3 g (0,66 mmol) of the monobenzylamine salt of (1R)-1-(N-benzyloxycarbonyl-L-3-fluoroalanylamino)-ethylphosphonic acid was dissolved in the minimum volume of 2 N ammonium hydroxide and passed down a column of 15 g of a sulfonated polystyrene cation exchange resin (Zerolit 225; freshly regenerated in the acid cycle). Elution was carried out with a methanol/water (1:1) mixture. To the acid eluate (ca. 100 ml) were added 0.3 g of 10% palladium-on-charcoal catalyst, 100 ml of methanol and three drops of glacial acetic acid. The mixture was hydrogenated for ca. 60 hours at room temperature and atmospheric pressure. After completion of the hydrogenation, the catalyst was filtered off. The filtrate was evaporated and then re-evaporated twice with n-propanol and once with ether. The residue was triturated with ether to give 80 mg of a pink solid of melting point ca. 150° C. (decomposition). Recrystallisation from a mixture of 1.5 ml of water and 4.5 ml of ethanol gave 30 mg of (1R)-1-(L-3-fluoroalanylamino)-ethylphosphonic acid of melting point 245° C. (decomposition); [α] D 20 = -30,4° (c = μ0.22% in water).
The starting material was prepared as follows.
(i) In a manner analogous to that described in Example 1, from 2.9 g (27 mmol) of L-3-fluoroalanine and 5.1 g (30 mmol) of benzyl chloroformate there were obtained 4.4 g of N-benzyloxycarbonyl-L-3-fluoroalanine of melting point 110°-116° C. (decomposition; softening at 140° C.), [α] D 20 = +5.4° (c = 0.5% in glacial acetic acid). Recrystallisation from a mixture of 25 ml of ether and 25 ml of petroleum ether gave 3.7 g of N-benzyloxycarbonyl-L-3-fluoroalanine of melting point 108°-115° C. (decomposition; softening at 104° C.); [α] D 20 = +5.6° (c = 0.5% in glacial acetic acid).
(ii) In a manner analogous to that described in Example 1, from 3.6 g (15 mmol) of N-benzyloxycarbonyl-L-3-fluoroalanine, 1.7 g (15 mmol) of N-hydroxysuccinimide and 3.4 g (16.4 mmol) of dicyclohexylcarbodiimide there were obtained 5.0 g of the succinimido ester of N-benzyloxycarbonyl-L-3-fluoroalanine of melting point 134°-138° C. (decomposition). Recrystallisation of a 0.5 g sample from 12 ml of isopropanol gave 0.4 g of the pure succinimido ester of melting point 138°-139° C. (decomposition); [α] D 20 = -37.5° (c = 0.5% in ethanol).
(iii) 1.7 g (13 mmol) of (1R)-1-aminoethylphosphonic acid were stirred in a mixture of 13 ml of water, 26 ml of dimethylformamide and 3.7 ml (27 mmol) of triethylamine at 0° C. while 4.5 g (13 mmol) of the succinimido ester of N-benzyloxycarbonyl-L-3-fluoroalanine were added as a solid in a single portion. The resulting heterogeneous mixture was stirred for 2 hours at 0° C. and then overnight at room temperature. The almost homogeneous mixture thus obtained was filtered to remove a small amount (0.19 g) of white solid. The filtrate was evaporated under an oil-pump vacuum to remove the solvents. The residual gum was dissolved in a minimum volume (ca 50 ml) of ethanol/water (1:1) and passed down a column of 50 g of a sulfonated polystyrene cation exchange resin (Zerolit 225; freshly regenerated in the acid cycle). Elution with ethanol/water (1:1) gave ca.200 ml of acid eluate which was evaporated. The resulting gum was partitioned between 100 ml of water and 100 ml of ether. The aqueous layer was extracted with 50 ml of ether. The ether phases were back-washed with water. The combined aqueous extracts were titrated to pH 4.5 with 4 M aqueous benzylamine and the solution was evaporated. The resulting gum-like solid was re-evaporated twice with ethanol and was then triturated with ethanol to give, after filtration, 1.15 g of a hygroscopic solid of melting point 196°-205° C. (decomposition). Recrystallisation of this solid from a mixture of 4 ml of water, 8 ml of ethanol and 8 ml of ether gave ca.0.3 g (Crop 1) of the monobenzylamine salt of (1R)-1-(N-benzyloxycarbonyl-L-3-fluoroalanylamino)-ethylphosphonic acid as a gelatinous solid of melting point 205°-215° C. (decomposition). Working-up of the mother liquors yielded a further 0.75 g (Crop 2) of the monobenzylamine salt of (1R)-1-(N-benzyloxycarbonyl-L-3-fluoroalanylamino)-ethylphosphonic acid.
The following Example illustrates a typical pharmaceutical preparation containing a peptide derivative provided by the present invention:
EXAMPLE 3
A 1000 ml injection solution containing the following ingredients was prepared:
______________________________________Ingredient Per 1000 ml______________________________________Peptide derivative 100.0 gChlorocresol 1.0 gAcetic acid (glacial) 1.2 gSodium hydroxide solution (0.1 N)q.s. ad pH 4.5Water for injection ad 1000 ml______________________________________
The peptide derivative was dissolved in 500 ml of water and there was added to the solution formed a solution of the chlorocresol in 200 ml of water for injection. Then, the acetic acid was added while stirring. The resulting solution was adjusted to pH 4.5 with 0.1 N sodium hydroxide in water for injection while stirring. The solution obtained was made up to 1000 ml with water for injection, filtered through a sterile 0.22 micron membrane filter and filled into ampoules which were sealed and then sterilised in an autoclave at 121° C. for 20 minutes. | The present disclosure relates to halo-phosphonopeptides. The subject compounds are antibacterial agents and also potentiate the activity of antibiotics. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for controlling an air intake system of an internal combustion engine. More particularly, it relates to an apparatus for controlling an air intake system having a variable effective length.
2. Description of the Related Art
This invention is directed to an apparatus for controlling a variable-effective-length air intake system disclosed in a copending U.S. patent application Ser. No. 805,740 filed Dec. 6, 1985 now U.S. Pat. No. 4,738,229 and assigned to the assignee of the present invention. The air intake system disclosed therein comprises a surge tank, the inside of which is divided by a partition wall into two elongated parallel volumetric chambers. The surge tank has a portion extending beyond the branch tube located at a position most remote from the air inlet of the surge tank. The partition wall of the surge tank extension is provided with an opening communicating the volumetric chambers with each other. This opening is opened and closed by a control valve operated by an actuator in response to varying engine operating conditions. When the control valve is closed to isolate the two volumetric chambers of the surge tank from each other, the air intake system operates as if the effective length thereof is elongated to match a lower resonance frequency of the air column in the intake system, thereby increasing the flow rate of the intake air and generating a high output torque during a lower engine speed. Conversely, when the control valve is opened to communicate the volumetric chambers with each other, the effective length of the air intake system in reduced, thereby reducing the flow resistance through the system and improving the power at high speed operation of the engine.
The control valve is controlled, for example, by a vacuum actuator which, in turn, is controlled by an electronic control unit. The effective length of the air intake system is controlled, in the first place, in accordance with the rotational speed of the engine, in such a manner that, during high speed operation of the engine, the effective length is reduced and, during low speed operation, the effective length is extended as mentioned above. During the low speed condition, however, it is desirable to reduce the effective length of the air intake system when the engine is running under a light load condition, in order to reduce the flow rate of the intake air and, hence, the fuel comsumption. Accordingly, in the second place, the effective length of the air intake system is controlled depending on the engine load.
Detection of the engine load may be performed in various ways. For example, manifold vacuum may be used, or in another method, the engine load is decided on the basis of the amount of intake air drawn into the engine per one revolution of the engine. Alternatively, the throttle valve opening may be used as a parameter reflecting the engine load. The manifold vacuum and the amount of intake air per revolution are capable of adequately accurately reflecting the engine load during the steady load condition but have a disadvantage in that their responsiveness to the transitional condition of the engine load is so poor that an unacceptable delay is caused in the control of the effective length of the intake system. The throttle valve opening will quickly respond to a rapid change in the engine load but will not accurately refect the engine load during a steady load condition.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an apparatus for controlling a variable-effective-length air intake system, which apparatus provides an improved responsiveness during a transitional condition of the engine.
The apparatus for controlling the variable- effective-length air intake system according to the present invention is designed so that, during the transitional period of the engine load, the effective length of the system is controlled based on the throttle valve opening which rapidly reflects the changes in the engine load and, during the steady load condition, the air intake system is controlled in accordance with the amount of intake air per one revolution of the engine, which accurately reflects the engine load.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation, partly in cross-section and partly in block diagrammatic form, of a V-6 engine having a variable-effective-length air intake system controlled by the apparatus according to the present invention;
FIG. 2 is a block diagram showing the control apparatus of the invention; and
FIG. 3 is a flow diagram of the control unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein a preferred embodiment of the present apparatus 100 is shown, FIG. 1 schematically illustrates a V-6 fuel injection engine 10 having an air intake system 22 with a variable effective length. The air intake system 22 is similar to that described in the copending patent application Ser. No. 805,740 filed Dec. 6, 1985, the disclosure of which is incorporated by reference herein. More specifically, the engine 10 comprises inclined cylinder banks 14A, 14B each having three engine cylinders as indicated by the broken circles 12. Intake air for the respective engine cylinders 12 is fed through a air cleaner 16, an air flow meter assembly 18, a throttle body assembly 20, and the air intake system 22. The air intake system 22 includes a surge tank 24 and six branch tubes 26A through 26F integral therewith or separate therefrom. Respective intake tubes 26A to 26F have fuel injectors 28 provided in a known manner for injecting controlled amounts of fuel into the intake air drawn into the cylinder 12, to form a combustible mixture.
The surge tank 24 includes an elongated hollow outer shell 30 extending lengthwise of the engine 10 and has an air inlet 32 connected to the throttle body assembly 20. The surge tank 24 is provided with a partition wall 34 that extends therethrough in the longitudinal direction to divide the inside of the shell 30 into two volumetric chambers 36 and 38. One volumetric chamber 36 is connected through respective intake tubes 26A to 26C to the combustion chambers of the first cylinder bank 14A and the other chamber 38 is connected to the combustion chambers of the second cylinder bank 14B through respective branch tubes 26D to 26F. The cylinder banks 14A and 14B are provided with respective exhaust manifolds 40A and 40B.
The surge tank 24 has an extension 42 that extends opposite the air inlet 32 beyond the intake tube 26F which is situated at a position most remote from the inlet 32. The surge tank extension 42 comprises a shell extension 44 and a partition wall extension 46. The surge tank extension 42 is made separate from the main body 48 forming the remainder of the surge tank and is removably secured thereto by conventional fastening means such as bolts. The extension 42 and main body 48 together form the surge tank assembly 24. The partition wall extension 46 is provided with an aperture 51 which is opened and closed by a flow control valve in the form of a butterfly valve 50. The surge tank extension 42 and the flow control valve 50 together form a detachable valve assembly 52 which is easy to manufacture and facilitates maintenance and inspection.
The flow control valve 50 is controlled by the control apparatus 100 in order to reduce or extend the effective length of the air intake system 22. The apparatus 100 includes a vacuum actuator 58 having a movable output rod 60 connected through a linkage 56 to the valve shaft 54 of the control valve 50. The actuator 58 opens and closes the butterfly valve 50 in response to the amount of vacuum applied to a vacuum chamber 62. In the illustrated embodiment, the vacuum actuator 58 is designed to normally open the flow control valve 50 and to close the valve 50 when vacuum is applied to the vacuum chamber 62. The vacuum to be applied to the vacuum actuator 58 is obtained at a vacuum source 68, such as a vacuum pump or a vacuum port in the intake manifold, and is controlled by a solenoid valve 66 controlled by an electronic control unit 64 which implements part of the present apparatus 100. The solenoid valve 66 is designed to communicate the source of vacuum 68 with the vacuum chamber 62 when energized and to connect the chamber 62 to the ambient atmosphere when deenergized.
The electronic control unit (ECU) 64 is a conventional programmable digital microcomputer which is primarily used to control the electronic fuel injection system of the engine and comprises a central processing unit (CPU) 70, a memory device 72, and an I/O interface 74 which is connected to the air flow meter 18, a throttle sensor 78 associated with a throttle valve 76 of the throttle body 20, and a crank angle sensor 82 incorporated in a distributor 80. The air flow meter 18 provides an analog signal representing the flow rate Q of intake air drawn into the engine 10. The throttle sensor 78 senses the opening of the throttle valve 76 and provides an analog signal indicative of the throttle opening. The crank angle sensor 82 delivers a pulse signal for a predetermined rotational angle of the engine crank shaft (not shown) and the ECU 64 calculates the rotational speed of the engine in the known manner upon receipt of each pulse.
FIG. 2 is a block diagram showing the control apparatus 100. The engine speed decision means 102 detects the rotational speed of the engine, compares the actual engine speed with a predetermined first value (for example, 2000 rpm), delivers a first signal over a line 104 when the actual engine speed is less than the first value, and delivers a second signal over a line 106 when the engine speed is greater than the first value.
The control mean 108 is operated in response to the first signal, detects the rate of acceleration of the engine, compares the acceleration rate with a predetermined second value, delivers a third signal over a line 110 when the acceleration rate is greater than the second value, and delivers a fourth signal over a line 112 when the acceleration rate is less than the second value. Preferably, the decision of the acceleration rate is performed in accordance with the rate of variation in the opening of the throttle valve 76, which is calculated based on the signal from the throttle sensor 78.
The throttle aperture decision means 114 is operated in response to the third signal, detects the throttle valve 76 opening, compares the actual throttle opening with a predetermined third value, delivers a fifth signal over a line 116 when the actual throttle aperture is greater than the third value, and delivers a sixth signal over a line 118 when the throttle opening is less than the third value.
The air flow rate decision means 120 is operated upon receipt of the fourth signal. The means 120 detects the flow rate Q of the intake air, which is divided by the engine rpm NE to calculate the amount Q/N of intake air drawn per one revolution of the engine. The air flow rate decision means 120 then compares the amount Q/N with a predetermined fourth value, delivers a seventh signal over a line 122 when the amount Q/N is greater than the fourth value, and delivers an eighth signal over a line 124 when the amount Q/N is less than the fourth value.
The valve actuating means 126 opens the flow control valve 50 upon receipt of the second, sixth, and eighth signals and closes the valve 50 upon receipt of the fifth and seventh signals.
The valve actuating means 126 may comprise the vacuum actuator 58, the solenoid valve 66, the vacuum source 68, and the ECU 64 implementing part thereof, and the foregoing engine speed decision means 102, the control means 108, the throttle aperture decision means 114, and the air flow rate decision means 120 may be implemented by the ECU 64.
Referring to the flow diagram of FIG. 3 showing the operation of the ECU 64, at point 201, the ECU 64 calculates the rotational speed NE of the engine and compares the actual engine speed with a present value A which may be selected to be in the range of 2,000 to 3,000 rpm. When the actual engine speed NE is greater than the value A, the ECU carries out the step at point 206 wherein the solenoid valve 66 is deenergized, thereby subjecting the vacuum chamber 62 of the vacuum actuator 58 to the atmospheric pressure and causing the flow control valve 50 to be opened. In this state, the intake air drawn into one of the volumetric chambers 36 and 38 is allowed to freely enter the other volumetric chamber so that any engine cylinder moving under in take stroke will draw intake air through both volumetric chambers 36 and 38. This results in obtaining an effect as if the effective length of the intake system is reduced so that the effective length is matched to a high rotational speed and the flow resistance of the system is reduced, thereby increasing the engine power at high speed.
When the actual engine speed NE is less than the preset value A, the step at point 202 is performed to decide whether the engine is in an accelerating condition. This may be done by calculating the variation ΔTA per unit time interval in the throttle aperture TA and by comparing the throttle aperture variation ΔTA with a predetermined second value B. Depending on the result of this comparison, the control of the flow control valve will be changed over between a condition wherein the engine load is detected according to the throttle aperture and another condition wherein the load is sensed in accordance with the amount Q/N of intake air per one revolution of the engine. That is, when the throttle aperture variation is greater than the preset value B, meaning the engine is operating under an accelerating condition, the step at point 203 is executed wherein the actual throttle aperture TA is detected based on the signal from the throttle sensor 78 and the actual throttle aperture TA is compared with a predetermined value C, for example, 6°.
If the throttle aperture is greater than the preset value C, then the solenoid valve 66 is energized at point 205 causing the vacuum at the source 68 to be applied to the vacuum chamber 62 of the actuator 58, thereby closing the flow control valve 50 and interrupting the communication between the volumetric chambers 36 and 38. As a result, the cylinder banks 14A and 14B will draw intake air only through associated volumetric chambers 36 and 38, respectively, thereby producing the effect as if the effective length of the intake system is increased, to enhance the low speed engine torque due to the inertia supercharging effect.
If in the decision of point 203 the throttle aperture is less than the preset value C, then the solenoid valve 66 is deenergized at point 206 to thereby open the flow control valve 50.
In this manner, the flow control valve 50 is controlled depending on the throttle aperture when the engine load is in a transitional condition. It should be appreciated that, because the throttle aperture varies in response to the movement of the accelerator pedal and quickly reflects the changes in the engine load, the responsiveness of the control system is improved by controlling flow control valve in accordance with the throttle aperture during a transitional condition of the engine.
If in the decision at point 102 the engine is in the steady load condition, then the engine load is determined at point 204 based on the amount Q/N of intake air per one revolution of the engine. To this end, the ECU 64 calculates the amount Q/N from the air flow rate Q sensed by the air flow meter 18 and from the engine rotational speed NE, and compares the thus-calculated amount Q/N with a predetermined value D. If the amount Q/N is greater than the value D, then the solenoid valve 66 is energized at point 205 to close the flow control valve 50. Conversely, if the amount Q/N is less than the preset value D, then the valve 66 is deenergized at point 206 thereby opening the valve 50 to provide the reduced effective length effect. In this manner, during the steady load condition of the engine, the flow control valve 50 is controlled depending on the amount Q/N, which more accurately reflects the engine load. | The control apparatus is intended for use in controlling a variable-effective-length air intake system of the type which has two volumetric chambers connected, respectively, to two groups of engine cylinders and which incorporates a flow control valve for controlling the communication between the two volumetric chambers to vary the effective length of the intake system in response to the rotational speed and load of an internal combustion engine. The control apparatus comprises a control means that detects the rate of acceleration of the engine and selectively causes the flow control valve to be controlled according to the throttle valve aperture during an accelerating condition of the engine and according to the amount of intake air per one revolution of the engine during steady load condition. Such a selective control improves the responsiveness of the control apparatus during acceleration while ensuring accurate control during a steady load condition. | 5 |
PRIORITY INFORMATION
The present application is a division of U.S. patent application Ser. No. 10/405,858, filed Apr. 2, 2003, the contents of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to spoken dialog systems and more specifically to methods of designing and implementing labeling guides associated with spoken dialog services.
2. Introduction
Building spoken dialog systems is a complicated and time-consuming process. The various modules necessary to carry on a meaningful conversation between a person and a spoken dialog system include an automatic speech recognition module, a spoken language understanding module, a dialog manager, and a text-to-speech language generation module. When a spoken dialog system for a particular domain is developed, the developers must train the various components to recognize and interact appropriately for the particular domain. For example, if the domain relates to an airline reservation service, each module must be trained to recognize and expect input from users related to air travel and reservations. The present invention relates to the process of training the spoken language understanding module of a spoken dialog system.
Most spoken language understanding (SLU) modules need some kind of internal representation of meaning that enables it to appropriately interpret and identify the meaning or intent of user input. The internal representation is typically organized into semantic classes. For example, to represent an entity type such as a person in a dialog, the person can be referred to in terms of her name (Betty), a pronoun (Her or She) or her relationship to others (Joe's manager). Thus three semantic classes can be derived from this entity type. For each spoken dialog application, the organization of the semantic classes for the potential entity types encountered in dialogues must be designed and then a large amount of training data is needed to build the semantic classifier models. For more information on semantic representations, see Huang, Acero and Hon, Spoken Language Processing , Prentice Hall, 2001, pages 867-880.
Producing the training data is a difficult and time-consuming process and is pivotal for the success of the application. Generating the training data requires recording a large number of user utterances, transcribing them and then labeling each one with appropriate semantic class or classes. Before labeling can be done, however, a person designs a set of semantic labels needed for the application. FIG. 1 illustrates a known process of generating a labeling guide. The set of semantic labels or tags used for the labeling guide is shown as step 102 . The semantic label meanings along with both positive and negative examples are documented. The documentation is organized into a detailed labeling guide ( 104 ) that is then provided to labelers to follow during an implementation phase ( 106 ). Trained labelers then carry out the physical task of labeling the data. For every application, this process must be started from scratch ( 108 ), and labelers must be retrained.
The typical process of generating training data, designing semantic labels and manual labeling of training data is a very expensive process. In addition, the process also introduces the opportunity of labeling errors, at least in the early phase of the learning cycle. Because of the highly specialized nature of each spoken dialog system, the data labeled for one application cannot be used for any other application; and if the functionality of the application needs to be extended or modified, new labels must be designed and data must be labeled again. The ultimate goal of the semantic labeling process is to train the SLU module to determine the appropriate action or responsive statement based on the received user utterance.
SUMMARY OF THE INVENTION
The present invention addresses the inherent cost and expense of designing labeling guides for labelers to use when labeling data for use by the SLU module. Such a trained SLU module may then be implemented into a spoken dialog service or any other kind of application. The invention provides a design and implementation scheme that can be reused across applications and that reduces the need of re-training the labelers and re-labeling of the data when an application needs to be extended or modified.
The preferred embodiment of the invention relates to a method of designing a labeling guide for use by a labeler in labeling data used for training a spoken language understanding (SLU) module for an application. Such a guide may be used for modules beyond just SLU modules. The method comprises a labeling guide designer selecting domain-independent actions applicable to an application, selecting domain-dependent actions and/or objects (all elements that may be selected are generically referred to herein as “objects”) according to characteristics of the application, and generating a labeling guide using the selected domain-independent actions and selected domain-dependent objects. An advantage of the labeling guide generated in this manner is that the labeling guide designer can easily port the labeling guide to a new application by selecting a set of domain-independent action and then selecting the domain-dependent objects related to the new application.
In some cases, a pre-existing set of domain-independent actions may exist from which the labeling guide designer can select those related to the present application. Similarly, a company or entity for which a spoken dialogue application is being developed may have pre-existing documentation on domain-dependent objects from which the labeling guide designer can easily select domain-dependent data for the labeling guide.
An advantage of the present invention includes a more efficient process for generating a labeling guide used by labelers in the implementation phase of a spoken dialogue service or other system that uses a spoken language understanding unit. This advantage is expressly not to be incorporated as a required limitation of the claimed limitations but reflects one of many potential general contexts in which the claimed invention may apply. It is appreciated that the principles of the present invention may also be applied to other modules within a spoken dialog system that require training, such as an automatic speech recognition (ASR) module or a text-to-speech (TTS) module.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth herein.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates a known process for generating a labeling guide for use by a labeler; and
FIG. 2 illustrates an exemplary process for generating a labeling guide according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention addresses the cost and lack of efficiency in known method of generating a labeling guide. Instead of starting from scratch with each new application for which a labeling guide must be generated, the present invention enables a labeling guide designed as disclosed herein to be ported or used for new applications by requiring labeling guide designers to modify a smaller set of data that relates to the new application or new domain. In this regard, the designer of the labeling guide has a reduced workload and can more quickly and efficiently design the labeling guide for new applications.
According to the invention, user's utterances should be labeled with the intent of the speaker as opposed to the action that the system must take in response. Once the intent is captured, changes or extensions in application only require changes in the responses to the intents. To capture the intent, a two-tiered tagging scheme is proposed. FIG. 2 illustrates an exemplary flow-chart for the method of the present invention. The first tier of each Label (tag) may be a domain-independent verb (also referred to as predicate) that reflects the action the user is trying to perform by the utterance. A labeling guide designer selects domain-independent actions ( 202 ) according to this first tier organization. These predicates are sometimes also referred to as Dialog Acts but will generally be referred to herein as domain-independent actions. The designer may select a set of domain-independent actions from a pre-existing set that may be derived from a previous labeling guide or from other documentation. In other cases, the designer may generate a new set of domain-independent actions for an application. Clearly, as more sets of domain-independent actions are developed, the more these existing sets will be used and drawn upon for newly developed labeling guides.
Included within the file history of the present application is an example labeling guide generated according to this two-tiered approach. This labeling guide is incorporated herein by reference. This example labeling guide is for a telecom industry customer care application. Labelers who use the information contained in the labeling guide listen to numerous calls and label each call according to calltypes and other information. For example, in this labeling guide, there are five groups of calltypes in a verb(noun) format: Billing for general billing services; Service for general service queries; Named Entities for specific data items requested or supplied by the caller; Discourse for generated speech used when the user converses with the system; and Miscellaneous. Other calltypes are contemplated and will come within the scope of the invention.
An example of a calltype in the verb(noun) format is Combine(Account). This is for when a caller wants only one bill from the company for all user accounts. For example, the caller wants to receive their charges on another company's bill—such as they desire to have their Verizon bill shown on their AT&T account. The “Combine” first-tier component of this calltype is independent from the domain and reflects a user intent or a general action (combine account) that the user desires. The “noun” or “Account” second-tier portion of the calltype reflects the domain-related objects, action or concept (also known as argument) on which the first-tier action is being performed. In this case, the user desires to “combine” “accounts.”
Since the meaning of domain-independent actions remain the same across the applications, one could use data from other applications to build the models for a new application. One could directly use the same data in a new application if the domain objects offered in the previous application were the same as in the new applications. For example, many applications deal with “Bills” and caller requests are commonly requests for an explanation of their bill. In such fortunate cases, data previously labeled by “Explain(Bill)” can be directly used for the new application. In other cases, a labeling guide designer would have to transform the data to make it suitable for the new application. In the telecom domain, for example, if a labeling guide designer has data labeled for Report (Service_Problem), the designer could use this data for a software company that attends to the software problems, i.e., Report(Software_Problem), by replacing the phrase that points to the service problem with those indicating a software problem.
An example of the steps necessary to manage this portability follows: the utterance “I have a <Company> corporate calling card it doesn't work I want to know why” having a calltype of Report(Service_Problem) can be changed to “I have a <Company> tax software it doesn't work I want to know why” having a calltype of Report(Software_Problem) by simply changing the “corporate calling card” which is a domain object in the telecom domain to “tax software” which is a domain object for the software company. Such modification to previously labeled data can be done automatically by using pattern recognizers of domain objects and actions. The terms “actions” and “objects” and/or “concepts” that reflect the arguments or subject matter of a domain-independent or domain-dependent analysis are used interchangeably and may have a broad or narrow meaning depending on the concept of the use of any particular term.
After the labeling guide designer identifies and selects the domain, the second-tier action constitutes the domain related objects actions or concepts (also referred to as arguments) on which this action (from first tier) is being performed. Some examples of predicates from the first tier follow—Request: an utterance embodying a request for specific object; Tellme: an utterance in which there is a request for specific information; Report: an utterance in which some information is being reported; Verify: an utterance in which there is a request to verify something; Explain: an utterance embodying a request for some observation.
Some further examples of the arguments (the second tier) from a transactional domain are Credit, Payment, and Bill_Charge. Having identified the domain-dependent objects and concepts, a list of labels (tags) can be generated by joining them with domain-independent predicates—for example: Request(Credit), Verify(Payment), Explain(Bill_Charge), and Report(Payment).
For illustration purposes, some examples of the utterances and their labels from this set are given below.
Utterance: “I see charges on my bill that I do not understand” Label: Explain(Bill_Charge)
Utterance: “I am just wanting to tell you that I have made the payment” Label: Report(Payment)
Utterance: “I am calling to check if you received my payment” Label: Verify(Payment)
Notice that by separating domain-dependent aspects from domain-independent aspects of labeling provides a systematic method to create a labeling guide. Once labelers understand the semantics of predicates, they only need to learn to spot the domain-dependent object/concepts in the utterances from a new and different application. This reduces the complexity and training necessary when training labelers for new applications. These labels capture the intents embedded in the utterance; therefore changes/extensions in application only require changes in the responses to the intents and do not require re-labeling of data. Since the labeling scheme captures the intent that is consistent across applications, it is possible to use data labeled for one application for developing other applications. For example, data labeled as Request(Credit) can be used for all applications where a caller is likely to ask for credit.
Embodiments within the scope of the present invention may also include a labeling guide generated according to the process described above. In this regard, such a labeling guide will be similar in general principles to the labeling guide incorporated discussed above that is incorporated herein by reference.
Although the above description may contain specific details, they should not be construed as limiting the claims in any way. Other configurations of the described embodiments of the invention are part of the scope of this invention. For example, some aspects of the process of generating a labeling guide may be automated where possible. In this regard, although the general description of the invention above relates to a more manual process of labeling guide designers selecting domain-independent and domain-dependent objects, some of these may be presented and selected in a software or multi-media electronic context and such software applications that control computing devices are considered within the scope of the invention. Accordingly, the appended claims and their legal equivalents should only define the invention, rather than any specific examples given. | A method is disclosed for designing a labeling guide for use by a labeler in labeling data used for training a spoken language understanding (SLU) module for an application. The method comprises a labeling guide designer selecting domain-independent actions applicable to an application, selecting domain-dependent objects according to characteristics of the application, and generating a labeling guide using the selected domain-independent actions and selected domain-dependent objects. An advantage of the labeling guide generated in this manner is that the labeling guide designer can easily port the labeling guide to a new application by selecting a set of domain-independent action and then selecting the domain-dependent objects related to the new application. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/625,576, filed Jan. 22, 2007 the entire content and disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a semiconductor structure and a method of fabricating the same. More particularly, the present invention relates to a hybrid interconnect structure that exhibits improved performance as well as enhanced reliability.
BACKGROUND OF THE INVENTION
[0003] Generally, semiconductor devices include a plurality of circuits that form an integrated circuit (IC) fabricated on a semiconductor substrate. A complex network of signal paths will normally be routed to connect the circuit elements distributed on the surface of the substrate. Efficient routing of these signals across the device requires formation of multilevel or multilayered schemes, such as, for example, single or dual damascene wiring structures. The wiring structure typically includes copper, Cu, since Cu based interconnects provide higher speed signal transmission between large numbers of transistors on a complex semiconductor chip as compared with aluminum, Al, based interconnects.
[0004] Within a typical interconnect structure, metal vias run perpendicular to the semiconductor substrate and metal lines run parallel to the semiconductor substrate. Further enhancement of the signal speed and reduction of signals in adjacent metal lines (known as “crosstalk”) are achieved in today's IC product chips by embedding the metal lines and metal vias (e.g., conductive features) in a dielectric material having a dielectric constant of less than 4.0.
[0005] That is, in order to reduce the interconnect portion of circuit delay, conventional dielectric materials having a dielectric constant of about 4.0 or greater such as, for example, silicon dioxide, have been replaced with dense lower-k dielectric materials having a dielectric constant of less than 4.0, preferably less than 3.5. It is noted that all dielectric constants mentioned throughout this application are relative to vacuum. For further performance improvement, more dielectric capacitance reduction is required for advanced devices.
[0006] Capacitance improvements can be made by replacing the dense low-k dielectric materials with porous low-k dielectric materials. Despite the improvement in capacitance, porous low-k dielectric materials have relatively weak mechanical properties as compared to dense dielectrics. Additionally, it is a significant challenge for current interconnects processing to integrate porous low-k dielectric materials with other module processes.
[0007] For example, the conventional chemical mechanical polishing (CMP) process has difficulty in planarizing a low mechanical-module porous dielectric, and the conventional physical vapor deposition (PVD) diffusion barrier deposition technology cannot offer reasonable coverage on the surface of the porous low-k dielectric material. That is, the conventional PVD process provides a discontinuous PVD liner on the exposed surfaces of the porous low-k dielectric material. It is noted that the presence of a discontinuous PVD liner around the conductive feature embedded in a porous low k dielectric material is a sever circuit reliability concern.
[0008] Referring back to dense low-k dielectric materials, the applicants have observed that an undercut profile, such as shown, in FIG. 1A , exists because of the etching rate difference between the dense low-k dielectric material and the oxide-containing hard mask material. A similar result may exist with some porous low-dielectric materials as well. Specifically, FIG. 1A shows a partially formed prior art interconnect structure 10 which includes a lower interconnect level 12 A and an upper interconnect level 12 B which are separated by a dielectric capping layer 20 . The lower interconnect level 12 A includes a first dielectric material 14 A having at least one conductive feature represented by conductive material 18 A embedded therein. A diffusion barrier 16 A separates the conductive material 18 A from the first dielectric material 14 A. Atop the dielectric capping layer 20 , is the upper interconnect level 12 B which, at this stage of the prior art process, includes a patterned dense low-k dielectric material 14 B and a patterned oxide-containing hard mask 22 located on a surface of the low-k dielectric material 14 B. The undercut region is labeled as 24 in FIG. 1A .
[0009] This undercut profile results in poor conductor fill property in the final interconnect structure and leaves voids between the diffusion barrier and the interconnect conductive material. This is clearly seen in FIGS. 1B (actual cross sectional photograph of a prior art interconnect structure) and 1 C (actual top down view). The term ILD denotes the second dielectric material 14 B mentioned above, barrier represents a second diffusion barrier that is formed in the opening of the patterned ILD, Cu represents the conductive material used in filling the openings. Reliability related issues may be caused by having the voids present inside the interconnect structure.
[0010] In view of the above, there is a need for providing a new and improved interconnect structure which overcomes all of the drawbacks mentioned above. That is, there is a need for providing a new and improved interconnect structure that has improved performance as well as enhanced reliability without changing the existing materials or the process flow significantly.
SUMMARY OF THE INVENTION
[0011] The present invention provides an interconnect structure (of the single or dual damascene type) and a method of forming the same, in which a dense (i.e., non-porous) dielectric spacer is present on the sidewalls of a dielectric material. The presence of the dense dielectric spacer results in a hybrid interconnect structure that has improved reliability and performance as compared with existing prior art interconnect structures which do not include such dense dielectric spacers. Moreover, the inventive hybrid interconnect structure provides for better process control which leads to the potential for high volume manufacturing.
[0012] It is noted that by ‘improved reliability’ it is meant that the inventive hybrid interconnect structure has improved barrier coverage and improved conductor/barrier adhesion. The improved barrier coverage means less leakage concerns within the inventive interconnect structure, while improved adhesion means less electromigration within the inventive interconnect structure.
[0013] The present invention provides a hybrid interconnect structure that contains a dense dielectric spacer located on patterned sidewalls of an interconnect dielectric material which avoids maintaining an undercut region within the final interconnect structure. The present invention also provides, in some embodiments, an embedded air gap within the interconnect structure which helps to reduce the overall interconnect capacitance and to enhance the circuit performance.
[0014] In one embodiment, the present invention provides a hybrid interconnect structure that comprises:
[0015] a dielectric material having a conductive material embedded within at least one opening in said dielectric material, wherein said conductive material is laterally spaced apart from said dielectric material by a diffusion barrier and a dense dielectric spacer, said diffusion barrier is in contact with said conductive material.
[0016] In another embodiment, the present invention provides a hybrid interconnect structure that comprises:
[0017] a dielectric material having a conductive material embedded within at least one opening in said dielectric material, wherein said conductive material is laterally spaced apart from said dielectric material by a diffusion barrier, a dense dielectric spacer and an air gap, said diffusion barrier is in contact with said conductive material.
[0018] In yet another embodiment of the present invention, an interconnect structure is provided that includes:
[0019] a lower interconnect level comprising a first dielectric material having a first conductive material embedded therein; and
[0020] an upper interconnect level comprising a second dielectric material having at least one opening that is in contact with said first conductive material of the lower interconnect level, wherein said second dielectric material has a second conductive material embedded within said at least one opening that is laterally spaced apart from said second dielectric material by a diffusion barrier and a dense dielectric spacer, said diffusion barrier is in contact with at least said second conductive material.
[0021] In some embodiments, an optional air gap may also be present in the upper interconnect level.
[0022] In any of the embodiments mentioned above, the dielectric material includes any dielectric level of an interconnect structure. The dielectric material may be dense or porous, with porous being highly preferred. The dielectric material employed in any of the embodiments has a dielectric constant of about 4.0 or less. Examples of some dielectric materials that can be employed include SiO 2 , silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H), thermosetting polyarylene ethers, or multilayers thereof. Preferably, a dielectric material having a dielectric constant of less than silicon dioxide is employed.
[0023] The dielectric spacer employed in the present invention comprises any dielectric material whose composition is typically, but not necessarily always, different from that of the dielectric material including the embedded conductive material. Examples of dielectric spacers that can be used in the present invention include, but are not limited to: SiO 2 , Si 3 N 4 , SiC, silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H) or thermosetting polyarylene ethers. Multilayered dense dielectric spacers are also within the scope of the present invention.
[0024] In addition to the hybrid interconnect structure mentioned above, the present invention also relates to a method of fabricating such a hybrid interconnect structure. The inventive method is compatible within current interconnect processing and, as such, no significant cost increase is associated with the fabrication thereof. Additionally, the inventive method (as well as the interconnect structure) does not put any limitations on the possible choices for the ILD material which means that the inventive method (as well as interconnect structure) provides for better technology extendibility.
[0025] In general terms, the method of the present invention comprises:
[0026] forming at least one opening in a dielectric material utilizing a patterned hard mask located on a surface of said dielectric material as a mask, wherein an undercut is present beneath said patterned hard mask;
[0027] forming a dense dielectric spacer in said at least one opening on exposed sidewalls of said dielectric material;
[0028] forming a diffusion barrier within said at least one opening on at least said dense dielectric spacer; and
[0029] forming a conductive material within said at least one opening on said diffusion barrier.
[0030] In some embodiments of the inventive method, an air gap remains between the dense dielectric spacer and the dielectric material. The air gap is typically located near the undercut region mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1A is a pictorial representation (through a cross sectional view) of a partially formed prior art interconnect structure which includes undercuts between an oxide-containing hard mask and a low-k dielectric material.
[0032] FIG. 1B is a cross sectional photograph of an actual prior art interconnect structure which includes voids created from the undercuts shown in FIG. 1A .
[0033] FIG. 1C is a top-down photograph of the prior art interconnect structure whose cross sectional view is shown in FIG. 1B .
[0034] FIGS. 2A-2B are pictorial representations (through cross sectional views) illustrating the inventive hybrid interconnect structure in accordance with a first embodiment and a second embodiment of the present invention.
[0035] FIGS. 3A-3F are pictorial representations (through cross sectional views) depicting the basic processing steps employed in the present invention for fabricating the inventive interconnect structure shown in FIG. 2A .
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention, which provides a hybrid interconnect structure including a dense dielectric spacer on sidewalls of a patterned dielectric material as well as a method of fabricating the same, will now be described in greater detail by referring to the following discussion and drawings that accompany the present application. The drawings of the present invention, which are referred to in the present application, are provided for illustrative purposes and, as such, they are not drawn to scale.
[0037] In the following description, numerous specific details are set forth, such as particular structures, components, materials, dimensions, processing steps and techniques, in order to provide a thorough understanding of the present invention. However, it will be appreciated by one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the invention.
[0038] It will be understood that when an element as a layer, region or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
[0039] Generally, the present invention provides a hybrid interconnect structure (see, for example, FIGS. 2A-2B ) which includes a dielectric material 56 B having a conductive material 60 B embedded within at least one opening in the dielectric material 56 B, wherein the conductive material 60 B is laterally spaced apart from the dielectric material 56 B by a diffusion barrier 58 B, a dense dielectric spacer 66 ′ and, optionally, an air gap 68 .
[0040] More particularly, FIGS. 2A and 2B illustrates various embodiments of the present invention. FIG. 2A is an embodiment including an air gap, while FIG. 2B is an embodiment which does not include an air gap. Both embodiments shown include the following elements: a lower interconnect level 52 A comprising a first dielectric material 56 A having a first conductive material 60 A embedded therein. An upper interconnect level 52 B is also present in the two illustrated embodiments. Specifically, the upper interconnect level 52 B includes a second dielectric material 56 B having at least one opening that is in contact with the first conductive material 60 A of the lower interconnect level 52 A. The second dielectric material 56 B has a second conductive material 60 B embedded within said at least one opening and the conductive material 60 B is laterally spaced apart from the second dielectric material 56 B by a diffusion barrier 58 B, a dense dielectric spacer 66 ′ and, optionally, an air gap 68 . If present, the air gap 68 is located in an undercut region that was created beneath the hard mask that was used in patterning the second dielectric material 56 B.
[0041] The other elements illustrated and referenced in FIGS. 2A-2B will be described in detail in the process flow that follows.
[0042] Reference is now made to FIGS. 3A-3F which illustrate the basic processing steps that are employed in the present invention for fabricating the inventive structure shown in FIG. 2A . Although the basic processing steps can be used in forming the inventive interconnect structure shown in FIG. 2A , the same can also be used in forming the inventive interconnect structure shown in FIG. 2B except that during the formation of the dense dielectric liner 66 a better conformal deposition technique is employed to completely fill in the undercut feature 64 . An alternative method to create more volume of air gap 68 is to exaggerate the undercut feature 64 intentionally post/during the etching process.
[0043] In accordance with the present invention, the process flow begins with providing the initial interconnect structure 50 shown in FIG. 3A . Specifically, the initial interconnect structure 50 shown in FIG. 3A comprises a multilevel interconnect including a lower interconnect level 52 A and an upper interconnect level 52 B that are typically, but not necessarily always, separated by dielectric capping layer 54 . The lower interconnect level 52 A, which may be located above a semiconductor substrate including one or more semiconductor devices, comprises a first dielectric material 56 A having at least one conductive feature (represented by a first conductive material 60 A) that is separated from the first dielectric material 56 A by a first diffusion barrier 58 A. The upper interconnect level 52 B comprises a second dielectric material 56 B that has at least one opening located therein. FIG. 3A also shows a patterned hard mask 62 located atop the second dielectric material and an undercut region 64 located beneath the patterned hard mask 62 .
[0044] In FIG. 3A , two openings are shown; reference number 106 denotes a line opening for a single damascene structure, and reference numeral 108 denotes a combined via and a line opening for a dual damascene structure. Although such a structure is shown, the present application is not limited to such a structure. Instead, the present application contemplates structures that include at least one opening to the underlying conductive feature, i.e., the first conductive material 60 A. Typically, that at least one opening is a via opening located beneath a line opening.
[0045] The initial interconnect structure 50 shown in FIG. 3A is made utilizing standard interconnect processing which is well known in the art. For example, the initial interconnect structure 50 can be formed by first applying the first dielectric material 56 A to a surface of a substrate (not shown). The substrate, which is not shown, may comprise a semiconducting material, an insulating material, a conductive material or any combination thereof. When the substrate is comprised of a semiconducting material, any semiconductor such as Si, SiGe, SiGeC, SiC, Ge alloys, GaAs, InAs, InP and other III/V or II/VI compound semiconductors may be used. In addition to these listed types of semiconducting materials, the present invention also contemplates cases in which the semiconductor substrate is a layered semiconductor such as, for example, Si/SiGe, Si/SiC, silicon-on-insulators (SOIs) or silicon germanium-on-insulators (SGOIs).
[0046] When the substrate is an insulating material, the insulating material can be an organic insulator, an inorganic insulator or a combination thereof including multilayers. When the substrate is a conducting material, the substrate may include, for example, polySi, an elemental metal, alloys of elemental metals, a metal silicide, a metal nitride or combinations thereof including multilayers. When the substrate comprises a semiconducting material, one or more semiconductor devices such as, for example, complementary metal oxide semiconductor (CMOS) devices can be fabricated thereon.
[0047] The first dielectric material 56 A of the lower interconnect level 52 A may comprise any interlevel or intralevel dielectric including inorganic dielectrics or organic dielectrics. The first dielectric material 56 A may be porous or non-porous. Some examples of suitable dielectrics that can be used as the first dielectric material 56 A include, but are not limited to SiO 2 , silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H), thermosetting polyarylene ethers, or multilayers thereof. The term “polyarylene” is used in this application to denote aryl moieties or inertly substituted aryl moieties which are linked together by bonds, fused rings, or inert linking groups such as, for example, oxygen, sulfur, sulfone, sulfoxide, carbonyl and the like.
[0048] The first dielectric material 56 A typically has a dielectric constant that is about 4.0 or less, with a dielectric constant of about 2.8 or less being even more typical. It is noted that the low-k dielectrics (less than 4.0) generally have a lower parasitic crosstalk as compared with dielectric materials that have a higher dielectric constant than 4.0. The thickness of the first dielectric material 56 A may vary depending upon the dielectric material used as well as the exact number of dielectrics within the lower interconnect level 52 A. Typically, and for normal interconnect structures, the first dielectric material 52 A has a thickness from about 200 to about 450 nm.
[0049] The lower interconnect level 52 A also has at least one conductive feature that is embedded in (i.e., located within) the first dielectric material 56 A. The conductive feature comprises a first conductive material 60 A, which is separated from the first dielectric material 56 A by a first diffusion barrier 58 A. The conductive feature is formed by lithography (i.e., applying a photoresist to the surface of the first dielectric material 56 A, exposing the photoresist to a desired pattern of radiation, and developing the exposed resist utilizing a conventional resist developer), etching (dry etching or wet etching) an opening in the first dielectric material 56 A and filling the etched region with the first diffusion barrier 58 A and then with a first conductive material 60 A forming the conductive region. The first diffusion barrier 58 A, which may comprise Ta, TaN, Ti, TiN, Ru, Ir(Ta), Ir(TaN), Ru(Ta), Ru(TaN), W, WN or any other material that can serve as a barrier to prevent conductive material from diffusing there through, is formed by a deposition process such as, for example, atomic layer deposition (ALD), chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), physical vapor deposition (PVD), sputtering, chemical solution deposition, or plating.
[0050] The thickness of the first diffusion barrier 58 A may vary depending on the exact means of the deposition process as well as the material employed. Typically, the first diffusion barrier 58 A has a thickness from about 4 to about 40 nm, with a thickness from about 7 to about 20 nm being more typical.
[0051] Following the formation of the first diffusion barrier 58 A, the remaining region of the opening within the first dielectric material 56 A is filled with a first conductive material 60 A. The conductive material 60 A includes, for example, polySi, a conductive metal, an alloy comprising at least one conductive metal, a conductive metal silicide or combinations thereof. Preferably, the conductive material 60 A is a conductive metal such as Cu, W or Al, with Cu or a Cu alloy (such as AlCu) being highly preferred in the present invention. The conductive material 60 A is filled into the remaining opening in the first dielectric material 56 A utilizing a conventional deposition process including, but not limited to: CVD, PECVD, sputtering, chemical solution deposition or plating. After deposition, a conventional planarization process such as, for example, chemical mechanical polishing (CMP) can be used to provide a structure in which the first diffusion barrier 58 A and the conductive material 60 A each have an upper surface that is substantially coplanar with the upper surface of the first dielectric material 56 A.
[0052] It should be noted that the inventive dielectric spacer 66 ′ to be described in greater detail herein below may be formed in the lower interconnect level 52 A. If present, the dielectric spacer 66 ′ would line the sidewalls of the at least one opening including first conductive material 60 A.
[0053] After forming the at least one conductive feature 60 A, the dielectric capping layer 54 is formed on the surface of the lower interconnect level 52 A utilizing a conventional deposition process such as, for example, CVD, PECVD, chemical solution deposition, or evaporation. It is noted that the dielectric capping layer is not necessarily required in all circumstances. The dielectric capping layer 54 comprises any suitable dielectric capping material such as, for example, SiC, Si 4 NH 3 , SiO 2 , Si 3 N 4 , a carbon doped oxide, a nitrogen and hydrogen doped silicon carbide SiC(N,H) or multilayers thereof. The thickness of the dielectric capping layer 54 may vary depending on the technique used to form the same as well as the material make-up of the layer. Typically, the dielectric capping layer 54 has a thickness from about 15 to about 55 nm, with a thickness from about 25 to about 45 nm being more typical.
[0054] Next, the upper interconnect level 52 B is formed by applying the second dielectric material 56 B to the upper exposed surface of the dielectric capping layer 54 . The second dielectric material 56 B may comprise the same or different, preferably the same, dielectric material as that of the first dielectric material 56 A of the lower interconnect level 52 A. In one embodiment, it is highly preferred to utilize a dielectric material whose dielectric constant is less than 4.0 as the second dielectric material 56 B. Porous and non-porous dielectrics, with porous dielectrics being highly preferred, can be used. The processing techniques and thickness ranges for the first dielectric material 56 A are also applicable here for the second dielectric material 56 B.
[0055] A blanket layer of hard mask material such as an oxide-containing material is then formed atop the second dielectric material 56 B utilizing a standard deposition process including, for example, chemical vapor deposition, plasma enhanced chemical vapor deposition, chemical solution deposition and atomic layer deposition. Alternatively, the hard mask material can be formed by a thermal process such as, for example, oxidation.
[0056] Next, at least one opening is formed into the second dielectric material 56 B utilizing lithography, as described above, and etching. The hard mask material is used as a patterned mask during the etching step. The lithographic step includes applying a photoresist atop the hard mask material, exposing the photoresist to a pattern of radiation and developing the exposed resist. After resist development, the pattern is transferred first into the hard mask material (forming patterned hard mask 62 ) and then into the second dielectric material 56 B. The lithographically patterned resist is typically, but not necessarily always, removed after transferring the pattern into the hard mask material. The etching may comprise a dry etching process, a wet chemical etching process or a combination thereof. The term “dry etching” is used herein to denote an etching technique such as reactive-ion etching, ion beam etching, plasma etching or laser ablation.
[0057] It should be noted that during the above described etching step and because of the different etching rates between the hard mask material and the second dielectric material 56 B, an undercut region 64 forms beneath the patterned hard mask 62 .
[0058] After providing the initial interconnect structure 50 shown in FIG. 3A , the exposed surfaces of the structure, i.e., the patterned hard mask 62 , the exposed sidewalls of the second dielectric material 56 B, and the dielectric capping layer 54 , are lined with a dielectric liner 66 . The resultant structure including dielectric liner 66 is shown, for example, in FIG. 3B .
[0059] The dielectric liner 66 is any dense dielectric material including, for example, any of the dielectrics mentioned above for the first and second dielectric materials. The dielectric liner 66 typically, but not necessarily always, has a different composition than the second dielectric material 56 B. Example of dielectric materials that can be used as liner 66 include silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, thermosetting polyarylene ethers, SiO 2 , Si 3 N 4 , SiC(N,H), SiC or multilayers thereof.
[0060] The dielectric liner 66 is formed utilizing any deposition process including, for example, chemical vapor deposition and plasma enhanced chemical vapor deposition. The thickness of the dielectric liner 66 that is deposited is typically from about 100 to about 2000 Å, with a thickness from about 300 to about 800 Å being even more typical.
[0061] It is noted that under normal deposition conditions, an air gap 68 remains in the structure after deposition of the dielectric liner 66 . The presence of the air gap 68 is advantageous since it lowers the overall capacitance of the interconnect structure. As shown, the air gap 68 is located beneath the patterned hard mask 62 and between the liner 66 and the patterned second dielectric material 56 B.
[0062] The dielectric liner 66 shown in FIG. 3B is then subjected to an anisotropic etching process which provides a dielectric spacer 66 ′ (see, for example, FIG. 3C ) which is present on the exposed sidewall portions of the patterned second dielectric material 56 B; the anisotropic etching removes the dielectric material that is present on all horizontal surfaces within the structure. The resultant structure including dielectric spacer 66 ′ is shown, for example, in FIG. 3C .
[0063] It is emphasized that during the above mentioned anisotropic etch, a portion of the dielectric capping layer 54 is typically removed. If the etching used in forming the dielectric spacer 66 ′ does not remove the underlying dielectric capping layer 54 , a separate etching process can be used to selectively remove the exposed portion of the dielectric capping layer 54 .
[0064] Next, a second diffusion barrier 58 B is provided by forming the second diffusion barrier 58 B on exposed surfaces including the previously formed dielectric spacer 66 ′. The resultant structure is shown, for example, in FIG. 3D . The second diffusion barrier 58 B comprises at least one of TaN, Ta, TiN, TiN, Ir(Ta), Ir(TaN), Ru(Ta), Ru(TaN), W and WN. The second diffusion barrier 58 B is formed utilizing a deposition process such as, for example, atomic layer deposition (ALD), chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), physical vapor deposition (PVD), sputtering, chemical solution deposition, or plating.
[0065] The thickness of the second diffusion barrier 58 B may vary depending on the number of material layers, the technique used in forming the same as well as the material of the second diffusion barrier 58 B itself. Typically, the second diffusion barrier 58 B has a thickness from about 4 to about 40 nm, with a thickness from about 7 to about 20 nm being even more typical.
[0066] It is noted that the presence of the dense dielectric spacer 66 ′ aids in providing a second diffusion barrier 58 B that is continuous.
[0067] At this point of the present invention, an optional plating seed layer (not shown) can be formed at least within the openings atop the second diffusion barrier 58 B. Although optional, it is preferred to include a plating seed layer within the structure to aid in growth of the conductive material. This is especially the case when a conductive metal or metal alloy is to be subsequently formed within the at least one opening. When present, the plating seed layer may comprise a conductive metal or metal alloy such as that used in forming the conductive material to be described in greater detail herein below. Typically, and when the conductive material comprises Cu, the plating seed layer comprises Cu, CuAl, CuIr, CuTa, CuRh, Ru, Ir, CuRu, or other alloys of Cu, i.e., Cu-containing alloys.
[0068] The plating seed layer is formed by a conventional deposition process including, for example, ALD, CVD, PECVD, PVD, chemical solution deposition and other like deposition processes. The thickness of the plating seed layer may vary and it is within ranges that are well known to those skilled in the art. Typically, the plating seed layer has a thickness from about 2 to about 80 nm.
[0069] Next, a second conductive material 60 B which is the same or different from that of the first conductive material 60 A is formed within the at least one opening. The second conductive material 60 B forms a second conductive feature within the structure. Preferably, Cu, Al, W or alloys thereof are used, with Cu or AlCu being most preferred. The second conductive material 60 B is formed utilizing the same deposition processing as described above in forming the first conductive material 60 A and following deposition of the second conductive material 60 B, the structure is subjected to planarization. FIG. 3E shows the interconnect structure after conductive material 60 B deposition, while FIG. 3F shows the interconnect structure after planarization. The planarization process, which includes grinding and/or chemical mechanical polishing (CMP) removes the patterned hard mask 62 from the structure.
[0070] Following the planarization process, a second dielectric capping layer 54 B can be formed as described above providing the structure illustrated in FIG. 2A .
[0071] It is again noted that the same basic processing steps as described above can be used in forming the structure shown, in FIG. 2B except that a better conformal deposition of the dielectric liner 66 is performed such that no air gap is present in the structure. An alternative method to create more volume of air gap 68 is to exaggerate the undercut feature 24 intentionally post/during the etching process.
[0072] It is noted that the embodiment depicted above is for a closed via-bottom structure. In another embodiment of the present invention, an open-via bottom structure can be provided. In the open-via bottom structure, the second conductive material 60 B is in direct contact with a surface of the first conductive material 60 A. The open-via bottom structure is formed by removing the second diffusion barrier from the bottom of via utilizing ion bombardment or another like directional etching process. The present invention also contemplates an anchored-via bottom structure. The anchored-via bottom structure is formed by first etching a recess into the conductive feature in the first dielectric material 56 A utilizing a selective etching process. After formation of the second diffusion barrier, the second diffusion barrier is typically removed from the bottom portion of the via and recess by a directional etching process. The second conductive material is then formed as described above.
[0073] While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims. | The present invention provides an interconnect structure (of the single or dual damascene type) and a method of forming the same, in which a dense (i.e., non-porous) dielectric spacer is present on the sidewalls of a dielectric material. More specifically, the inventive structure includes a dielectric material having a conductive material embedded within at least one opening in the dielectric material, wherein the conductive material is laterally spaced apart from the dielectric material by a diffusion barrier, a dense dielectric spacer and, optionally, an air gap. The presence of the dense dielectric spacer results in a hybrid interconnect structure that has improved reliability and performance as compared with existing prior art interconnect structures which do not include such dense dielectric spacers. Moreover, the inventive hybrid interconnect structure provides for better process control which leads to the potential for high volume manufacturing. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radio frequency communications and, more specifically, to an antenna system employed in radio frequency communications.
2. Description of the Prior Art
Radio signals usually start with electrical signals that have been modulated onto a radio frequency carrier wave. The resulting radio signal is transmitted using an antenna. The antenna is a system that generates an electrical field (E field) and a magnetic field (H field) that vary in correspondence with the radio signal, thereby forming radio frequency radiation. At a distance from the antenna, as a result of transmission effects of the medium through which the radio frequency radiation is being transmitted, the E field and the H field fall into phase with each other, thereby generating a Poynting vector, which is given by S=E×H, where S is the Poynting vector, E is the E field vector and H is the H field vector.
Conventional Hertz antenna systems are resonant systems that take the form of wire dipoles or ground plane antennas that run electrically in parallel to the output circuitry of radio frequency transmitters and receivers. Such antenna systems require, for maximum performance, that the length of each wire of the dipole, or the radiator or the ground plane be one fourth of the wavelength of the radiation being transmitted or received. For example, if the wavelength of the radiation is 1000 ft., the length of the wire must be 250 ft. Thus, the typical wire antenna requires a substantial amount of space as a function of the wavelength being transmitted and received.
A Crossed Field Antenna, as disclosed in U.S. Pat. No. 6,025,813, employs two separate sections which independently develop the E and H fields and are configured to allow combining the E and H fields to generate radio frequency radiation. The result is that the antenna is not a resonant structure, thus a single structure may be used over a wide frequency range. The Crossed Field Antenna is small, relative to wavelength (typically 1% to 3% of wavelength) and provides high efficiency. The Crossed Field Antenna has the disadvantage of requiring a complicated physical structure to develop the E and H fields in separate sections of the antenna. The Crossed Field Antenna also requires an associated complex matching/phasing network to feed the antenna.
SUMMARY OF THE INVENTION
The disadvantages of the prior art are overcome by the present invention which, in one aspect is an antenna for generating radiation that includes a primary E-field generating circuit and a secondary E-field generating circuit. The primary E-field generating circuit generates a primary E-field in response to a source RF signal being applied to the antenna. The secondary E-field generating circuit generates a secondary E-Field, disposed apart from the primary E-field, in response to the source RF signal and develops an H-field that is in time phase with the primary E-field. This causes the antenna to develop a radiation resistance as an indication of radiation.
In another aspect, the invention is an antenna system, for use with a signal cable having a signal lead and a common lead. The antenna system includes a first elongated dipole element and a second elongated dipole element that is coupled to the common lead and spaced apart from the first elongated dipole element. An inductor is spaced apart from the first elongated dipole element and the second elongated dipole element, and is substantially coaxial with the first elongated dipole element and the second elongated dipole element. The inductor has an inductor proximal end and an inductor distal end. The inductor proximal end is electrically coupled to the signal lead and the inductor distal end is electrically coupled to the first elongated dipole element.
In another aspect, the invention is an antenna for use with a signal cable having a signal lead and a common lead. The antenna includes an insulating elongated support member. A first cylindrical conductor is disposed about a first portion of the support member. The first cylindrical conductor has a proximal end and an opposite distal end. A second cylindrical conductor is disposed about a second portion of the support member and is spaced apart from the first cylindrical member. The second cylindrical conductor has a proximal end and an opposite distal end. The proximal end is in electrical communication with the common lead. A conductive coil is coiled about the elongated support member and is spaced apart from and substantially coaxial with the first cylindrical conductor and the second cylindrical conductor. The conductive coil has a proximal end and an opposite distal end. The proximal end is in electrical communication with the signal lead and the distal end is in electrical communication with the proximal end of the first cylindrical conductor. A moveable contact is electrically coupled to the signal lead and electrically couples the signal lead to the conductive coil. The moveable contact is capable of coupling the signal lead to the conductive coil at a selected position of the inductor so as to make the antenna tunable with respect to resonant frequency.
In yet another aspect, the invention is a communications antenna for both transmitting and receiving in association with a communications system through a feed line having a high side and a ground. The antenna includes two dipole elements that are short relative to a predetermined operating wavelength and that have a diameter so as to have a predetermined capacity therebetween. An inductance, having a source end, is disposed proximal to the two dipole elements. A first end of the inductance is electrically coupled to a first one of the two dipole elements. A second one of the two dipole elements is electrically coupled to the feed line. The high side of the feed line is connected to an end of the inductance opposite the source end, so that the predetermined capacity is resonated with an inductance and so that at a resonant frequency a large voltage forming a primary E field is developed between the two dipole elements and at the source end of the inductance a source voltage is 90 degrees delayed relative to the primary E field and so that the source voltage forms a secondary E field between the source end of the inductance and the two dipole elements and so that the secondary E field causes a displacement current to flow in a natural capacity of the space between the source end of the inductance and the dipole elements, such that the displacement current is advanced 90 degrees through the capacity so as to be in phase with the primary E field and develop a magnetic (H) field that surrounds the primary E field.
These and other aspects of the invention will become apparent from the following description of the preferred embodiments taken in conjunction with the following drawings. As would be obvious to one skilled in the art, many variations and modifications of the invention may be effected without departing from the spirit and scope of the novel concepts of the disclosure.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a schematic diagram of a first illustrative embodiment of the invention.
FIG. 2 is a schematic diagram of the embodiment of FIG. 1 mounted on a tube.
FIG. 3 is a schematic diagram of one illustrative embodiment of the invention showing the relationship between various fields generated by the antenna.
FIG. 4 is a schematic diagram of a tunable frequency embodiment of the invention.
FIG. 5 is a chart showing performance parameters for one example of an antenna according to the invention.
FIG. 6 is a schematic diagram of an RF choke.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention is now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,” “an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.”
A general discussion of Poynting vector theory may be found in the disclosure of U.S. Pat. Nos. 5,155,495 and 6,025,813, which are incorporated herein by reference.
The concept of the invention is based on the Poynting Theorem, where S=E×H. If an E field and an H field are developed and they have the proper relationship in amplitude, time (phase) and physical relationship, radiation will be developed.
As shown in FIG. 1 , one embodiment of the invention includes an antenna 100 for use with a signal cable 102 having a signal lead 104 and a common lead 106 (also referred to as a ground lead or a reference lead). The signal cable 102 could be a feed line selected from one of many types of signal cables, including a coaxial cable, a twisted pair, a parallel wire cable or other type of balanced line.
The antenna 100 includes a first elongated dipole element 110 (such as a cylinder made of metal foil) having a proximal end 112 and an opposite distal end 114 . A second elongated dipole element 120 (which could also include a cylinder made of metal foil), having a proximal end 122 and an opposite distal end 124 , is coupled to the common lead 106 , typically, but not necessarily, at the proximal end 122 . An inductor 130 is spaced apart from the first elongated dipole element 110 and the second elongated dipole element 120 . Typically, but not necessarily, the first elongated dipole element 110 , the second elongated dipole element 120 and the inductor 130 are coaxial with each other. The inductor 130 has an inductor proximal end 132 and an inductor distal end 134 . The inductor proximal end 132 is electrically coupled to the signal lead 104 (and thus may be referred to as the “source end”). The inductor distal end 134 is electrically coupled to the first elongated dipole element 110 , typically, but not necessarily, to the proximal end 112 . The inductor 130 may be placed in positions other than shown in FIG. 1 , without departing from the scope of the invention.
While the system shown in FIG. 1 does not show a particular form of support for the inductor 130 and the dipole elements 110 and 120 , support could be accomplished in one of many ways. For example, in an embodiment shown in FIG. 2 , the first elongated dipole element 110 and the second elongated dipole element 120 both comprise cylinders of copper (or other metal) foil wrapped about an insulating tube 140 (such as a polyvinyl chloride tube or a fiberglass tube), with the inductor 130 being a coil of wire wrapped about the tube 104 . Other methods of support may also be used, including using a solid rod, suspending the elements in air and placing the elements on the inside of a cavity.
The various fields created by the system are shown in FIG. 3 . When a signal is applied to the signal cable, a primary E-field 152 is created between the first elongated dipole element 110 and the second elongated dipole element 120 . A secondary E-field 154 is created between the dipole elements 110 and 120 and the inductor 130 . An H-field 156 is then created by the current flowing through the capacity between the components. Because the inductor 130 induces a 90° phase delay between the Primary E field 152 and the secondary E field 154 , and current through the capacity caused by the secondary E field 154 is phase advanced 90 degrees, the H-field 156 resulting from that current is in nominal time phase with the primary E-field 152 .
As shown in FIG. 4 , a moveable contact 160 may be used to couple the signal lead 104 to the inductor 130 to allow the antenna to be tuned to a desired resonant frequency. The moveable contact 160 could be a roller, a brush or one of many types of contacts used to vary contact position along a coil. In such a configuration, the inductor 130 can be held in a fixed position, while the moveable contact 160 is moved to a desired location on the inductor 130 . Conversely, the moveable contact 160 can be held in the fixed position, while the inductor 130 is moved to achieve tuning. This embodiment allows the antenna to be tuned to many different resonant frequencies within a range defined by the inductor 130 . As is clear to those skilled in the art, many different types of variable inductors or tuning circuits may be employed without departing from the scope of the invention.
When the H field of the antenna is developed as a result of displacement current, the current leads the applied voltage by 90 degrees. Because this current is the source of the H field, it is necessary to delay the applied voltage by 90 degrees so that the H-field is in phase with the primary E-field, thus the need for a delay network. Because there is a natural 90 degree phase delay across the inductor, a proper physical arrangement would allow full operation because the proper phase delay is part of the simplest implementation. The antenna input impedance of the antenna will be nominally the same as the source impedance at the resonant frequency. Thus, the antenna has a low Voltage Standing Wave ratio (VSWR) when fed as a series circuit. Alternately, the antenna can be connected as a parallel resonant circuit and use either a tap for matching to the feed line or use a coupling loop.
An inductance is connected to the top cylinder and to the transmission line. The lower cylinder is connected to the coax shield, which is ground reference for this instance. For the purpose of discussion, assume the instantaneous phase of the RF signal is 0 degrees relative at the bottom of the inductor, thus the top cylinder is at 0 degrees, relative. The inductor is chosen to cause resonance at the desired frequency with the capacity between cylinders. The large voltage between the cylinders establishes an E field between cylinders. This can be referred to as the primary E field.
The voltage applied to the inductor from the feed line is much smaller that applied to the top cylinder, but is significant. Because the voltage at this point on the inductor is 90 degrees delayed relative to the voltage on the top cylinder, an E field is developed between that part of the inductor and the cylinders. This may be referred to as the secondary E field. Since this E field is 90 degrees delayed, the displacement current caused by this E field is advanced 90 degrees. Thus the resulting current is in phase with the primary E field. Because the H field is developed surrounding the E field, and both the primary E field and the secondary E fields are physically located in alignment, radiation develops.
Considering the magnitudes of the two fields, the ratio between the E and H fields must be the same as the impedance of free space (377 ohms). Because this antenna is an efficient radiator (and receiver), the ratio assumes its natural function causing the input impedance (resistance) at the resonant frequency to be nominally the same as the source impedance.
The only loss in the antenna system is the loss in the tuning inductor, which is very small if proper construction is used. Typically, the cylinders are made of copper or aluminum. Therefore, the effective terminating resistance is the radiation resistance. The bandwidth of the antenna is limited by the capacity of the cylinders. Due to their physical configuration, the capacity is small, thus the reactance is high. Typical Q is nominally 35 for small antennas according to the invention and operating in the HF spectrum. This compares to values of Q of about 30 for large Hertz dipoles which are physically 25 to 50 times larger in physical dimensions.
The impedance of the antenna is a function of the physical characteristics and frequency. Typically, the cylinders each have a length of 0.01% to 2.5% of a wavelength with length to diameter ratios of 1 to 6, dependent on the desired radiation pattern. The inductance is chosen to provide resonance at the desired frequency with the natural capacity between cylinders. The inductance is aligned coaxially with the cylinders.
A performance parameter chart 500 for one exemplary antenna according to the invention is shown in FIG. 5 , which presents the impedance of this antenna as a function of frequency. The specific presentation is for an operating frequency near 7 MHz (the 40 meter Amateur Radio Band), but the shape of the curves is essentially the same at any frequency for which this type of EH Antenna is designed.
A VSWR curve relative to 50 ohms is presented to indicate one operating mode. A second mode is achieved when the source impedance is nominally 200 ohms. Both modes are at those frequencies where the reactance is near zero ohms. In either mode the radiation resistance of the antenna is high. The inductance can use a large wire to offer low loss resistance and there is very little resistance in the cylinders if they are made of high conductivity material such as aluminum or copper. Therefore, this antenna has exceptionally high efficiency, yet is a miniature antenna by conventional antenna standards.
Because radiation is created at the antenna, the E and H fields are contained in a volume not much larger than the dimensions of the antenna. This greatly reduces electromagnetic interference (EMI). When used as a receiving antenna, the reduced fields have a high rejection of E or H field noise, yet the capture of radiation equals that of conventionally-sized antennas. Therefore, the signal to noise ratio of the antenna is significantly higher than Hertz antennas.
The antenna of the invention can achieve optimum performance only if the transmission line feeding the antenna does not interfere. As shown in FIG. 6 , this may be achieved by using a RF choke 600 in the feed line. For example, a few turns of a coaxial cable 102 over a ferrite rod 602 will offer a large effective reactance to currents on the external shield of the coaxial cable 102 without disturbing the currents internal to the coaxial cable 102 . This allows the source (transmitter or receiver) to be properly coupled to the antenna.
The above-described embodiments are given as illustrative examples only. It will be readily appreciated that many deviations may be made from the specific embodiments disclosed in this specification without departing from the invention. Accordingly, the scope of the invention is to be determined by the claims below rather than being limited to the specifically described embodiments above. | An antenna for generating radiation includes a primary E-field generating circuit and a secondary E-field generating circuit. The primary E-field generating circuit generates a primary E-field in response to a source RF signal being applied to the antenna. The secondary E-field generating circuit generates a secondary E-Field, disposed apart from the primary E-field, in response to the source RF signal and develops an H-field that is in time phase with the primary E-field. This causes the antenna to develop a radiation resistance as an indication of radiation. | 7 |
TECHNICAL FIELD
This invention relates to differential disconnect drive assemblies or mechanisms, and in particular to dual disconnect drive assemblies, for four-wheel drive vehicles which can be operated in either a two-wheel drive mode or a four-wheel drive mode.
BACKGROUND ART
Four-wheel drive vehicles which are operable in either a two-wheel drive mode or a four-wheel drive mode have gained widespread popularity. Axle disconnect mechanisms, or differential disconnect mechanisms or assemblies for such vehicles are known.
Commonly used disconnect mechanisms for four-wheel drive vehicles disconnect only one of the two output shafts on an axle assembly which is driven part time. This causes the pinion gears and the side gears of the differential to rotate due to back driving, although the differential case remains stationary. This is not compatible with speed-sensitive limited slip differentials. Also, single axle disconnect mechanisms may cause noise and wear and poor fuel economy due to rotation of the differential components while the vehicle is in two-wheel drive mode.
Various dual disconnect differential assemblies or mechanisms have been proposed. These mechanisms in general have a number of moving parts, are fairly complex, and would be suitable only for installation on relatively wide vehicles because of the space required. None has achieved commercial acceptance.
SUMMARY OF THE INVENTION
This invention comprises a differential having first and second side gears which are rotatable about a common transverse axis. Rotatable first and second output shafts are co-axial with the side gears, and a clutch mechanism is used for placing the output shafts simultaneously into or simultaneously out of driving engagement with the respective side gears. An actuator is used to slidably move the driven gears between the clutch engaging position and the clutch disengaging position. There is further provided clutch members on each of the side gears, and a plurality of axially slidable members in abutting end-to-end relationship which comprises first and second driven gears slidably and non-rotatably mounted on the first and second output shafts, respectively. The driven gears have clutch members for engaging the clutch members of the respective first and second side gears, with the driven gears being simultaneously slidable in a first direction to a clutch engaging position and simultaneously slidable in a second direction to a clutch disengaging position.
A preferred dual disconnect differential assembly according to the invention further includes, as axially slidable members, a slide collar between the first and second driven gears, and a clutch collar slidably mounted on one of the output shafts in a position outboard of an adjacent driven gear. A biasing means is provided for biasing the driven gears to a clutch disengaging position. The vehicle is in two-wheel drive mode when the clutch is disengaged and in four-wheel drive mode when the clutch is engaged.
The differential assembly of the present invention possesses several advantages, including greater fuel economy, less wear, and less noise compared to previously known disconnect mechanism in which only a single output shaft and its axle shaft are disengaged from driving engagement with a differential when two-wheel drive mode is selected. Advantages of the present invention compared to previously known dual disconnect differential assemblies include fewer parts and greater compactness, which makes it possible to utilize the present dual disconnect drive mechanism on any size vehicle, including a sub-compact automobile. This makes it possible to offer four-wheel drive on smaller vehicles, including sub-compact automobiles, which have not previously had optional four-wheel drive because of the space requirements of presently known dual disconnect mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a sectional plan view of apparatus according to a preferred embodiment of the invention.
FIGS. 2 and 3 are longitudinal sectional views, on an enlarged scale, of a left-hand side gear and a right-hand side gear, respectively, according to the preferred embodiment of this invention.
FIG. 4 is a plan view of a slide collar according to the preferred embodiment of this invention.
FIG. 5 is an end view of a driven gear according to the preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention will now be described in detail with reference to the best mode and preferred embodiments thereof.
Referring now to FIG. 1, a dual disconnect differential assembly 10 (or mechanism) according to this invention is shown for a front axle of a four-wheel drive (4WD) vehicle having a full-time rear axle and a part-time front axle.
The differential assembly 10 in general is driven by a longitudinally extending pinion shaft (or input shaft) not shown, which in turn may be driven by a drive shaft (not shown) which extends longitudinally from a vehicle transmission. The pinion shaft may engage a ring gear (not shown), which is affixed (e.g., bolted) to a differential case 12. Differential case 12 is rotatably mounted in a differential housing (not shown) by means of bearings (not shown). Differential case 12 and the ring gear affixed thereto rotate about a transverse horizontal axis, which is the axis of output shafts (to be described later) and axle shafts coupled respectively thereto.
The differential used in the practice of this invention may further include a differential cross pin 16, and pinion gears 18 which are rotatably mounted with respect to cross pin 16. The differential further includes first (or left-hand) and second (or right-hand) side gears 20 and 21, respectively (see FIGS. 1, 2, and 3). Side gears 20 and 21 are coaxial and rotate about a common transverse axis, which is also the common axis of the aforementioned output shafts and axle shafts.
Side gears 20, 21 have respective clutch members in the form of splines 22, 23, respectively, as best seen in FIGS. 2 and 3. These splines are formed on central bores of respective side gears 20, 21 near the left-hand ends thereof, at the outboard end of left-hand side gear 20 and at the inboard end of right-hand side gear 21.
The dual disconnect differential assembly 10 of this invention further includes coaxial first (or left-hand) and second (or right-hand) output shafts 24. These output shafts 24 extend transversely and are coaxial with side gears 20, 21. These output shafts 24 extend from inboard ends near cross pin 16 to outboard ends which extend outside the differential housing. Splines 26 are provided at the inboard ends of output shafts for driving the same. Joints or flanges which may be conventional (e.g., universal joints), are provided at respective outboard ends of output shafts 24 for coupling of axle shafts to respective output shafts 24 in driving engagement. These axle shafts are coaxial with the output shafts 24 and extend transversely outwardly to wheels (not shown) at the sides of the vehicle.
The dual disconnect differential assembly 10 of this invention includes a clutch mechanism for simultaneously placing both output shafts 24 either into or out of driving engagement with respective side gears 20, 21. The splines 22, 23 on respective side gears 20, 21 form part of this clutch assembly or mechanism.
The clutch mechanism further includes a plurality of axially slidable coaxial annular members in abutting end-to-end relationship. The axially slidable members, from left to right as seen in FIG. 1, are a first or left-hand driven gear 30 having clutch members in the form of external splines formed on the outer surface thereof, and internal splines 32 for drivingly engaging respective output shafts 24. A slide collar 34 (seen in plan view in FIG. 4), having diametrically opposite laterally extending slots 35 is provided, along with a second or right-hand driven gear 30, identical to the first or left-hand driven gear 30. A clutch collar 36 is provided, and has, on the outer surface thereof, a pair of spaced collars 37 which form a groove 38 for receipt of a clutch actuator 40.
It is noted that only one clutch collar 36 is required. This clutch collar is slidably and rotatably mounted on one of the output shafts 24 (in this case, the right-hand output shaft) and is outboard of and in abutting end-to-end relationship with an adjacent driven gear 30.
Driven gears 30 are slidably but non-rotatably mounted on respective output shafts 24. Internal splines 32 on the driven gears 30, and external splines 26 on the output shafts 24, prevent relative rotation while permitting axial sliding movement of the driven gears. Thus, driven gears 30 rotate with the respective output shafts 24 on which they are mounted.
The entire set of axially slidable members, including driven gears 30, slide collar 34, and clutch collar 36, are shown in clutch disengaging position in FIG. 1, being the normal position. Upon actuation, as will be described subsequently, the axially slidable members 30, 34, and 36 slide to the left as seen in FIG. 1 into a clutch engaging position, in which clutch members or splines 31 on respective driven gears 30 are in engagement with respective splines 22, 23 on respective side gears 20, 21. Output shafts 24 rotate with respective side gears 20, 21 when the clutch mechanism is in the clutch engaging position, and rotate independently of the respective side gears 20, 21 when the clutch mechanism is in the clutch disengaging position.
The slide collar 34 is slidably mounted on output shafts 24, at the inboard ends thereof. The slide collar 34 extends across the gap between the inboard ends of output shafts 24. Diametrically opposite slots 35 in slide collar 34 receive the differential cross shaft 16. The ends of slide collar 34 are in end-to-end abutting relationship with respective driven gears 30 on either side. Driven gears 30 and output shafts 24 rotate independent of slide collar 34.
The clutch collar 36 is slidably and rotatably mounted on the second or right-hand output shaft 24. One end of clutch collar 36 (the left end as seen in FIG. 1) is in end-to-end abutting relationship with the second (or proximate) driven gear 30, so that when clutch collar 36 moves axially to the left (to clutch engaging position), the entire set of axially slidable annular members 30, 34, and 36 will simultaneously move to the left.
A compression spring 42 serves as biasing means to urge the axially slidable annular members 30, 34, and 36 to clutch disengaging position, i.e., to the right as seen in FIG. 1. Spring 42 surrounds the first or left-hand output shaft 24. The ends of spring 42 are in engagement with the outer (or left) end of first driven gear 30 and with a shoulder in left-hand output shaft 24.
To actuate the clutch mechanism, a clutch actuator 40 may be provided as a shift fork having a bifurcated end portion which is received in groove 38 of clutch collar 36. The shift fork 40 may be actuated by known means, e.g., by vacuum (which is preferred) or by hydraulic, pneumatic, electrical, or mechanical means. Actuation may be initiated either automatically or by a manual operator, such as a manual or pedal control in the vehicle cab.
The driven gears 30 and clutch collar 36 are normally in clutch disengaging position, i.e., to the right as seen in FIG. 1. The vehicle is in two-wheel drive (2WD) mode when the clutch is disengaged. To engage the clutch mechanism and place the vehicle in four-wheel drive (4WD) mode, clutch actuator 40 moves clutch collar 36 to the left as seen in FIG. 1 against the bias of compression spring 42. Clutch collar 36 pushes the driven gears 30 and the slide collar 34 to the left against the bias of spring 42, thereby placing the clutch members or splines 31 on respective driven gears in engagement with respective clutch members or splines 22, 23 on respective side gears 20, 21. With the clutch mechanism thus engaged, the output shafts 24 are constrained to rotate at the same speeds as respective side gears 20, 21 and power is transmitted to the respective axle shafts (not shown). When the need for four-wheel drive no longer exists, clutch actuator 40 is moved to the right. This also slides clutch collar 36 to the right. Compression spring 42 then pushes driven gears 30 and slide collar 34 to the right, i.e., to the clutch disengaging position, to return the vehicle to two-wheel drive mode.
The drawings herein show a differential assembly for a front axle of a vehicle. Most current vehicles which have four-wheel drive have a full-time rear axle and a part-time front axle. However, some recent four-wheel drive vehicles have a full-time front axle and a part-time rear axle. The differential assembly of this invention can be used on either the front axle or the rear axle, whichever is the part-time axle.
The compression spring 42 (or other biasing means) is normally biased toward the clutch disengaging position, which results in disengagement of the part-time axle, since it is normally preferred to operate in two-wheel drive mode with the part-time axle disengaged except when driving conditions call for four-wheel drive operation. However, this spring can be biased toward clutch engaging position if desired. Other biasing means, as for example, an air spring, can be used in place of the compression spring shown if desired.
Further, the biasing means can be dispensed with entirely provided that some means, such as magnets on the abutting ends of each coaxial member 34 and 36 are provided (except that no such magnets are required on the outside ends of left-hand driven gear 30 or clutch collar 36) so as to keep the axially slidable members 30, 34, and 36 in abutting relationship. Such magnets, if used, must not be so strong as to prevent or impede relative rotation between adjacent axially slidable members. Other mechanical mechanisms which function to shift the driven gears 30 and slide collar 34 to the clutch disengaging position are also contemplated herein.
It is possible to use a solenoid operator, e.g., an annular solenoid operator surrounding the output shafts 24 just beyond the outermost axially slidable member, and, in that case, to dispense with clutch collar 36 if desired. However, the illustrated apparatus, including a clutch collar 36 and a shift fork 40, is preferred since this gives more versatility both as to type and location of the actuator.
It is also possible to use a spider (which typically including a ring at its center with a plurality of radially extending arms extending outwardly from the ring) in place of the cross pin 16 if desired. In that case, it is possible (although not preferred) to eliminate slide collar 34 and to extend the two driven gears 30 axially inwardly so that they are directly in abutting end-to-end relationship.
While driven gears 30 have external splines for such purposes extending over their entire length are illustrated, it will be apparent that the axial length of the driven gears may be longer than that herein illustrated, and that these external splines need not extend over the entire length. In such case, the splined portion would be to the right as seen in FIG. 1. This is ordinarily not preferred because it would require left and right driven gears which are not identical to each other in most cases, except where the axial length of the splined portion is exactly one-half the total axial length of the driven gear.
The present invention provides a simple and reliable mechanism for simultaneous differential connect and simultaneously disconnect. In other words, both output shafts 24 are simultaneously connected or disconnected from their respective side gears 20, 21 in the apparatus of this invention. The novel dual disconnect differential assembly herein avoids the known disadvantages of single shaft disconnect mechanism, such as back drive, as has been discussed earlier.
The dual disconnect differential assembly of this invention is also compact. This makes part-time, dual disconnect four-wheel drive for compact and sub-compact vehicles possible.
The two side gears 20, 21 are free to rotate at different speeds, whether the output shafts 24 are engaged with or disengaged from the respective side gears 20, 21. However, if desired, a differential assembly for a part-time axle as herein illustrate can be further provided with a differential lockout mechanism (which may be conventional) if desired.
While this invention has been described in detail with reference to the preferred embodiments thereof, it shall be understood that various modifications (including those specifically discussed above and others) can be made without departing from the scope and spirit of this invention. | A dual disconnect differential assembly for four-wheel drive (4WD) vehicle is disclosed. This disconnect differential assembly connects both output shafts of a differential assembly (and correspondingly both axle shafts which are driven by the respective output shafts) simultaneously. The dual differential assembly herein also disconnects both output shafts simultaneously. A clutch mechanism associated with the two differential side gears (which may be otherwise conventional) and with annular driven gears which are in driving engagement with respective output shafts, is provided for simultaneous connection and simultaneous disconnection of the output shafts. The dual disconnect differential assembly herein is simple, compact, and reliable. It overcomes the disadvantages associated with single axle disconnect mechanisms presently in use. It also provides a simpler, more compact, and more reliable dual disconnect differential mechanism than any such mechanism presently known. | 5 |
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